Ford of Canada sees benefits in flexible manufacturing

Manufacturing innovations are at the heart of Ford of Canada's all-new Ford Edge and Lincoln MKX production at the Oakville, Ontario, Assembly Complex (OAC).

Flexible manufacturing is a game changer for Ford of Canada. Through the use of reprogrammable and quick change tooling, OAC can build multiple models on unique platforms, enabling the plant to change the mix, volume and options of products more quickly in response to consumer demand.

Flexible manufacturing represents a new level of market agility and eliminates the lengthy and expensive retooling process required for traditional model changeovers. Several highlights of OAC's flexible system include:

• In a flexible plant, products come together using the same machinery, process and parts in three primary areas – body assembly, the paint facility and in final assembly, allowing OAC to manufacture products in a more efficient manner using standard assembly sequences and equipment.

• To improve efficiencies, OAC is one of seven flexible Ford facilities in North America to employ the same 16-cell flexible body assembly system; a cell is a self-contained work station that enables a common assembly sequence regardless of the type of vehicle. Each cell shares more than 300 standardized components and robots within cells are programmed to respond to variation in work flow and functions without missing a beat. Similarly, Ford's paint facilities and final assembly lines use similar standard-cell concepts to spread the cost savings throughout the manufacturing organization.

• The benefits of flexible manufacturing include economies of scale and standardization, which offers cons istent quality, allowing for more predictable output and improved quality management.

• Flexible manufacturing can provide an estimated initial new product launch cost savings of 10-15% and over 50% cost reductions on mid-cycle changeovers. There is also a significant increase in productivity and reduction in waste.

• Ford is on track to have 77% of its North American assembly facilities flexible, up from 38% in 2004.

Making it happen

Investment, new technologies and a shared vision on work practices have enabled OAC to secure its place as a jewel in Ford's manufacturing world. OAC's transformation included these highlights:

Investment / Infrastructure

• The $1 billion transformation of OAC includes the company's latest version of flexible manufacturing, incorporating the latest tooling technology and all that has been learned at Ford's six other North American flexible plants. OAC utilizes palletized systems which can accommodate vehicles of varying lengths, and the latest robotics for material-handling, welding, and sealer/adhesive applications.
  
• The Oakville "complex" is derived from the buildings that once housed the Oakville Assembly Plant and the Ontario Truck Plant, a total space of 5.4 million square feet. All redeveloped buildings feature the latest in water and air quality management.

• The largest investment was made in OAC Body #1 which houses 250 pallets and approximately 400 robots. Fully flexible to accept different models or variations on the same platform, OAC Body #1 welds and assembles metal body stampings/assemblies, including underbodies, body sides, roofs, hoods and lift gates, to name some.

• Another re-developed building, OAC Body #2 contains nearly 200 robots and produces Front/Rear door s and rear underbody assemblies.

Advanced Technology

• Wireless technology installed at the plant and on delivery trucks carrying inbound supplies enable the plant to monitor truck status and improve the efficiency of just-in-time shipments, reducing freight and inventory carrying costs.

• Advanced vision systems use a form of artificial intelligence in reviewing body and floor panel dimensions. In the past, measuring and qualifying parts for dimensional accuracy was less precise - part visual, part machine. Vision and Laser Tracking Systems are used to analyze the accuracy of the pallets and tooling.

• Newly-installed servo-electric weld guns in the flex body shop eliminate the loud noise associated with the older, air-powered tools. The guns are also programmed to find "perfect centres" each time two pieces of sheet metal are brought together for welding. The old system relied on a less sophisticated system of springs.

• The OAC in-house Center of Excellence is dedicated to checking all components and optimizing part-to-part coordination. Previously, the plant focused on the coordination of sheet metal components only. This new approach focuses on the coordination of the entire vehicle.

Operational Work Pattern / Training

• Flexible manufacturing and a flexible operational pattern work hand-in-hand. To be competitive for future products, OAC was very strategic in successfully negotiating the option of activating several three-shift operating iterations to meet potential future capacity or volume needs.
  
• Employees have completed extensive training in flexible assembly techniques, utilizing the latest computer technology. OAC houses a multi-million dollar training facility which duplicates the work stations on the floor in a quiet school environment.