Home » One more step towards getting a North American Focus RS…???

One more step towards getting a North American Focus RS…???

by DrivingEnthusiast

focus-rsReducing costs in the manufacturing process increases profit, which in turn opens up new possibilities for additional products and models.

The new Focus assembly plant in Wayne, Michigan will be Ford’s most flexible plant in the world. The plant will build the new 2012 model year Focus (at long last North America gets the worldwide Focus!) as well as a plug-in electric Focus. Production of the “Focus Electric” is a very important fact to note because that car will obviously be so different from the conventional Focus that major differences in the production process will be necessary. Those types of differences would have required an entirely different production line in the past. Now it will be the same line – saving enormous costs and helping to turn a questionable profit model around.  The assembly line will be so flexible that it may also be used to build the Focus-based C-Max minivan and other products post-2012.

Lack of assembly line flexibility has been one of the problems with building the European Focus RS: it has usually required a separate assembly line. The extreme example of this problem is it’s Escort predecessor, the Escort RS Cosworth, which had an entirely different floorpan with a north-south drivetrain and all-wheel drive. The current Focus RS is purposely much more conventional, right down to using a mildly modified version of an optional engine. One of the reasons the Focus RS doesn’t have all-wheel drive is because it would have muddied the assembly process – and costs – even more.

The current RS requires a separate post-assembly process, as shown here: http://www.drivingenthusiast.net/sec-blog/?p=7201. That adds cost to the financials and makes it very difficult to build the RS anywhere else or in enough quantity to make a significant profit. So, if Ford can develop a more flexible assembly line, one which can handle major differences without impacting the process and slowing down the line, then maybe – just maybe – one more piece has fallen into place that will allow the RS to be built in and for North America one day.

Ford press release follows:



  • Michigan Assembly Plant in Wayne, Mich., home of the 2012 Ford Focus, will be Ford’s most flexible high-volume manufacturing facility in the world when production begins
  • More than 80 percent of the body side tooling and equipment in the Michigan Assembly Plant body shop can be programmed to weld the bodies of a variety of vehicles, enabling production of many different vehicle body styles in the same facility without lengthy tooling changeovers
  • Ford’s system at Michigan Assembly Plant provides manufacturing flexibility – specifically in body construction – the company never has had before, allowing it to more quickly and efficiently meet changing consumer preferences

TRAVERSE CITY, Mich., Aug. 2, 2010 – When production of the all-new 2012 Ford Focus begins later this year, Ford Motor Company’s newly transformed Michigan Assembly Plant will be the company’s new benchmark for flexible manufacturing around the world.

Michigan Assembly is one of three truck plants in North America that Ford is revamping to make fuel-efficient passenger cars.  The plant will build the new Focus and Focus Electric beginning next year with more models coming in the future.

At Michigan Assembly, Ford will utilize programmable equipment in its body shop, which will allow the company to run multiple body styles down the same production line without requiring considerable downtime for changeover of tooling.  In fact, more than 80 percent of the body tooling in the plant’s body shop can be programmed to weld a variety of body styles without delay in tooling changeover and can adjust the mix between models without restrictions.

“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.”

While the state-of-the-art Michigan Assembly facility is utilizing Ford’s industry-leading virtual manufacturing technology, three-wet paint process and a common build sequence in the final assembly area, the most significant step toward improving flexibility is taking place in its body shop.  The company’s Manufacturing operations worked closely with its Product Development teams to construct product platform designs that enable use of the programmable equipment to produce multiple variations of products in one facility.

Body construction has long been a limiting factor in any plant’s flexibility.  Under traditional systems, unique tooling is required to weld each individual vehicle body style.  Running a different body style down the same line traditionally requires considerable additional downtime for physical tooling changeover.

In recent years, Ford has made important strides in assembly plant body shop flexibility in plants such as Chicago Assembly, Oakville Assembly and Kentucky Truck, where significantly different products are built on a common system.  However, Ford’s latest strategy dramatically reduces physical tooling constraints through use of the programmable tooling technologies that eliminate the need to replace model-specific tooling for locating, clamping and welding.  This saves time and limits disruption to the plant’s operations.

“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.”

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