On the Line:
2004 F-150 Launch
The new 2004 F-150 is off to a great start, thanks to the hundreds of employees who worked for many months to bring the vehicle to production. In Kansas City last month and in Norfolk earlier this summer, we showed the automotive press -- and the world -- that this great vehicle will hold its place as the best, and best loved, truck in America.
Tough, capable and powerful, the F-Series has been the best-selling full-size pickup for 26 years and the nation's favorite vehicle for 21 years running.
When the 2004 F-150 hits showrooms this summer and fall, customers will discover a broad range of exciting new product enhancements. The truck's strong backbone -- the industry's stiffest, fully boxed frame -- gives it great handling precision. Its wider track provides exceptional stability, and the all-new coil-over-shock front suspension system provides a greater sense of control.
Powering the new F-150 is a 5.4-liter, 3-valve Triton V-8 engine that produces 300 peak horsepower -- a 15-percent improvement over the previous award -- winning 5.4-liter engine, and 365 foot-pounds of torque for improved low-speed and peak pulling power. Mated with the new 4R75E transmission for smoother shifts and improved fuel efficiency, the 5.4L 3V also contributes to a quieter cab environment for F-150 customers.
But the new F-150 wasn't the only thing we showed the world in Kansas City and Norfolk. With the launch of the F-150, we also introduced our new flexible manufacturing processes and heralded a new era of automotive leadership.
Flexible manufacturing is the most significant change in our business since Henry Ford's introduction of the moving assembly line. Flexible plants have 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.
Our new system standardizes the assembly process, which improves productivity through reduced changeover downtime. Standardization helps boost quality through increased repeatability. Plus, improved ease of access results in greater safety and ergonomics for operators and maintenance crews.
The new flexible systems in Kansas City and Norfolk can build up to eight different models off two platforms.
It's all part of our overall flexible manufacturing strategy, which also includes the addition of modern, flexible Computer Numerically Controlled Machines in Powertrain-we call them CNC machines. They can be easily retooled and reprogrammed to perform new tasks with minimal disruption.
The use of these flexible CNC machines will be expanded to Cleveland, Lima and Romeo throughout the next two to three years.
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.
During that time, we expect to save up to $2 billion because flexible systems cost 10 to 15 percent less than traditional systems, with an added 50 percent savings in changeover costs.
In addition to Kansas City and Norfolk, other plants to install the flexible system include the new Dearborn (Mich.) Truck Plant, which will begin building the F- Series truck in 2004; 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.
We also have maximized our opportunities to learn and improve. That's why we had Kansas City work teams in Norfolk-learning the build, helping to identify problem areas and working together on solutions.
Congratulations to the fine teams involved in all aspects of the Norfolk and Kansas City launches. Your good work is being closely watched as a model for all future launches.
I also wish our plant employees continued good fortune as they build the new F-150. The best truck in America, already built Ford tough, is only getting better.