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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Friday, June 27th, 2008
Quality Operating System Coordinators ensure that Ford accelerates quality.
Several of Ford’s powertrain plant employees received Six Sigma Black Belt training under a new program that formalizes the Quality Operating System Coordinator (QOSC) position. The positions, which give UAW members control over quality, were first introduced in the early 2000s as a one-year experiment, but quickly became an integral part of quality management.
The QOSCs finished their Black Belt coursework and will take the mandatory tests to achieve the prestigious Six Sigma Black Belt certification, with the goal of having at least two Black Belts per plant. The number of QOSCs per plant varies depending upon size, product and volume, but on average there are six per plant.
The QOSCs devote 100 percent of their workday to monitoring quality process and procedure adherence and cannot be pulled from their job to replace an absent employee on the line. They ensure that every employee at every station understands precisely what they need to do and how to do it.
Since the introduction of QOSCs, Ford’s rating in initial and long-term quality surveys has seen an upward trend. Ford’s brand went up by eight points over last year, beating the industry seven-point rate of improvement, according to J.D. Powers and Associate’s Initial Quality Study. Shortly thereafter, the Global Quality Research System durability study noted that Ford brand improved at a rate of 3 percent verses the industry average of 1 percent.
Tags: Ford Quality, J.D. Powers and Associate, quality operating system coordinators, vehicle quality assurance
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Friday, June 27th, 2008
The popular Ford Focus bests industry segment average as most improved model.
A top industry study named Ford Focus the most improved model in the industry. The 2008 Automotive Performance, Execution and Layout (APEAL) Study by J.D. Power and Associates showed that Focus gained 88 index points over last year.
With the biggest improvement score in the industry, Focus performed better across all categories with significant improvements in the areas of fuel economy, audio/entertainment/navigation, interior styling and exterior styling.
Earning a 36-index point improvement was the Ford Escape, which put the strong seller in the top 10 of most improved vehicles in the industry. Five Ford Motor Company vehicles received second or third honors in their segments:
- Ford Explorer Sport Trac, 2nd place in Midsize Pickup segment
- Mazda CX7, 2nd place in Compact Multi-Activity Vehicle (MAV) segment
- Mazda CX9, 2nd place in Midsize MAV segment
- Ford Focus, 3rd place in Compact Car segment
- Lincoln Navigator, 3rd place in Large Premium MAV segment
Overall, Ford moved up five positions to 22nd, with a 14-point improvement. Lincoln checked in at 12th place and Mercury placed 29th, improving by 12 index points.
Tags: Ford Escape, Ford Focus, Ford Quality, J.D. Power and Associates, Lincoln Navigator, Mazda CX7, Mazda CX9, Mercury, vehicle quality assurance
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Friday, June 6th, 2008
Ford brand quality improves at a rate faster than the industry average.
Year after year, Ford continues to make significant quality gains. According to the latest third-party study by J.D. Power and Associates, Ford’s brand vehicles increased in quality faster than the industry average.
Continuing its five-year upward trend and beating the industry average seven-point rate of improvement, Ford brand improved by eight points over last year’s study. Mercury improved by four points over last year, and the Lincoln brand exceeded the industry average. The Mazda brand improved the most, jumping 36 points from the 2007 study.
The Ford Motor Company received 10 vehicle honors, including three vehicles that scored highest rankings in their respective segments. They are:
- Lincoln Navigator, large premium multi-activity vehicle segment
- Ford E-Series, van segment
- Mazda MX5 Miata, compact sporty car segment
The 2008 Initial Quality Study (IQS) by J.D. Power and Associates is based on responses from 81,500 new 2008 model-year vehicle owners after having driven their vehicles for three months.
Tags: Ford E-Series, Ford Quality, J.D. Power and Associates, Lincoln Navigator, Mazda MX5 Miata, Mercury, quality testing, vehicle quality assurance
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