As Ford Authority reported back in October 2023, Ford previously purchased the same type of giga press machine that Tesla has used, which can create massive pieces of a vehicle’s underbody, helping to save time and cut down on the costs associated with manufacturing. We later learned that Ford’s skunkworks team developing a low-cost EV platform was laser-focused on reducing complexity, and that the Louisville Assembly plant will be retooled for the production of future EVs later this year. Now, Ford has debuted the universal EV production system that the plant will utilize for those tasks.
This new universal Ford EV production system is quite a bit different than a regular assembly line in many ways, as it’s laser-focused on improving efficiency throughout that process – largely by transforming the traditional assembly line into an “assembly tree.” This means that rather than utilizing one, long conveyer, Ford will employ three subassemblies running down their own lines at the same time, which then join together, as we can see in this chart.
From there, Ford has replaced dozens of smaller parts with large, single-piece aluminum unicastings, which gives it the ability to assemble the front and rear of vehicles separately. Once that process is complete, the front and rear are mated to a third sub-assembly, the battery pack, seats, consoles, and carpeting, all of which are independently assembled along with the pack. Those operating the assembly tree will receive parts via kits, which contain all of the power tools, scanners, and fasteners needed to complete the job – neatly organized, to boot.
The result is an assembly process that’s not only more efficient, but also, one that improves ergonomics for workers by reducing the need to bend, twist, and reach for things. According to Ford, the assembly tree will result in a production process at the Louisville Assembly plant that could be up to 40 percent faster than existing methods, though some of that time savings will be reinvested in automation and insourcing – which means that speed improvements will total around 15 percent, ultimately.
“We put our employees at the center and re-created the factory from scratch,” said Bryce Currie, Ford vice president, Americas Manufacturing. “We live and breathe continuous improvement, but sometimes you need a dramatic leap forward. We expect ergonomic breakthroughs and complexity reduction – through elimination of parts, connectors and wire – will flow through to significant quality and cost wins.”
A way to deal with worn out physical controls.
It's in great condition, too.
The automaker showed off six different potential body styles.
It's a cheap and quick repair, thankfully.
The facility is set to undergo a major transformation.
The shocks can be upgraded or replaced, as needed.
