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First 2004 Ford F-150 Rolls Off Assembly Line Into History
United Auto Worker Vice President Gerald Bantom (left) & Ford Chairman and CEO Bill Ford celebrate the first 2004 F-150.
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Norfolk (Va.) Assembly is first plant to use new flexible
manufacturing system. First 2004 F-150 is equipped with
Ford's 100-millionth V-8 engine. Ford plans to install
flexible system in 75 percent of plants by end of decade.
NORFOLK, Va., June 10, 2003 - Ford Motor Company's F-Series
trucks, led by the Ford F-150, reached another leadership milestone
today. The first 2004 F-150, a sporty red SuperCab Lariat, rolled
off the Norfolk Assembly Plant line, using an all-new flexible
manufacturing system. To enhance today's milestone, the
company equipped the first truck with Ford's 100-millionth V-8
engine - the new 5.4-liter 3-valve TritonT V-8, which was produced
April 29 at Ford's Essex Engine Plant in Windsor, Ont. The
debut of the 2004 F-150 comes only six days before the company that
Henry Ford founded a century ago officially observes its
Centennial celebration. "In the last 50 years, nothing has
been more central to our success, or more important to us, than
the F-Series," said Bill Ford, Chairman and CEO. "The power,
styling and interiors of this fantastic all-new 2004 Ford F-150 are
built to delight our customers and help maintain its place as
America's favorite truck." F-Series has been the nation's
best-selling truck for 26 consecutive years and the best-selling
vehicle for 21 years in a row. During the celebration
2,500 employees and guests applauded as Bill Ford drove the first
new Ford F-150 off the line and into an arena with Gerald Bantom,
United Auto Worker vice president and director of the UAW National
Ford Department. "The work force at Norfolk Assembly has
tremendous skill and experience, with a long tradition of
producing some of the highest quality vehicles in the plant's
78-year history," Bantom said. Virginia Gov. Mark Warner
presented the company with a proclamation in observance of Ford's
Centennial on June 16. "The people of Virginia and Ford Motor
Company have enjoyed a successful partnership for 78 of Ford's 100
years," Warner said. "I believe our business partnership should
serve as an example for the kind of reinvestment in people and
facilities that can stimulate regional economies and the corporate
bottom line." Flexible Manufacturing
Start-Up With the launch of the new 2004 Ford F-150
at Norfolk Assembly, Ford also introduced its new flexible
production technology. "Just as the F-Series has defined the truck
market for more than 26 years, our all-new flexible manufacturing
system introduces a new era of flexible manufacturing at Ford,"
said Roman Krygier, group vice president, Global Manufacturing and
Quality. Norfolk is the first of several Ford plants to
install a next-generation flexible system, allowing it to build up
to eight different models off two platforms. "Norfolk Assembly now
has the ability to change the mix, volume and options of products
in response to consumer demand and market segmentation - all with
minimal investment and changeover loss," said Krygier.
Over the next decade, Ford expects to save up to $2 billion
because its flexible system will cost 10 percent to 15 percent
less than traditional systems, with an added 50 percent savings in
changeover costs. Ford's flexible body shops employ an
industry-first system of 16 standardized cells, or modules, all
built from about 300 components. Only product-specific tooling
needs to be changed, or computers and robots reprogrammed, to
launch new products. By mid-decade in North America, about
half of Ford's body shops, trim and final assembly operations will
be flexible. That number rises to 75 percent by the end of the
decade. Ford's Kansas City (Mo.) Assembly Plant will begin
building the new 2004 Ford F-150 later this summer, and the new
Dearborn (Mich.) Truck Plant will begin building the F-Series
truck in 2004. Both will be among the first plants to install a
flexible production system. Other plants to install the
flexible system include the Chicago Assembly Plant, which will
build the all-new 2005 Ford Freestyle, Ford Five Hundred and
Mercury Montego, and AutoAlliance International in Flat Rock,
Mich., which will build the new 2005 Mustang beginning next year.
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