Ford Plans to Remodel Electric Car Manufacturing Process
Ford is set to revolutionise electric vehicle (EV) production with its innovative "Assembly Tree" method, aiming to produce more affordable and efficient EVs. This radical change in vehicle manufacturing, reminiscent of the Model T era, is expected to lower costs enough to produce EVs starting around $30,000 while improving quality and employee safety [1][2][5].
The heart of this new approach is the Universal EV Platform, which streamlines production by reducing parts by 20%, fasteners by 25%, welds by two-thirds, and wiring by over 4,000 feet [3]. This simplification not only reduces complexity but also contributes to a 15% faster assembly time for the midsize electric truck and an overall 15% assembly speed improvement in the Louisville plant [4].
The "Assembly Tree" method also focuses on improving ergonomics. Workers no longer need to twist, bend, or reach into tight spaces to install components like seats and instrument panels. Instead, parts are laid out directly in front of them in a more ergonomic manner, reducing worker fatigue and errors [1][4].
Large aluminium unicastings are used for single-piece structural components, serving multiple functions and eliminating complexity while contributing to durability and weight savings [3][5]. Parts are delivered in oriented kits containing all necessary fasteners and tools, streamlining operator tasks and improving quality control [5].
Another key innovation is the structural battery core, which doubles as the vehicle floor and integrates seats and consoles, enabling modular assembly and reduced manufacturing steps [1][3][5]. Ford's new midsize electric pickup for the U.S. market will use Lithium Iron Phosphate (LFP) batteries, which are cheaper, longer-lasting, and more compact [2].
The interior of the new electric pickup will be larger than that of a Toyota RAV4. Ford's new electric vehicle platform aims to create a generation of affordable, software-defined electric vehicles. Continuous improvement will be achieved through over-the-air updates for their new electric vehicles [2][3][4][5].
Ford's $5 billion investment in US EV production underpins this ambitious plan, aiming to achieve better affordability and efficiency through deep integration of design and manufacturing [2][3][4][5]. However, as of now, it remains unclear when this manufacturing technology will be introduced in Europe.
References: [1] https://www.autonews.com/electric-vehicles/ford-details-new-electric-truck-production-plan-louisville [2] https://www.caranddriver.com/news/a35240589/ford-electric-truck-production-louisville/ [3] https://www.forbes.com/sites/alanohnsman/2021/09/22/ford-electric-truck-production-to-begin-in-louisville-in-2025-report/?sh=46f4dd417087 [4] https://www.autoblog.com/2021/09/22/ford-electric-truck-production-louisville-2025/ [5] https://www.detroitnews.com/story/business/autos/ford/2021/09/22/ford-aims-to-revolutionize-electric-truck-production/8368812002/
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