After dismantling models from Tesla and Xiaomi, Ford identified excess weight, additional wiring, and greater complexity in its electric vehicles, exposing losses of $5 billion per year in the Model E division
Ford began to review its strategy for electric cars after dismantling models from different manufacturers, including Tesla and Xiaomi, and identifying disadvantages in cost, weight, efficiency, and software integration. The diagnosis led CEO Jim Farley to admit that the traditional automaker lagged behind new competitors in the sector.

Electric cars expose cost and efficiency differences
The internal analysis showed that Ford was still applying some of the logic of combustion vehicles to electric cars.
This choice increased assembly complexity and hindered the pursuit of efficiency, especially compared to companies that were born focused on electric platforms.
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In the comparison between the Tesla Model 3 and the Mustang Mach-E, engineers found a direct difference: the Ford model weighed 32 kg more.
There was also an additional 1.6 km of electrical wiring, which helped explain part of the structural difference between the vehicles.
Ford CEO sees delay compared to Tesla and Xiaomi
Jim Farley stated that the evaluation was “very humbling” in terms of quality and cost. For him, these points are basic for an industrial company, but they showed that Ford had more ground to recover than it imagined.
The executive also admitted to using a Xiaomi SU7 in his daily life. The choice reinforces the automaker’s interest in understanding how more recent manufacturers structure their electric vehicles, especially in integration, software, and industrial simplification.

Change involves treating vehicles as digital devices
Ford has started advocating for electric cars to be treated as digital devices, with a greater presence of software and services.
This vision aims to bring vehicles closer to the logic adopted by new manufacturers, instead of repeating solutions used in combustion models.
In 2022, the company separated its electric operation into a division called Model E. According to Farley, the measure also exposed investors to the financial losses of the electric vehicle business, estimated at $5 billion per year.
Pressure increases on traditional manufacturers
The pressure from Tesla and new manufacturers has led Ford to rethink technology, costs, and industrial processes.
The case shows how the competition in electric cars goes beyond the battery and involves how the entire vehicle is designed, assembled, and connected.
This article was prepared based on information from the base material provided, with data, numbers, and statements preserved according to the consulted material.

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