Ford’s Game-Changing Strategy to Compete With China
▼ Summary
– Ford CEO Jim Farley introduced a revolutionary three-part assembly method for EVs, contrasting traditional linear production lines.
– The new “assembly tree” system splits EVs into front, middle, and rear sections, enabling faster, cheaper production with fewer parts.
– Ford’s Universal EV Production System will reduce assembly time by 40%, cut workstations, and use 20% fewer parts.
– The scalable “Ford Universal EV Platform” features a modular 400-volt design and cheaper LFP batteries as structural components.
– Ford plans to launch its first vehicle under this platform in 2027—a $30,000 electric pickup with performance rivaling a Mustang EcoBoost.
Ford is revolutionizing electric vehicle production with an innovative three-part assembly system that could dramatically cut costs and boost efficiency. The automaker’s bold new approach challenges traditional manufacturing methods by splitting EVs into front, middle, and rear sections built separately before final assembly.
Unlike conventional assembly lines where workers install components piece by piece along a single conveyor, Ford’s “assembly tree” concept allows three parallel production streams to operate simultaneously. This breakthrough enables the use of massive single-piece aluminum castings for each vehicle section, replacing hundreds of smaller parts. The streamlined process gives technicians unprecedented access during assembly, workers can literally build components from inside the vehicle frame itself.
Dubbed the Ford Universal EV Production System, this $2 billion initiative will debut at the company’s Louisville plant. Early projections suggest 40% faster production times with 30% fewer workstations required. The simplified design slashes part counts by 20% and reduces fasteners by nearly a third. Wiring harnesses in upcoming models will shrink by over a mile while shedding 10 kilograms in weight, just some of the efficiency gains driving down expenses.
Supporting this manufacturing shift is Ford’s new 400-volt Universal EV Platform, designed specifically for modular three-section assembly. The scalable architecture accommodates everything from compact cars to full-size SUVs, with the midsection integrating cost-effective lithium iron phosphate (LFP) batteries as structural components. These safer, more affordable power packs, popular in China, cost 30% less than traditional lithium-ion batteries while maintaining performance.
The first vehicle using this system, a $30,000 electric pickup truck, arrives in 2027 with Mustang-level acceleration and Toyota RAV4-beating interior space. Behind the scenes, Ford’s secret skunkworks team, led by former Tesla and Apple executive Doug Field, has been refining this game-changing production method. By rethinking EV manufacturing from the ground up, Ford aims to compete aggressively on both price and innovation in the rapidly evolving electric vehicle market.
(Source: Wired)
