[GTO]

NOTE : Click here to read Khan Sultan's detailed report on the Jaguar Factory at Castle Bromwich.



Have you ever seen a car factory in India? Been explained, in the highest detail, the entire production process by Heads of Manufacturing? Right from the time that sheets of steel come in, to the car actually rolling out? I've been to other factories before, but no one allowed a camera inside. I was pleasantly surprised when Ford accepted my request to click pictures inside their production facility. And why not? Ford has a facility that's worthy of showing off

I am no engineer, and what follows is a pictoral report of the Ford Factory at Chennai. Through the eyes of a regular car enthusiast. I'm trying to keep this report as simple as possible, so that the average enthusiast as well as the technically inclined find it informative.

Visiting any Ford plant is a special experience; after all, its Henry Ford who originally mastered the assembly line. Some highpoints on Ford's Chennai factory:

• Without doubt, Ford upgraded its facility to meet the demand generated by its entry into the hatchback segment (i.e. the Figo). Brand new engine manufacturing facility completed in end '09. First Figo rolled off these lines in Feb '10. 18,000 booked and 13,000 already delivered.

• We aren't talking mere assembly here; this is a full-fledged production line. Massive localisation. To the tune of 80 - 85% on the Figo & Fiesta.

• Total investment of 2,500 crore rupees over the last 2 years. Chennai factory will serve local as well as export markets. Engine plant capacity of 250,000 per annum. IB5 gearboxes also locally sourced.

• Engines produced include 4 cylinder petrol & diesel, with sizes ranging from 1.2 - 1.6 liters. Yup, we also saw a 1.6 liter 118 BHP petrol unit on the presentation slides. Terribly disappointing that the said unit isn't offered to Indian enthusiasts.

• Same production line can handle the Figo, Fiesta and Ikon. Multiple engine variants too (complete product mix) in any order (no need for batches)!

• 4 engine dynos located onsite.

• Currently running on a single 8 hour shift. Fully ready for three 8 hour shifts in the future (effectively meaning that the facility runs 24 hours daily, 6 days a week).

• Employee count at factory currently stands at 3,000. Will add another 2,000 in the near future. That said, crucial processes are fully automated. 66 robots recently installed.

• Environment-friendly, Ford claims that their new painting process reduces volatile organic compounds by 20 percent, and is a first for India.

The now familiar red dashboard leads us in. Max speed limit within Ford's facility = 15 kph:


P.S. : You better have a high-speed internet connection to view this thread. It's a biggie

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Stage ONE : The Metal Blanking Section

Coils of steel being lifted and brought to the blanking machines:


Neatly placed into cradles:


Here is where the steel is uncoiled, washed and then cut:


To the right is the end of processing:


Scrap (excess from cut sheets):


The Control Panel. Notice the real-time video screen that tells this engineer exactly whats happening inside:


Heavy duty machine that stacks the blanks on a palette:

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Stage TWO : The Stamping Process

The Stamping Machine:


Grippers (arms to hold the metal sheets) of varying sizes (for different body parts):


Measurement of panels, ensuring that the stamping is perfect:



Finished panels of the Figo's bonnet lined up, and ready to proceed to the body shop:


That’s the Figo’s roof:


Side body panels:


You'll see the Fiesta's side body panels on top:

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Stage THREE : The Body Shop

Underbody being automatically fed to the underbody line. All the points are welded (front and rear sub assemblies included):


Being transferred to the framing line, where the side panels & roof will be fitted:


The Ikon assembly line:


Robots – this is an entirely automated line – are in charge of welding the side panels & roof:


Welding done!


Fiesta on the same framing line. On its way to pick up the doors, fenders, hood and trunk:


Look to the extreme left of the picture. An engineer is manually checking the frame for dents / defects (just in case). The Endeavour & Figo (picture center) are being prepared for painting:


Figos going for a bath. Literally (Water jet wash, then spray paint):


Coming out of the paint shop:

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Concurrent Stage : The Engines!

Engine Cylinder head. Fully localised:


The rather smallish looking Turbocharger:


The seal press machine:


Engineers running a check on the cylinder heads:


Internals assembly line:


Being transported to the next stage:


Flywheel fitment. At the back, you’ll see the engines being cold-tested. Most other manufacturers use “hot testing” (where the engine is actually started). Ford uses the cold testing approach (no need to start the engine at all). Checks include fuel injectors, sensor connectivity, fuel rail leakage, oil pressure and camshaft positioning:


On the way to get “dressed”:


This is where the engine is “dressed up” with the starter, alternator, oil filter and more:


The finished engine:


Automatic storage & recovery system. Machines store the engines on top (caged area), remember the positioning, and automatically retrieve the units when required (remembering what was stored where too). On the RHS is the hot testing room (engines are pulled out randomly for testing. Only 1 – 2 from a batch of hundreds):

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Stage FOUR : Trim Chassis and Final Line

Cars waiting for their trim:



This is the pre-trim stage. Some basic parts are being fitted:


That’s the Endeavours assembly line at the back. At the top right, you’ll see doors getting their wiring, window mechanism etc:


Under-hood trim line. This is where the compressor pipes, firewall insulation etc. are installed:


Dashboard, interior plastics and more being fitted. Note that the parts bins moves ALONG WITH its respective car:



The Figo’s interiors being kitted out. Notice how the body panels are covered to prevent scratches / damage:


Windshield experts:


An automated guided vehicle installing the engine, suspension, steering and transmission onto these Fiestas. Components installed from down up. Body remains suspended. Its only some nuts & bolts that are fitted manually. The process is overall fully automated:


Finito!


Final inspection:




Lined up & ready to be shipped:

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Safety messages being amply communicated to staff members:

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"Driving Skills for Life"

As part of its "Corporate Social Responsibility" initiative, Ford has recently launched the "Driving Skills for Life" education program in India. The program's scope will cover its employees, while some dealers too have evinced interest in conducting the program at their level.

So, what is the Driving Skills for life program?

• Training that includes theoretical (classroom) and practical sessions
• Total time = About 2 hours in the classroom, and another 1.5 hours for practicals
• Subjects : Driving for Safety. Driving for Economy.
• Several points covered, including the importance of seat belts (for rear passengers too), maintaining a "3 second" distance from the car ahead, right of way at intersections, the dangers of speeding (e.g. the dramatic difference in braking distances from 60 versus 65 mph), blind spots, avoiding distractions (SMS'ing while driving) and, of course, maximising fuel economy (the right gear changes).
• Videos made the training interesting. Sure-shot way of captivating the audience.
• Mr. Shakti from Hubert Ebner (Ford's partner in the event) is so obviously well-read on the subject. He frequently backed up bits of safety advice with sheer statistics (nothing like numbers to drive the safety message home).
• Though the program is targeting regular drivers, even as a petrolhead, I benefited from some key points (e.g. seat belts for rear passengers, importance of daytime running lights etc.). Great refresher of safety pointers for pros too.

More info at the Driving Skills for Life Homepage

[GTO]

A Fiesta 1.6S on Ford's Test Track

The "Driving Experience for Life" practical session being conducted. Among other things, how braking distances can vary in real-life conditions was demonstrated:


Me & the 1.6S getting ready for the arrow straight section of the track:


Indian "rough road" conditions have been artificially created on the track. Don't miss the potholes:




Amazing, fast, right-hander:


Where handbrakes and low gear ratios are tested:


The "Belgian Block" section. Engineers switch the engine off, let the car roll down, and check for unwanted noises:


That's the Endeavour's territory. Nope, I didn't take the Fiesta down this way:


You do realise what an empty lock-to-lock test track and a Fiesta 1.6S mean, right? I had an absolute blast:


Among other things, the steering & suspension are checked on this section:

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Child Parts

Ford carries the "expensive to maintain" reputation from the early Ikon / Mondeo days. In its effort to reduce ownership costs, Ford has adopted the "child parts" approach. To give you an example of the child parts approach, if the solenoid of your starter fails, you do NOT need to change the entire starter assembly. Rather, Ford will sell you only the solenoid assembly (which will, of course, cost only a fraction of that for the entire starter).

The door & door skin sold separately:


Important in India - Mirror glass and cover sold independent of the assembly:


Starter motor parts:


Ditto for the compressor:


And the Alternator:


Float unit can be purchased separately:


That's what your gears look like. Again, ratios can be bought individually:

[GTO]

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.

To pick a few lines:

If there were no cars, there would be
- no car pools
- No lying about your age for a licence
- No romancing in the back seat
- Nothing to put a just married sticker on
- No peeping into new cars
- No eyes meeting in the rear-view mirror
- No "Are we there yet, Daddy?"
- No "new car smell"
- No Women drivers
- No Driving off into the sunset
- No 0 - 60
- No love bug...........

Just the thought scared the heck out of me

[Captain Slow]

Very Impressive !! Ford seems to have started playing hard and wants to catch up with maruti. Good going ford!
GTO you were invited down to chennai for this?


Edit -
So many Figos? And I wonder why people complain about not getting their cars on time.

[anachronix]

Awesome! Just awesome GTO.

The whole write up made me feel that I was there at the Ford facility!

Btw, I have heard about a internal crash test facility. Is that true!?

[RajaTaurus]

GTO, Awesome pictures from inside factory. Engineer's delight to visit one and you brought the factory live in front of us. Salutes to you.
One thing I noticed. Many of these pictures could be unique and there are no Team-bhp water marks on any photos? Me Curious.

[kvish]

Awesome stuff! Just makes me want to take up a job in Automobile engineering. Great report! as always.