“Have you ever seen a car factory in India? Been explained, in the highest detail, the entire production process by Heads of Manufacturing? Right from the time that sheets of steel come in, to the car actually rolling out? I’ve been to other factories before, but no one allowed a camera inside. I was pleasantly surprised when Ford accepted my request to click pictures inside their production facility. And why not? Ford has a facility that’s worthy of showing off.” This is what Rush Parekh of Team BHP had to say about his visit to Ford India’s world-class facility at Maraimalai Nagar, near Chennai.

Ford India took a select group of auto bloggers on an exclusive tour of its state-of-the-art facility on 19 May, 2010. The facility that sprawls over 350 acres has a capacity to produce up to 200,000 vehicles a year and 250,000 engines.

For the invited bloggers, it was a rare opportunity to see a car take shape from a coil of steel. Their tour began at the Blanking, where the coils are cut into flat sections called ‘blanks’. These blanks are then sent to the Stamping, where they are ‘stamped’ into the different parts of the car, such as the roof, side body panels, etc. through both automatic and semi-automatic press lines.

The action then continued at the Body Shop, where the parts of the car are assembled together. The bloggers were fascinated by the sight of 66 robots going about their jobs in their own relentlessly robotic way, carrying out critical processes like spot welding and door hemming.

The Ford India facility uses a hi-tech painting process that’s a first of its kind in India. Called the Three-Wet, High-Solids Painting process, it helps to reduce VOCs emitted while painting the car by 20%. The secret behind this process lies in an increase in the proportion of resins used in the paint versus the solvent, in other words, to increase the ‘solids’ within a given paint sample. As a next step, Ford India’s Paint Shop eliminates the need to ‘bake’, or heat, the car after each coat of paint – the base coat, top coat and the clear coat, thus further reducing emissions. As a result for the consumer get a better paint finish and more scratch resistance on their car!

Next stop was  the Trim, Chassis and Finish (TCF), where the car’s interiors and electrical fittings are installed. This is the area where highly trained Ford India technicians use high-power tools to fit in all the components of the car, from the hand break to steering column and the seats to the exhaust pipes.  At the final stages, the engine, which is manufactured at the Ford India’s New Engine Plant on site, is fitted into the car, the front suspension is fixed and, once the nuts and bolts are tightened, the car get its wheels. Finally, after a quick process of filling the various fluids, the car is rolled at end of the line for its robust validation and quality checks.

“The mechanisms used at every stage of Ford car’s production took our breaths away,” Charu Kishnani of CarDekho wrote on her website after the visit. “The facility is widely spread and has designed a customized robotic mechanism for every phase of manufacturing except the assembling of glasses (front and rear windscreens). Having had a close peep at Ford’s manufacturing utility at Chennai, it becomes clear on why and how the company has been able to deliver outstanding results and great customer satisfaction.”

Part 2 of this exciting visit coming soon!

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More people die in road accidents in India than anywhere else in the world, according to the Global Status Report on Road Safety by the World Health Organization. Each of us can reduce the likelihood of an accident by driving safely and cultivating good driving habits.

Ford conducts the Driving Skills for Life programme that helps new and old drivers stay safe behind the wheel. Here are a few of our best tips:

Tip 1: Use seat belts all the time

-A seat belt can significantly reduce the chance of a serious injury or death
-Fasten your seat belt before you turn on the engine
-Insist that all your passengers use their seat belts

Tip 2: Adjust rear view and side mirrors

-Before you turn on the engine, adjust your rear and side view mirrors to the appropriate angles to maximise your field of vision
-Your views from the back window and along the sides of the vehicle should be clear and unobstructed

Tip 3: Drive relaxed by anticipating traffic situations

-Avoid constant accelerating-braking sequences
-Change lanes early when approaching obstacles – always use left/ right turn signals
-Smoothly equalise speed differences
-Allow other vehicles to proceed before you – be courteous to other drivers

Tip 4: Avoid distractions while driving

-Driving demands your full attention and distractions can increase the risk of a crash
-Distractions include adjusting the radio, talking on mobile phones or with other passengers, sending text messages… which can take your attention away from the road, and increase driving risk

Tip 5: Maintain a safe three-second distance between vehicles

-Keep a safe distance between your vehicle and the one in front of you, to prevent crashing into it if it stops abruptly
-Use the three-second rule – as safe distances change with different speeds
-Pick a stationary point on the road; when the car in front of you passes it, you should be able to count to 3 before you pass the same object
-If the weather is bad and visibility is low – i.e. if there is heavy rain or fog – increase he time interval to 6 seconds

Tip 6: Use your gears effectively

-You should shift to the next highest gear when engine speeds reach 2,000-2,500 rpm
-Maintain uniform driving at engine speed of 2,000 rpm and below.

Target Gear      Speed

1st Gear                Start up
2nd Gear              After 1 car length
3rd Gear               at 30 km/h
4th Gear               at 40 km/h
5th Gear               at 50 km/h
6th Gear               possible above 50 km/h

Tip 7: Use the vehicle’s momentum and built-up energy

Take the foot off the accelerator pedal early and roll with the traffic when:

-Approaching a red light
-Before changing direction
-In stop-and-go traffic
-At a “give-way” or “yield” traffic sign
-Approaching a “Stop” traffic sign

Tip 8: Switch off the engine selectively

If you expect to stop your vehicle and remain idle for more than 20 seconds, you can save fuel by switching off the engine. An engine idling for three minutes is equivalent to driving one kilometre at 50 km per hour. Typical situations include:

-While loading and unloading
-At traffic lights
-In traffic jams
-At closed gates (railway crossing).

Note: Switching the engine on off frequently does not damage the starter switch or decrease its life

Tip 9: Ensure adequate tyre pressure

-Check your tyres regularly and adjust it to appropriate pressure (see car manual). It saves fuel and increases safety!
-Correct tyre pressure can improve fuel economy by up to 1%-3%
-Tyre pressure that is 0.3 BAR below the optimum can increase the rolling resistance by up to 10%
-A tyre can lose up to half of its air pressure without appearing flat

Tip 10: Remove weight and unused racks

-An additional weight of 20 kg can increase fuel consumption by approximately 1%
-Remove unnecessary weight from the trunk (boot)
-Take off racks (roof and rear) when they’re not being used
-Use lower speeds while transporting goods with roof or rear racks for better fuel economy and safety

We would like to hear how you practise safe driving. Please leave a comment with your own driving tips.

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Road accidents are often the result of poor driving habits and skills. Most of us tend to forget the basics of good driving and put ourselves and others on the road at risk. To inculcate good driving skills in drivers, Ford India conducts the Driving Skills for Life (DSFL) program. The unique DSFL program is a CSR initiative by Ford to train new and seasoned drivers in safe, efficient and eco-friendly driving through a mix of theory and practical sessions.

“We take a lot of things for granted while driving, and with time get ignorant about certain vital things that are of utmost importance for safety. This event was a great refresher about these basic precautions. It reminded us that we don’t need to wait for an accident to happen before incorporating basic safety precautions into our routine.” said Amit Chhangani of Motoroids.com

Amit was part of a group of bloggers whom Ford India had invited to take part in a DSFL session at the Maraimalai Nagar plant, near Chennai. The bloggers spent an eventful two days in Chennai.

Title: Michael Boneham, President and MD of Ford India with bloggers at the Driving Skills for Life session at the Ford facility at Maraimalai Nagar near Chennai

On the first day, Mike Boneham, President & MD, Ford India, and Nigel Wark, Executive Director, Marketing, Sales and Service, made presentations to the visitors on the success of Ford’s newly launched car, the Ford Figo. The bloggers were then taken on a tour of Ford’s world-class facility. The group came away impressed after the visit to various assembly lines at the body shop, stamping, TCF and the new engine plant. “It’s heartening to see this big facility pumping out 1000s of Figos,” said Karthick of Vicky.in, who had, in fact, visited the plant a few years ago. Karthick was also impressed with the eco-friendliness of the plant, and said he was looking forward to the day when Ford begins exports of the Figo.

The second day was reserved for honing our car-driving skills. The seasoned bloggers, no mean drivers themselves, gamely participated in the theory sessions; and later in the practical demonstrations with the Figo and Fiesta on test tracks. The group had an engaging discussion on road safety, and eco-friendly and economical driving. The bloggers also exchanged insightful tips and learnings.

Title: Rush Parekh (Team-BHP.com) driving the Ford Figo

“DFSL is a good initiative taken up by Ford. We as auto journalists play a very important part in educating the people about safety and driving habits and not just about cars,” said Ritesh, who blogs at Dance with Shadows. We couldn’t agree more, Ritesh.

For more pics of the event, please check out our albums of – the Plant Tour and the DSFL session on Facebook

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It wasn’t an ordinary ride. And it wasn’t an ordinary car. When Michael Boneham drove off in a brand new Fiesta from our Chennai factory on May 5, 2010, he was driving away in a very special car. It was the 100,000th Fiesta to come off the line in our Chennai manufacturing facility.

Boneham was justifiably proud of the achievement. “The event marks a new milestone for us,” he said. “Ford Fiesta continues to make us feel proud and is a significant product in our portfolio. The popularity of the Fiesta testifies that more and more customers have been reassured by its quality, features and performance.”

Title: Michael Boneham; Sandip, Exec. Director, Operations; Nigel Wark, Exec. Director, Marketing, Sales & Service and Ram Ramanathan, GM-Vehicle Quality with the 100,0000 Fiesta.

The Fiesta is a significant car for Ford in India in many ways. “The Fiesta has helped to positively shift consumer and dealer perception of Ford cars and added emotional appeal to its rationale strengths,” says Vinothkumar. “It has helped Ford create a strong imagery in the premium B segment and will continue to grab attention among the target consumers for many years.”

Title: Michael Boneham president and managing director, Ford India and Ford India employees give the 100,000th Fiesta a big thumbs up.

The six-figure mark is just another milestone in Fiesta’s successful run on the India roads since its launch. The premium sedan has won rave reviews and coveted awards during its 5-year journey. The special edition Fiesta 1.6 S was adjudged the Best Drivers’ Car amongst top 10 cars by Formula-1 driver Narain Karthikeyan in 2008. Fiesta was ranked No. 1 in ‘Total Customer Satisfaction in the Diesel Midsize Segment’ in the TNS Automotive 2009-TCS Study.

Title: 100,000th Ford Fiesta

While these awards mean a lot to us, what truly motivates us is the appreciation and support of those who drive and ride in the Fiesta. People like Anoop Jain. Here’s what he had to say: “Ford Fiesta has been an excellent experience for me and my family in terms of the driving dynamics. There is no comparison with Ford Fiesta when it comes to safety and experiencing the delight of driving. I have booked the new Figo as well, as my experience with Ford cars has been an amazing one.”

Title: Employees celebrating 100,000th Fiesta roll-out.

Or someone like Sandeep Gulati, whose favourite weekend companion, apart from his family, is the Fiesta. “Ford Fiesta has always been an amazing driving experience to the hill stations like Nainital where the roads are rough and bumpy. Fiesta makes the overall drive experience a very smooth and pleasant one,” he says.

Such words are a constant source of inspiration to all of us at Ford. Go Fiesta!

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We already told you how the new Ford Figo helped resolve the Smart and Smarter debate between men and women. Here’s your chance to watch the debates see why the Figo is both smart and smarter! Watch the videos below and tell us what you think!

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Who is smart and who is smarter? Men or women?

There’s never been an end to this raging debate between men and women, so we decided to settle the matter by bringing to life the concept of “smart and smarter” at the launch of the new Ford Figo in Delhi and Mumbai.

For this, we did the daring thing—we got a newly-married couple to slog it out in a live debate in front of the television, print and web media. The couple was Sandeep and Priya, who were smart and smarter, played by the vivacious Gul Panag and the witty Gaurav Kapur.

In this fun and engaging debate, the husband-wife duo took to the stage with India’s favourite quiz master Derek O’Brien. So while Priya said “smart” was great music, cool comfort, and vibrant colours in a car, Sandeep said “smarter” was phonebook and friends, excellent boot space, and enough leg room for his tall frame. As the couple battled on, Derek offered a solution—the Ford Figo with its smart and smarter features!

As we tweeted about the debate, Gul replied: “[I] loved it:) @gauravkapur was the perfect ‘husband’.”

After the debate, Derek asked Michael Boneham, president and managing director, Ford India what he thought “smart” was. Michael responded: “Smart is cost of ownership!” To which Nigel Wark, executive director, marketing, sales and service added, “Smarter is the great pricing!”

We couldn’t agree more.

Soon after the Ford Figo rolled on to the stage, we asked Rahul Gautam, Ford Figo’s brand manager, about the idea behind this unique creative execution. “There are so many little nuggets in this car. The smart and smarter debate was a nice hook between the Figo and connect with consumers,” he said. Like in a relationship, Rahul explained, “It is not about one being better than the other, but how each can compliment the other to make a great couple.”

This debate was designed specially for the Figo’s launch, bringing the car’s features to life. “It drove home the first message about the smart and smarter features of the Figo,” Rahul said.

All those who saw the debate and experienced the Figo later said that the debate was an excellent out-of-the-box idea, and agreed that the car is a great buy. And they’re right—the Ford Figo is indeed a very cool car!

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The country is in the throes of excitement over the new IPL season, and so are we! This time, the IPL’s going to be different, we promise. It’s not just because it’s a brand-new season, but also because we’re bringing IPL matches to a theatre near you!

Yes, it’s true! Ford Figo presents UFO T20 Hungama, guaranteed to be a favourite among all cricket lovers!

The best part about the T20 Hungama is that you can enjoy all the cricketing action on the big screen with friends and family! It’s like being in the stadium, but more up, close and personal with the cricketers.

What’s more, there will also be a chance to check out the brand new Ford Figo and a chance to win exciting prizes, including the Figo itself.

Let the games begin!

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