Ford shows us the inside of its high-tech Rouge Electric Vehicle Center, where the F-150 Lightning will be built.
Sneak Peek
Ford has fully committed to electric vehicles, having most recently reinvented the iconic Mustang as the Mach-E EV crossover. But its biggest bet is yet to come - the 2022 F-150 Lightning, an electrified version of its most popular vehicle. This is obviously a big deal, which is why Ford has built a brand new, state-of-the-art facility to assemble it in - the Rouge Electric Vehicle Center, and the automaker recently gave us a sneak peek inside.
Photos: Ford
Big Investment
At this point, pre-production of the F-150 Lightning has already begun, but Ford is still finishing up the final details of the Rouge Electric Vehicle Center. In total, the automaker is investing $700 million to overhaul its Rouge Complex, which also contains the Dearborn Truck Plant, where the regular, ICE-powered F-150 is built.
Photos: Ford
>>Join the conversation about the new F-150 Lightning Plant right here in the Ford Trucks Forum!
High-Tech Process
The new Rouge Electric Vehicle Center spans 500,000 square feet and is chock full of high-tech equipment and surprisingly, no traditional assembly lines. Instead, Ford uses autonomous sleds to transport the Lightning from station to station, a process that it's currently testing and perfecting.
Photos: Ford
>>Join the conversation about the new F-150 Lightning Plant right here in the Ford Trucks Forum!
Various Locations
The Lightning's body and frame will still be produced at the Dearborn Truck Plant, then moved over to the Rouge, while its battery packs and electric motors are also built at another location. When the painted body parts roll in, Rouge workers begin adding all of the interior and exterior pieces it needs.
Photos: Ford
>>Join the conversation about the new F-150 Lightning Plant right here in the Ford Trucks Forum!
Keep Moving
Throughout the process, the autonomous sleds follow a magnetic track that's glued to the floor. The sleds are able to tell when someone is walking in front of them and stop or slow down as needed. There's also a built-in lift on each sled to lift up the truck as needed for easy access by factory workers. When the sleds are stopped, they use charging points in the floor to keep them juiced up and ready to go.
Photos: Ford
>>Join the conversation about the new F-150 Lightning Plant right here in the Ford Trucks Forum!
Smart Process
This process allows for far more flexibility than a traditional assembly line, as each sled can move at a different speed, while a line can only move at one speed. Each station contains a computer that instructs workers what to do next and keeps track of each configuration that's coming through. The sled is designed to stay put until everything is installed and bolted down properly, too.
Photos: Ford
>>Join the conversation about the new F-150 Lightning Plant right here in the Ford Trucks Forum!
Next-Gen Process
Smart electric tools are capable of sensing torque and preventing stripped and cross-threaded bolts, while robots assemble the heavy frame and battery packs together. Overall, the process combines what Ford has learned from its century-plus building vehicles with the latest technology available, which is perfectly fitting for such a futuristic vehicle.
Photos: Ford
>>Join the conversation about the new F-150 Lightning Plant right here in the Ford Trucks Forum!
For help with the service of your truck, check out the how-to section of Ford-Trucks.com
