Cleveland Engine Plant No. 1 reopens to become first site in the world to produce EcoBoost engines.

Ford invested $55 million for tooling and equipment upgrades at Cleveland Engine Plant No. 1, which has been idled since 2007, to build the EcoBoost engine. The powerful, fuel-efficient 3.5-liter EcoBoost V-6 engines represent the cornerstone of Ford’s technology plan to deliver fuel efficiency and performance to millions.

EcoBoost will first be available this summer in the 2010 Lincoln MKS, Lincoln MKT, Ford Taurus SHO and Ford Flex. Production is slated to begin this spring, with approximately 250 employees forming shifts to build the engine. The employees are a combination of employees who worked in the plant, before it was idled in 2007, and employees from other plants.

Employee training and flexible manufacturing are key components to the success of the Cleveland Engine Plant. Here are some highlights of this two-fold strategy:

Extensive Employee Training

• The workforce participated in an intensive three-tier training program aimed at improving quality and empowering employees. The first two phases of training covered basic manufacturing operations and employees learned how to manage their own equipment and work area through “manufacturing work teams” at the plant.


• For the final phase, the plant will be working with Cuyahoga Community College. During four weeks of onsite classroom training employees will upgrade skill sets for machining technicians and production team leaders, and will receive 10 credit hours toward an associate’s degree in Advanced Manufacturing Technology.

Flexible Manufacturing

• Outfitted with a flexible manufacturing system for powertrains, featuring modern, Computerized Numerical Control machine tools (CNC machines) the facility can easily be retooled and reprogrammed to perform new tasks with minimal disruption to production.


• A new, internal database will ensure quality is built into the engine from the outset. During production, each engine built at the plant will have a sophisticated engine “birth history” that allows plant engineers to trace the precise path taken by any part so any quality control issue can be traced back to its source.

Quotes
“The EcoBoost engine is a strategic product that will provide Ford with a competitive edge. The Cleveland site is thrilled to be delivering an important product for the company. We have an outstanding, specially trained workforce that is committed to delivering a world-class, quality product for our customers.”
- Jan Allman, Cleveland Site Manager

“This training approach not only delivers the technical training to the workforce but also empowers them which is a cultural change from the traditional management-directed system. You’re turning over the keys to the hourly team members to let them do what they need to do to get their jobs done. Each employee, working under a team leader, is responsible for his or her area and they work as a team to deliver a high quality engine.”
- Kevin Heck, Cleveland Engine No. 1 Area Manager

“What we do is primarily teach job skills, so this fits right in with our mission statement. What’s unique about this is we’re doing it in Ford-dedicated workspace; we’re bringing our instructors and our equipment to Ford and we’re offering the credit hours. We, along with Ford, understand the importance of helping people expand their skills and knowledge for the rapidly changing workplace.”
-John Gajewski, Executive Director of Cuyahoga Community College Workforce and Economic Development Division