Monday, June 22nd, 2009
Investing $550 million, Ford to transform its Michigan Assembly Plant to build small cars
The Michigan Assembly Plant – formerly the production site for Ford Expedition and Lincoln Navigators SUVs – is one of three North American light truck plants Ford is retooling to build fuel-efficient, global, small cars. Additionally, Ford and United Auto Workers are developing a framework of new and leading-edge operating practices at the plant that will ensure high quality and maximum efficiency.
When production launches in 2010, approximately 3,200 employees will be building the new Focus at the leaner, greener and more flexible manufacturing complex. The new Focus will begin rolling off the line next year and the battery-electric version of the Focus – Ford’s first all-electric passenger car – debuts in 2011.
Some key features of the assembly plant transformation include:
- A flexible body shop operation, which uses reprogrammable tooling in the body shop, standardized equipment in the paint shop and a common-build sequence in final assembly, enabling production of multiple models in the same plant.
- Ford’s industry-leading virtual manufacturing technology that allows engineers and plant operators evaluate tooling and product interfaces before costly installations are made on the plant floor. This method of collaboration improves launch quality and enables speed of execution.
- An integrated stamping facility, which allows the stamping and welding of all large sheet-metal parts on-site, ensuring maximum quality and minimum overhead.
The $550 million investment in Michigan Assembly Plant includes more than $430 million in manufacturing investment at the site, as well as $120 million for launch and engineering costs. Ford also will be making significant investment in supplier tooling to support the plant.
The state of Michigan and local governments provided tax incentives and grants that enabled the investment in Michigan Assembly, which will be designated as the state’s first automotive technology anchor site.
Quotes
“The transformation of Michigan Assembly Plant embodies the larger transformation under way at Ford. This is about investing in modern, efficient and flexible American manufacturing. It is about fuel economy and the electrification of vehicles. It is about leveraging our expertise and vehicle platforms around the world and partnering with the UAW to deliver best-in-class global small cars. It is about skilled and motivated teams working together in new ways to create the future of automobile manufacturing in the United States.” - Alan Mulally, Ford President and CEO
“Ford is investing in both the future of the American auto industry and the state of Michigan by bringing together world-class products, advanced technology applications and strong partnerships with the UAW to build the next generation of vehicles that will help end our nation’s dependence on foreign oil. In these challenging economic times, we applaud and appreciate Ford's commitment to Michigan and to our talented workforce.” - Jennifer Granholm, Michigan Governor
“We’re changing from a company focused mainly on trucks and SUVs to a company with a balanced product lineup that includes even more high-quality, fuel-efficient small cars, hybrids and all-electric vehicles. As customers move to more fuel-efficient vehicles, we’ll be there with more of the products they really want.” - Mark Fields, Ford’s President of The Americas
Related Links
Fact Sheet: Michigan Assembly Plant
Michigan Assembly Plant
Flexible Manufacturing Fact Sheet (PDF)
Tags: Ford, Ford engineering, Ford Focus, Ford manufacturing, Ford Motor Company, Ford Technology, Michigan Assembly Plant, vehicle quality assurance
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A Year In Review: 2009,
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Monday, June 22nd, 2009
Cleveland Engine Plant No. 1 becomes the first Ford manufacturing site to produce advanced fuel-efficient EcoBoost engines.
Ford invested $55 million to retool and reopen the plant, which had been idled in 2007. Approximately 250 employees have returned to the plant to build the new engines. Delivering up to 20 percent improved fuel economy, and up to 15 percent fewer CO2 emissions compared with larger displacement engines, and without sacrificing driving performance, EcoBoost engines are a key step in Ford’s plan to deliver affordable fuel economy for millions of customers.
The 3.5-liter EcoBoost V-6 engine, the first V-6 direct-injection twin-turbocharged engine produced in North America, will first be available this summer on the 2010 Lincoln MKS, Lincoln MKT, Ford Taurus SHO and Ford Flex. By 2013, EcoBoost will be available for 90 percent of Ford’s nameplates.
The Cleveland Engine Plant has been outfitted with a flexible powertrain manufacturing system that can be easily reprogrammed to perform new tasks with minimal disruption to production.
Plant upgrades included a special turbocharger installation and test line. After the turbos are added, each EcoBoost engine is turned on speeds between 60-600 RPM using an electric motor to simulate running conditions. Unique to the Cleveland site, this “cold test” checks for proper buildup of pressure on the turbo output side before the engine ever leaves the factory.
Opened in 1951 as Ford's first engine plant in Ohio, Cleveland Engine Plant No. 1 has produced more than 35 million engines, including 24.3 million engines in the famous 302 and 5.0-liter V-8 family. With the EcoBoost, a new, more fuel-efficient era has dawned for the storied plant.
Quotes
“This launch of the first EcoBoost engine is a significant milestone in Ford’s overall commitment to deliver affordable fuel efficiency for millions. We’ve spent the past two years developing EcoBoost technology and now our customers will finally have the opportunity to experience what this engine delivers, the power of a V-8 with the fuel economy of a V-6.” - Barb Samardzich, Vice President, Global Powertrain Engineering
“The ability to reprogram on the fly is a key feature of this new manufacturing system. We don’t have to shut down an entire plant in order to make major changes to the line, helping to speed up modifications and keep downtime to a minimum.” - Charles Binger, Cleveland Site Manager
Related Fact Sheets
EcoBoost Fact Sheet (PDF)
6F-55 Transmission Fact Sheet (PDF)
Tags: Cleveland Engine Plant No. 1, EcoBoost, EcoBoost V-6, Ford engineering, Ford manufacturing, Ford Technology, fuel efficiency
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Friday, December 5th, 2008
Ford proposes strategies to operate profitably at the current demand and vehicle mix.
Ford’s organizational restructuring plan takes place across all operations, including manufacturing, supplier relationships, dealer relationships, consumer credit operations, and salaried and hourly personnel.
Ford addressed manufacturing concerns, noting that approximately 50 percent of future U.S. manufacturing capacity would be dedicated to producing more fuel-efficient small and medium-size vehicles. As well, nearly all U.S. assembly plants will have flexible body shops to respond quickly to consumer demands.
Ford is also strengthening its relationship with U.S.-based suppliers, with specific attention to women and minority suppliers.
To address an overcapacity of dealers, Ford intends to downsize and restructure in 130 metropolitan market areas. And dealers can continue to rely on the wholly- owned subsidiary, Ford Motor Credit Company for wholesale, retail and lease financing programs, together with capital and facility loan programs.
Ford will have reduced salaried personnel costs by 40 percent over the past three years, including a 10 percent reduction effective February 2009. There have been significant changes to Compensation and Benefit packages as well, such as eliminating merit increases and bonuses due to be paid in 2009.
When it comes to hourly personnel, Ford is working closely with the UAW to transform our total labor costs. Through these efforts, as well as capping costs on benefits, Ford will realize a total of $5.5 billion in annualized operating cost reductions from 2005 through 2008.
To read the section on restructuring,
click here.
Tags: automotive industry, Ford manufacturing, Senate Banking Committee, UAW
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