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Ford Invests US$ 2 Billion in New Electric Vehicle Factory in Kentucky, Promising Simplified, Faster Production and Significantly Reduced Costs
A recent announcement from Ford echoed its revolutionary past. More than a hundred years after the Model T, which popularized the automobile with the assembly line, the automaker is betting on a similar leap. The promise is to reduce costs, simplify processes, and offer affordable electric vehicles.
A New Production Concept
The big news will be the remodeling of the Louisville factory in Kentucky. The plant will receive a completely restructured electric vehicle production system, with an investment of US$ 2 billion. The debut will take place in 2027, with a midsize four-door pickup.
The most important aspect is that the new framework will have 20% fewer parts, 25% fewer screws and nuts, and will allow for assembly that is 15% faster.
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In addition, the wiring harness will be 1,300 meters shorter and 10 kilograms lighter than the conventional one. This represents a direct advancement in saving time, space, and weight.
“Assembly Tree” Replaces the Conveyor Belt
The most symbolic change is the abandonment of the classic assembly line created by Henry Ford. In its place, the so-called “assembly tree” comes in. The process divides the car into three subassemblies.
One assembles the front, another the central part, which includes the battery, and the third the rear. The three proceed in parallel and join at the final line.
Thus, there is no longer a single conveyor belt, but rather flows that converge at the end of production.
Strategy in the Face of Chinese Competition
Jim Farley, president and CEO of Ford, highlighted that the decision came after visiting China. He stated that he was impressed by the local advancements in electric cars.
According to Farley, the challenge was to create affordable vehicles without compromising on design, innovation, space, and driving enjoyment. “We discarded the concept of a moving line and designed a better one,” he said.
In addition, Ford will be the first manufacturer to produce prismatic LFP batteries in the United States.
These batteries eliminate cobalt and nickel, save space, and offer greater durability. The new dedicated plant will require US$ 500 million.
Simplified Engineering at the New Plant
Another change is in the large aluminum components that replace dozens of smaller parts.
The front and rear will be assembled separately but connected to the central subassembly formed by the battery. This module also carries seats, consoles, and carpets already integrated.
Doug Field, hired by Ford after stints at Tesla and Apple, leads the Electric Vehicles, Digital, and Design area.
He explained that the project was based on principles of physics and simple, yet radical, engineering.
“This is not a simplified traditional vehicle,” Field stated. According to him, the zonal electric architecture created by Ford opens new possibilities for the entire industry.
A Different Driving Experience
The executive emphasized that the goal is not just to save space or reduce costs. Ford aims to deliver a product that combines passion, performance, and accessibility.
The pickup set to launch in 2027 will have a low center of gravity, instant torque, and a refined chassis. Field even compared the acceleration of the model: from 0 to 100 km/h as quickly as a Mustang EcoBoost, but with more stability.
A Historic Step
The Ford announcement shows that the company is betting on repeating the impact of the Model T, which transformed the automotive industry in the early 20th century.
Just as back then, the strategy is to reduce complexity, cut costs, and reach more consumers.
Thus, the Louisville factory is set to mark a new chapter. The bet on affordable electric vehicles may become a milestone similar to that of the moving assembly line.
What once put the world on wheels may now bring electrification within reach of millions of drivers.
With information from Auto Enthusiasts.
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