Ford Invests in Production of Electrified Vehicles

Ford Invests in Production of Electrified Vehicles

A $135 million investment will help create new jobs and more fuel-efficient options for customers

Ford is America’s largest domestic producer of hybrid vehicles. The brand that launched the Escape Hybrid in 2004 and the Fusion Hybrid in 2010 recently announced that it would be investing $135 million in the design, engineering and production of key components for next-generation hybrid-electric vehicles that are going into production this year.

The $135 million investment will help Ford create new green jobs, double its battery testing capabilities and send more hybrid and electrified vehicles to market up to 25 percent faster. More specifically, Ford plans to double its battery-testing capabilities, to 160 individual battery-test channels, by 2013; this will include using more of the specialized machines that test and simulate power, performance, battery life and thermal behavior over a wide range of potential operating conditions and temperatures.

Additionally, a 285,000-square-foot research and development lab in Dearborn, Michigan, will be dedicated solely to Ford hybrids and electrification. This lab, which houses most of the 1,000 engineers working on electrification and hybrid programs, was formerly known as the Advanced Engineering Center but has been renamed the Ford Advanced Electrification Center. Ford added 60 engineers to its electrification team in the last year and expects to fill dozens more positions this coming year.

By bringing research, development and production of hybrid and electrified vehicles in-house, Ford has been able to make hybrid engines more efficient and more affordable. Expanded battery-testing capabilities will allow Ford engineers to collect, analyze and apply large amounts of data quickly and modify tests when necessary; the result will be completed projects in 25 percent less time than what was necessary for previous-generation hybrids.

Buhler Ford’s investment will give customers the benefit of more fuel-efficient choices and even better value. Compared to the cost of the previous-generation hybrid system, Ford’s current hybrid system will cost 30 percent less. Ford will have five electrified vehicles this year as part of its “Power of Choice” strategy to produce leading fuel economy across its lineup and triple its production capacity of electrified vehicles by 2013. These five electrified vehicles are:

Focus Electric: America’s most fuel-efficient compact car with 110 miles per gallon equivalent, or “MPGe,” city, the Focus Electric has a four-hour charge time with its available 240-volt charging station, nearly half the charge time required by the Nissan Leaf. Production began in late 2011.

C-MAX Hybrid: This model is EPA-certified to deliver 47 mpg highway, 47 mpg city (at least three mpg more than Toyota Prius v) and 47 mpg combined, and features more technology and better performance at a base price that is $1,300 lower than the Prius v.

C-MAX Energi plug-in hybrid: Projected to achieve 95 MPGe with a total range of 550 miles, this model’s MPGe is more than three times that of the Toyota Prius plug-in hybrid, per EPA testing methods, and is coming this fall.

All-new Fusion Hybrid: Also coming this fall, this model beats out the Toyota Camry Hybrid by five mpg highway, with an expected 47 mpg.

Fusion Energi plug-in hybrid: Ford aims to make this model the most fuel-efficient midsize car in the world; production will begin by the end of 2012.

“The good news for customers is that they not only have more choice, but they have faster access to Ford’s latest and greatest in fuel-saving technologies and vehicles,” stated Ford Vice President of Powertrain Engineering Joe Bakaj. “This stems directly from our decisions to deliver true power of choice by expanding our dedicated electrified vehicle team and further investing in our facilities.”

Ford’s increased investment in electrified vehicles has resulted in a rapid growth in the number of people working on them, and has brought together talented engineers and innovators from diverse backgrounds. Many of these professionals have experience in the field of aerospace, working on rockets, jets, satellites, missiles and unmanned aircraft.

“We know what it takes to build world-class hybrids and are building on that expertise,” stated Ford Electrification Programs and Engineering Director Kevin Layden. “We’re continuing to invest so Ford can continue to lead in the delivery of top fuel economy, durability and driving dynamics in our electrified vehicles.”

Stop by Buhler Ford at the Jersey Shore in Eatontown, NJ for a test drive!

Ford Launches Global Manufacturing System

Ford Launches Global Manufacturing System

“One Manufacturing” will improve efficiency and lower total cost of production

Ford Motor Company, already one of the world’s leading automakers, is launching its largest global expansion in 50 years as it introduces a single manufacturing operating system meant to drive improved efficiencies, increase capacity utilization and put the company in the lead for lowest total cost production.

“The global One Ford plan is making it possible for us to deploy One Manufacturing, a single Ford production system that will pay tremendous dividends through standard processes, greater flexibility and improved investment efficiency,” stated Ford Executive Vice President of Global Manufacturing John Fleming, at the Center for Automotive Research Management Briefing Seminars in August.

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Ford is boosting capacities around the world, including a significant expansion in Asia Pacific Africa (APA), where nine new plants will be built. These new facilities will increase the region’s capacity to produce 2.9 million vehicles a year, part of Ford’s global plan to meet its goal of selling eight million vehicles a year by 2015.

With the addition of these new facilities, Ford is also expanding the use and application of common manufacturing processes and standard systems for tracking material, delivery maintenance and environmental costs so that both existing and new plants operate the same. Ford is also expanding the use of virtual tools to lower the cost of new plants and improve the efficiencies of new-model changeovers.

Ford’s One Manufacturing system will include:

Better flexibility: The percent of flexible body shops in Ford’s operations will increase from 55 to 65 percent in 2012. Each new plant launched will have a flexible body shop. Additionally, the number of vehicle derivatives that can be assembled in one single factory is also increasing; by 2015, Ford will be capable of producing 25 percent more derivatives per plant than in 2011. Some of the new plants in APA will have the ability to produce six and seven vehicles from one factory.

Process/quality Improvement: Buhler Ford is increasing the use of virtual tools that simulate vehicle assembly. By studying the best way for operators to build each part of the vehicle, Ford can create assembly lines that improve quality while reducing accidents and injuries.

Investment efficiency: The investment it takes to assemble a vehicle has been reduced by more than 20 percent since 2009 thanks to virtual tools. Additionally, Ford has reduced the investment to produce a vehicle derivative by 60 percent. By expanding the use of virtual tools and standard processes, total vehicle investment is expected to drop by eight percent per year.

Capacity utilization: With the launch of new plants, Ford is reducing the number of platforms from which vehicles are developed. When paired with more efficiencies and improved flexibility, Ford will be able to take advantage of global economies of scale and drastically improve capacity utilization; the brand’s global capacity utilization on a two-shift basis will increase 27 percent by 2016, compared to 2011.

Buhler Ford’s One Manufacturing process will allow assembly operations to work using the same language, regardless of where they are in the world, and will produce high-quality vehicles in a way that is both safe and efficient.