Ford’s Michigan Assembly Plant Gets Enhanced Flexibility

American manufacturer Ford has finished transforming its Michigan Assembly Plant in one of the most flexible manufacturing facilities in the world, preparing it for the production of the all-new 2012 Ford Focus later this year. The truck plant has been revamped to produce passenger cars such as the new Focus and Focus Electric for the beginning.

The plant will include programmable equipment in the body shop, allowing Ford to run multiple body styles down the same production line without delay in tooling changeover and can adjust the mix between models without restrictions.

In fact, the manufacturer says that more than 80 percent of the body tooling in the plant’s body shop can be programmed to weld a variety of body styles.

“If the last few years have taught us anything, it is that customer wants and needs can change quickly – much more quickly than we have been equipped to respond to efficiently in the past,” said Jim Tetreault, Ford vice president of North America Manufacturing. “At Michigan Assembly, we will achieve a level of flexibility we don’t have in any other plant around the world, which will allow us to meet shifting consumer preferences in real time.”

Aside from the changes made to the plant’s body shop, the facility also uses Ford’s virtual manufacturing technology, three-wet paint process and a common build sequence in the final assembly area.

“Manufacturing flexibility provides a competitive advantage, so it is essential that we continue to improve our flexible capability,” Tetreault said. “The automakers with true flexibility will be positioned to compete more effectively in the global marketplace. That’s why continuous improvement in flexibility is a priority for us.”