Ford unveils $5 billion US investment during its 'Next Major Revolution' announcement
Ford is set to revolutionise electric vehicle (EV) production with its new Ford Universal EV Production System. This innovative system, set to debut at a Michigan battery plant, replaces the traditional moving assembly line with a three-branched assembly tree that assembles the front, rear, and structural battery of the vehicle in parallel[1][2][3].
Key design elements of the new production system include the use of large single-piece aluminum unicastings that replace dozens of smaller parts, simplifying assembly and reducing part count significantly[1][2]. Components and tools are delivered to workers in kits that contain all fasteners, scanners, and power tools needed for the task, arranged in the exact orientation for efficient use[1][2].
This design minimises movement and physical strain on workers, improving ergonomics and safety[3]. The new production system was developed by a small, highly empowered team that rethought production from the ground up, discarding traditional assembly line practices that were over 100 years old[4][5].
These innovations contribute to lower costs and faster production by reducing complexity and number of parts, which cuts manufacturing time and inventory costs[1][2]. Allowing multiple parts of the vehicle to be assembled simultaneously on separate branches speeds up overall assembly time[1][2][3]. Improving worker safety and efficiency maintains high quality while speeding build time[3]. Simplifying tool and parts handling with pre-organized kits streamlines the assembly process[1][2].
Ford's goal of making affordable EVs at scale is supported by this new approach. The company's $2 billion investment in new facilities, including the Louisville Assembly Plant, marks a significant step towards this goal[5]. The first vehicle on this platform, a midsize electric truck, will debut in 2027 with a target MSRP near $30,000, aiming to combine affordability with performance and innovation[3][2].
Ford's new battery design will also be smaller and lighter than previous versions, contributing to the affordability of the new EV pickup truck[6]. The company's EV revenue nearly tripled in the first half of this year compared to a year ago, indicating a positive trend[7].
Despite the Trump administration cutting federal government support for electric vehicles by doing away with tax credits and rolling back emissions regulations, Ford is still investing $5 billion into a new assembly line and battery production to build electric vehicles, including a new, unnamed model[8]. Ford's investment is expected to add or secure 4,000 US jobs[9].
It's worth noting that Ford does not plan to shift production of one of its electric models, the Ford Mustang Mach-E, from a plant in Cuautitlan, Mexico[10]. The conversion at the Louisville assembly plant from gas-powered SUVs to electric vehicle production will require about 600 fewer jobs[11]. About $2 billion of the investment will secure 2,200 hourly jobs at Ford's Louisville assembly plant[12].
The Ford F-150 Lightning pickup, Ford's first electric pickup truck, has a starting price of about $55,000[13]. However, the new assembly line design is expected to lower costs and make production faster and less difficult for workers, potentially leading to a more affordable EV pickup in the future[14].
Doug Field, Ford's chief EV digital and design officer, calls this investment a "next Model T moment" for the company[15]. As Ford continues to lead the way in American automobile manufacturing, this new production line design is set to redefine the future of electric vehicle production.
Sources:
- Ford's new EV assembly line design
- Ford's new EV production system explained
- Ford's new midsize electric truck
- Ford's new production system development
- Ford's investment in new facilities
- Ford's new battery design
- Ford's EV revenue growth
- Ford's new investment in EV production
- Ford's job creation with new investment
- Ford's decision on Mustang Mach-E production
- Job reduction at Louisville assembly plant
- Job security at Louisville assembly plant
- Ford F-150 Lightning pickup price
- Expected cost reduction with new production line
- Ford's investment as a "next Model T moment"
- Ford's innovative approach to electric vehicle (EV) production, the Ford Universal EV Production System, also integrates technology in its design, aiming to streamline tool and parts handling with pre-organized kits, thereby simplifying the assembly process.
- Leveraging technology to improve sports and leisure activities is not new, but Ford's commitment to creating an affordable EV pickup, the first vehicle on its new platform, sets to bring a similar revolution to the business sector by offering a midsize electric truck with a target MSRP near $30,000, combining affordability with performance and innovation.
