Key Elements of Current Expansion Phase
- Vehicle production capacity at the Ford Maraimalai Nagar plant increases from 100,000 to 200,000 per year.
- New stamping press line with automated crossbar technology.
- New flexible body shop capable of producing different types of car bodies on one line. The new facility moves Ford India production from manual assembly to 30-percent automated assembly.
- All-new paint line featuring the pioneering application in India of the high-tech three-wet high-solids finishing process which eliminates baking between robot-applied paint coats for better finish quality and environmental benefits.
- Extension of the trim and chassis assembly line for flexible assembly of different models, taking advantage of centralized bulk material feeding and engine delivery via overhead conveyors. The new assembly line raises the plant capacity from 14 to 34 vehicles per hour.
- A major investment in quality assurance with the establishment of a dedicated testing facility that includes a new 3.2-kilometre quality testing circuit, a new squeak-and-rattle testing track for finished vehicles, dynamic water wading testbed and a four-post hydro-lifter for chassis testing.
- Establishment of new lean manufacturing techniques – technology-enabled by multiple computer systems – for build-to-order production with parts and components supplied from a new 35-acre adjacent supplier park. One example of the plant’s new lean approach is inventories of coil steel will be reduced from 60 days’ supply to two days of stock.
- Enlargement of the plant complex from 250 to 353 acres, approximately 60 percent of which is built-up area and the remaining acreage is comprised of lawns and green belt. The redevelopment includes a new zero-discharge wastewater treatment facility.
Stamping Facility Facts
- Two press lines, augmenting the plant’s existing Schuler semi-automated single press line with a new Komatsu (Japan) press line, featuring fully automated crossbar technology, capable of producing 15 parts per minute.
- Komatsu press line is configured for quick die changes of less than three minutes adding flexibility to production schedule.
- One Fagor tryout press to enhance tryout capability of tooling.
- Special robot crane with four-die stacking capability, up from two-die stacking previously.
- Expanded operation facilitates a reduction in two days of the stamping cycle for production of sheet metal components.
- The stamping plant incorporates new white light scanner technology for measuring the panels and dies. This “touchless” inspection method is used to measure all the stamping parts and dies for high levels of accuracy.
Flexible Body Shop Facts
- New single-line flow process includes automated robotic under body and flexible framing line designed for up to six different models in one line.
- Body shop automation level enhanced to 30 percent, which includes 66 robots for critical process like spot welding, sealer application and door hemming process.
- Body shop capacity enhanced to 34 jobs per hour from the current 15.
- Portable measuring machine is used to measure jigs and fixtures for build precision.
- Part checking fixture measures all major subassemblies, body, front-end and rear-end fit and finish.
- Real-time seal gap measuring equipment gives an edge over conventional method of measuring seal gaps with hand-held calipers.
- Body shop welding robots are equipped with new servo motor welding guns, another Ford investment in quality. Quieter than previous welding-gun technology, they deliver high-quality welds which are cleaner, with reduced expulsion and burring. Servo motors allow the welding tips to be brought smoothly into place, helping to eliminate distortion of the metal and ensure stable weld pressure.
Paint Line Facts
- The facility is first Ford car plant globally to introduce new Three-Wet High-Solids paint process, which delivers a superior finish with high gloss and depth of colour, improved durability and better resistance against scratches and stone chips.
- The Ford Chennai facility is the first automobile manufacturing plant in India with Three-Wet High-Solids paint technology.
- New automated paint booth features robots to apply three coats of paint – primer, base coat and clear coat – over top of one another. This “three-wet” approach eliminates the need for oven baking between coats.
- The new paint process produces less carbon dioxide emissions and reduces volatile organic compounds emissions by about 20 percent as compared to current medium-solids solvent-borne paints.
- Higher solids content, mixed with new polymers and other additives, minimises running and sagging during the application process. This facilitating the application of the three wet in series before oven curing.
- Paint shop capacity moves from 15 vehicles per hour to 34.
- The new paint booth uses 16 robots – eight for the base coat application and four each for the primer and clear coat.
- The new system also incorporates a new robotic underbody sealer application process. It uses three robots to apply the sealer, a quicker, higher quality approach for vehicle quality.
- Colour choice flexibility increases from eight to 11 different colours.
- Hydraulic pumps replace pneumatic pumps in the paint preparation and delivery process.
New Trim and Chassis Assembly Line Facts
- New assembly line facilitates the assembly of different cars on the same line via an integrated kitting conveyor.
- Line is extended by 425 meters.
- Off-line door assembly process.
- New combined ‘decking’ process for the installation of front and rear axle assemblies into each car body simultaneously using automated guided vehicles.
- New parts feed conveyor for other key components – wheels/tyres, bumpers, seats and instrument panel – replacing manual feed process.
- Fully dressed engines delivered in production sequence via a new overhead conveyor system from the new engine plant.
Quality Facilities Facts
- All-new, 3.2-kilometre test-driving track for the verification of new vehicle driving quality.
- The new test-driving track has been constructed on part of the plant’s 103 acres of expanded footprint.
- The circuit features various road surfaces designed to simulate real-world driving conditions, including straight road, twisting road, cement road, hill-climbing and village street conditions.
- Vehicles typically undergo about 40 kilometres of testing on the dedicated testing circuit. Its introduction means Ford of India will no longer routinely test new production vehicles on public highways around Chennai.
- New squeak-and-rattle test circuit after final assembly, mirroring the best practice of identical facilities at Ford assembly plants around the world. Requiring special manoeuvres over bumps and other surfaces, this is used to check vehicle quality and structural robustness before the vehicle is shipped – methodology that significantly reduces customer concerns about squeaks and rattles.
- An underbody hot check immediately after the squeak and rattle test checks that engine oil, transmission oil, engine coolant and air-conditioning refrigerant systems are operating without leaks when the vehicle is at full operating temperature. Engineers also check for air-conditioning system operation and even take the temperature of the grille as a final quality check.
- New enhanced dynamic testbed for water wading capability. This test validates vehicles meet Ford standards for water wading, a critical product attribute in markets like India prone to flooding. It involves driving at 10 kph through a tank of water 50 meters across and 450mm deep. The vehicle is then checked thoroughly to verify there are no leaks in the body or mechanical malfunctions.
- New four-post test device, which simulates a wide variety of road load conditions on a vehicle. This is used to verify the robustness of the vehicle chassis and to isolate the cause of squeaks and rattles if they are found.
- In-line water testing during the vehicle assembly process. This verifies that the vehicle is free from water leaks and that all weather seals and closures are performing optimally.
Lean Manufacturing Facts
- The enlarged Maraimalai Nagar plant has been built to a ‘lean journey’ approach to material logistics, taking advantage of a significant upgrade in automation and computer power. Logistics planning is built around a “build to order” approach, versus some manufacturing plants’ “build to stock” approach. This means each vehicle is specifically built to an individual customer or dealer order.
- The assembly line features lean line-side inventory, utilizing a kitting approach to deliver the right parts and components for each vehicle as it is assembled. The kitting system uses wheeled trolleys that follow alongside each vehicle through its assembly. The trolleys are designed to make the effort of production workers more ergonomically easy, such as reducing bending movements.
- Upgraded IT infrastructure uses multiple IT systems – including radio frequency identification (RFID) – to manage logistics within the plant facility.
- The plant has been designed for efficiency, managing smaller inventories of commodities and components. The blanking plant, which formerly required a 60-day supply of coil steel, now runs on just two days’ supply. This more compact approach allows warehousing closer to the assembly line, for greater speed.
- Greater automation is being used for material feeding, including conveyors and decking vehicles.
- Key suppliers are clustered in an adjacent supplier park, and 65 percent of the plant’s supply base is within 100 kilometers of the site.
Plant Site Facts
- Through Ford’s $500 million investment, the plant complex has been enlarged from 250 to 353 acres.
- Approximately 60 percent of the plant site is built-up area. The remaining acreage is comprised of lawns and green belt.
- The number of buildings on the site has increased with two new buildings – engine plant and machine shop.
- The site features an enlarged supplier park, which feeds components and assemblies for the assembly plant’s lean-manufacturing approach. Major on-site suppliers include Visteon, TATA Johnson Controls, YAPP and Cooper.
- Capacity for Ford India office staff has been expanded 27 percent to approximately 760.
- Canteen facilities and employee locker room are being enlarged to serve the plant’s higher employment levels.
- The redevelopment includes construction of a new zero-discharge wastewater treatment facility for the plant complex.
- The enlargement in the assembly plant facility was achieved in 21 months.
People and Employment Facts
- The plant directly employs 2,351 staff members, technicians, engineers and craftspeople.
- By the time the full plant expansion has been completed, the plant will have been responsible for hundreds of new direct employees.
- Thousands of indirect jobs are being generated in the Chennai area as Ford India increases its local supplier base.
- The average age of the technical staff is 27 years. Managerial and administrative employees average 32 years of age.
- Technical staffs have attained a minimum of 12th standard or have received a diploma in engineering, while staff members typically have engineering or management degrees.
History Facts
- Set up in 1999 at Maraimalai Nagar near Chennai with an original project outlay of Rs 1700 crores.
- Commissioned to manufacture Ford India's products, reinforcing Ford's commitment to the country and to Indian customers.
- Built to global standards in automobile manufacturing technology and processes.
- Fulfilled over 70-percent indigenisation in the manufacturing process at the time of its commissioning.
- Originally supported a manufacturing capacity of 100,000 units per annum.
- Incorporated the best practices and processes of Ford Motor Company.
- A significant initiative in Ford Motor Company's plans for India and the Asia Pacific and Africa region.
###
About Ford Motor Company
Ford Motor Company, a global automotive industry leader based in Dearborn, Mich., manufactures or distributes automobiles across six continents. With about 201,000 employees and about 90 plants worldwide, the company's automotive brands include Ford, Lincoln, Mercury and Volvo. The company provides financial services through Ford Motor Credit Company. For more information regarding Ford's products, please visit www.ford.com.
About Ford India
Established in 1995, Ford India is a wholly owned subsidiary of Ford Motor Company, a global automotive industry leader. Ford India manufactures and distributes automobiles made at its modern integrated manufacturing facility, at Maraimalai Nagar, near Chennai. With more than 2300 employees, the company's models include the Ikon, Fusion, Endeavour and the Fiesta. For more information, visit www.india.ford.com.