PICS : Ford's Chennai Factory. Detailed report on the making of Figos, Fiestas...

recshenoy · 21st May 2010, 18:35

WOW. very good report detailed report GTO! i felt as if i am going around factory in a guided tour!. Was team bhp invited by FORD or you had approached FORD for same?

Do they have auto robots which transfer parts between the different assembly
section? They are so lovely to watch.

OT:

Is this the second factory visit report! long back i remember reading a MERC factory visit. I really loved the white Figo line up photo!

sidindica · 21st May 2010, 18:37

wow! amazing! GTO, you must be one lucky man!

GTO · 21st May 2010, 18:38

Quote:

Do they have auto robots which transfer parts between the different assembly
section?

I believe so. What caught my eye was the "lights system". Say, an engineer has to fit a certain part and there are trays of components for the different cars / engines in front of him. Each bin has a light, which tells the engineer what bin he's to choose.

Quote:

Was team bhp invited by FORD or you had approached FORD for same?

Ford dropped an invite for this 1.5 day visit. I mean, c'mon, you need guts to show your internal operations to the world. Like I said, its Ford showing off

pulsar56 · 21st May 2010, 18:38

Impressive and detailed coverage of the FORD Plant GTO.

Ford is really trying hard to come out of the 'Expensive-to-maintain' image and the results can be seen with the FIGO bookings.

Quote:

I'm not sure if anyone else at the event noticed this board standing in the corner...but it sure as hell made me smile.

Those are really scary lines!

Damu · 21st May 2010, 18:55

Hi GTO,

That was very interesting. Superb photos!

Was it very noisy and hot inside?

Do you have any more pics? I would be interested to know how the monocoque is built up.

Regards
Damu

aman9393 · 21st May 2010, 19:02

Awesome coverage GTO.
Good that Ford is selling Child Parts separately. This will hugely bring down maintenance costs.

Quote:

I'm not sure if anyone else at the event noticed this board standing in the corner...but it sure as hell made me smile.

'Ford. We started it all.' was the best!

romeomidhun · 21st May 2010, 19:12

Stunning explanation, GTO!

But is there no body frames on which the panels are fitted? Or they are just welded only?

ampere · 21st May 2010, 19:13

GTO,
This is a 5 Star thread. Amazing info. One stop capsule of information.
Similar to what engg. college students for an industrial visit.

Sad, that I cannot ask questions to the production guys!

Very nice read.

jraj · 21st May 2010, 19:19

GTO I really envy you.
Being with Ford's IT division,my various attempts to visit the factory always turned futile.

I think I can make do with the wonderful pictorial report here.

recshenoy · 21st May 2010, 19:21

Quote:

Originally Posted by GTO

I believe so. What caught my eye was the "lights system". Say, an engineer has to fit a certain part and there are trays of components for the different cars / engines in front of him. Each bin has a light, which tells the engineer what bin he's to choose.

waw thats very innovative! One of my friends to whom i showed these pics now advised that "Ford factory in Oakland CA also had almost similar set up like this"!

Quote:

Ford dropped an invite for this 1.5 day visit. I mean, c'mon, you need guts to show your internal operations to the world. Like I said, its Ford showing off

When i visited Mitsubishi factory abroad, they strictly advised "No photos please we have some proprietary systems". This is testimony for team bhp's popularity i must say. hope other manufacturers will soon invite us

Is this factory 24 hours, i mean is there a night shift ?

ElantraGT · 21st May 2010, 19:24

GTO at the end of the final inspection, the vehicles will be tested for brake testing and water proofing. They drive the car inside a water wash kind of equipment to test for leaks inside the car. Did you notice that and also they had a small rumble strip track behind it. I am not sure if its still there. This thread brings back old memories.

Did you happen to have the photos taken inside the paint shop or didnt they allow it. The paint shop is really massive and its a clean environment.

extreme_torque · 21st May 2010, 19:32

No there is no inside crash test facility

Nice report Rush.

romeomidhun · 21st May 2010, 19:35

One more question, GTO: During last round road test, if any vehicle is found problematic, will it be rectified or dismantled completely?

extreme_torque · 21st May 2010, 19:39

By the way another news for you guys. The pilot production of the all new Fiesta will start somewhere around July and will be launched before the year end. The petrol 1.6 with 119 bhp is confirmed.

Reisender · 21st May 2010, 19:54

@GTO... Nice photos and good writeup
You rock as always..

Keep it up

21st May 2010, 18:35	#16
recshenoy Senior - BHPian Join Date: Mar 2008 Location: Mangalore / Bangalore Posts: 1,129 Thanked: 256 Times	WOW. very good report detailed report GTO! i felt as if i am going around factory in a guided tour!. Was team bhp invited by FORD or you had approached FORD for same? Do they have auto robots which transfer parts between the different assembly section? They are so lovely to watch. OT: Is this the second factory visit report! long back i remember reading a MERC factory visit. I really loved the white Figo line up photo!
	() Thanks

21st May 2010, 18:37	#17
sidindica Senior - BHPian Join Date: Jun 2007 Location: Earth Posts: 4,904 Thanked: 8,409 Times	wow! amazing! GTO, you must be one lucky man!
	() Thanks

21st May 2010, 18:55	#20
Damu BHPian Join Date: Mar 2005 Location: Bangalore Posts: 222 Thanked: 64 Times	Hi GTO, That was very interesting. Superb photos! Was it very noisy and hot inside? Do you have any more pics? I would be interested to know how the monocoque is built up. Regards Damu
	() Thanks

21st May 2010, 19:12	#22
romeomidhun BANNED Join Date: Nov 2007 Location: IN Posts: 3,381 Thanked: 5,460 Times	Stunning explanation, GTO! But is there no body frames on which the panels are fitted? Or they are just welded only?
	() Thanks

21st May 2010, 19:13	#23
ampere Team-BHP Support Join Date: Sep 2009 Location: Bangalore Posts: 18,351 Thanked: 13,660 Times View My Garage	GTO, This is a 5 Star thread. Amazing info. One stop capsule of information. Similar to what engg. college students for an industrial visit. Sad, that I cannot ask questions to the production guys! Very nice read.
	() Thanks

21st May 2010, 19:19	#24
jraj BHPian Join Date: Oct 2005 Location: Michigan,USA Posts: 490 Thanked: 212 Times View My Garage	GTO I really envy you. Being with Ford's IT division,my various attempts to visit the factory always turned futile. I think I can make do with the wonderful pictorial report here.
	() Thanks

21st May 2010, 19:24	#26
ElantraGT BHPian Join Date: Sep 2009 Location: Chennai Posts: 441 Thanked: 12 Times	GTO at the end of the final inspection, the vehicles will be tested for brake testing and water proofing. They drive the car inside a water wash kind of equipment to test for leaks inside the car. Did you notice that and also they had a small rumble strip track behind it. I am not sure if its still there. This thread brings back old memories. Did you happen to have the photos taken inside the paint shop or didnt they allow it. The paint shop is really massive and its a clean environment.
	() Thanks

21st May 2010, 19:32	#27
extreme_torque BANNED Join Date: Feb 2005 Location: Melbourne Posts: 4,461 Thanked: 5,535 Times	No there is no inside crash test facility Nice report Rush.
	() Thanks

21st May 2010, 19:35	#28
romeomidhun BANNED Join Date: Nov 2007 Location: IN Posts: 3,381 Thanked: 5,460 Times	One more question, GTO: During last round road test, if any vehicle is found problematic, will it be rectified or dismantled completely?
	() Thanks

21st May 2010, 19:39	#29
extreme_torque BANNED Join Date: Feb 2005 Location: Melbourne Posts: 4,461 Thanked: 5,535 Times	By the way another news for you guys. The pilot production of the all new Fiesta will start somewhere around July and will be launched before the year end. The petrol 1.6 with 119 bhp is confirmed.
	() Thanks

21st May 2010, 19:54	#30
Reisender BHPian Join Date: Jan 2010 Location: Atlanta, USA ; Chennai India Posts: 159 Thanked: 64 Times	@GTO... Nice photos and good writeup You rock as always.. Keep it up
	() Thanks