Opened: 

1968

Location: 

Sterling Heights, Mich.

Employment:  

1,260 employees (1,150 hourly; 110 salaried)

Products: 

6F35:  2009 Ford Escape, 2009 Mercury Mariner, 2009 Mazda Tribute.

6F50:  Ford Taurus, Taurus X, Edge, 2009 Flex, Mercury Sable, Lincoln MKX and 2009 Lincoln MKS.

4F72E:  Ford Focus. Also used in Ford C-Max, Fiesta (current model), Transit Connect, EcoSport and Focus that are built and sold in non-North American markets.

Transmission/Axle stampings:  For Sharonville Transmission,

Livonia Transmission, Batavia Transmission and Sterling Axle Plant. 

Technology:

• A $370 million investment in new assembly lines and flexible machining allows the plant to build different versions of 6-speed, front-wheel-drive transmissions, quickly change over to new products and rapidly integrate design modifications to satisfy the changing needs of consumers. 
• Computer Numerical Control (CNC) Machining Centers house precision cutting tools used to fabricate components to specific dimensions. The machines produce complex 3-D structures with relative ease and require fewer steps by the operator.
• A Condition Indicator Analysis Box (CIAB) detects tool wear. Used in conjunction with CNC machining, CIAB is an advanced vibration monitoring technology that analyzes real-time measurements to ensure proper equipment function and high-quality parts. 
• Minimum Quantity Lubrication (MQL) is integrated into CNC aluminum machining. Instead of dousing the part and cutting tool with gallons of coolant, MQL uses small amounts of lubricant atomized with compressed air to lubricate tools during machining. Not only is the process environmentally responsible, it also saves money.
• A Traceability Strategy is used to track each “tagged” component to specific transmissions and vehicles.  If a quality concern is detected, the plant can locate individual components by their laser-engraved IDs, whether they are in the plant or in a vehicle at a dealership.

Honors: 

Michigan Dept. of Environmental Quality 2007 Clean Corporate Citizen Quality Magazine 2008 Plant of the Year

2007 Environmental Highlights:

• Energy usage reduced by 17 percent
• Hazardous waste reduced by 76 percent
• Reduced water use by 32.6 percent
• Recycled (not landfilled) 337.5 tons of wood
• Reduced oil used in processes by 179,137 gallons