The robots at our Maraimalai plant are quite versatile. In an earlier post, we told you how they paint a Ford car. In this post, we will tell you how the robots put your vehicle together at the plant’s body shop.

The new state of the art facility has an array of high-tech robotics – a total of 92 new robots have been installed in the body shop, paint shop and final assembly.

The all-new body shop

Sixty-six robots are used in the body shop for critical processes like spot welding, sealer application and door hemming. The robots have increased the automation level at the expanded facility gearing for volume production to 30 percent.

Automated underbody framing robots build the lower and upper body structure of the vehicle. This operation requires absolute precision, as large metal structures are assembled and spot-welded into vehicle floorpans.

The body shop has also become “flexible”, with a framing line designed for handling up to six different models simultaneously in a single line.

Other features of the body shop include:

• Portable measuring machine: to measure jigs and fixtures for build precision.
• Part checking fixture: to measure all major subassemblies, body, front-end and rear-end fit and finish.
• Real-time seal gap measuring equipment: a step up over measuring seal gaps with hand-held calipers.

Why these robots are special
Once we program a robot, it can perform complex and repetitive tasks quickly and precisely. The body shop welding robots are equipped with new servo motor welding guns. These are quieter than the older welding-gun technology, and deliver high-quality welds that are cleaner, with reduced expulsion and burring. Servo motors allow the welding tips to be brought smoothly into place, which helps to eliminate distortion of the metal and ensure stable weld pressure.

Why robots? “A modern automobile plant needs robotics to get the precision that’s essential to a well-constructed vehicle,” says Tom Chackalackal, Vice-President, Manufacturing, Ford India.

Big impact
The robots have made processes speedier. Our body shop capacity has more than doubled, from 15 to 34 jobs an hour. The new line is “future engineered” – flexible enough to build different vehicles one after the other. The new body shop line will build vehicles in Ford India’s current product portfolio as well as the Figo.

With enhanced production efficiency and quantum leap in quality, the plant is now geared to deliver even higher quality cars to consumers that will be not only be great products but competitive in the market.

As Mr. Chackalackal puts it, “This huge conversion will make us very competitive with Indian manufacturers and give Indian customers a better product than ever. Much of our investment is centred on quality and our desire to be the best in class in India.”

What do you think of the robots in our new body shop? What else do you think robots could do in an automobile plant? Tell us!

Green is a favourite colour at Ford’s Maraimalai plant near Chennai, where the Figo is being produced. The plant has almost 50 acres of green cover that includes well-tended lawns and a green belt. This is just one aspect of Ford’s commitment to the environment and the community.

Across the plant, Ford has also put in place initiatives to reduce energy consumption and emissions. “The biggest user of energy and fuel in a manufacturing plant is the paint shop,” says Tom Chackalackal, vice president, Manufacturing, Ford India.

Ford’s revamped paint shop incorporates the three-wet high solids process, which has reduced carbon dioxide emission by 15 percent and Volatile Organic Compound (VOC) emission by 20 percent. We call this the next-generation environment-friendly technology.

In addition, the paint shop uses energy-efficient ovens and equipment. “By introducing this new technology, we’re cutting energy use and fuel consumption significantly, and that’s good for the environment and the community,” adds Chackalackal.

Ford has also installed a zero-discharge wastewater treatment facility for the plant complex. As a result, all the wastewater is treated and reused – saving plenty of water.

The company’s environmentally-aware practices do not end here. Manufacturing units often dump their solid waste in landfills, creating hazards for the environment. Ford has completely eliminated the need for landfills by building a zero solid waste facility. All the solid waste that is generated at the plant is recycled or co-processed in the cement industry.

Finally, Ford has also improved internal processes to reduce consumption of important resources. Here’s a tiny indicator: in the past three years, we have reduced water consumption by 30 percent per car, and electricity consumption by 10 percent per car.

What do you think of these green initiatives? How do you live a green life? Tell us!

- By the Ford Figo Team

Ford India and Ford Figo continue to bask in the media spotlight. Here are some snippets from last fortnight’s press coverage.

Economic Times reported that Ford will launch a new model in India every 12 to 18 months, while Wheels Unplugged mentioned the growing number of Ford dealerships in the country, breaching the 150-mark by end-2009.

The Figo got more mileage in the Financial Express and Business Standard with Michael Boneham’s statement that the Figo’s pricing would be “extremely competitive”. The latter story also highlighted that Ford would ensure that the cost of ownership of the car will be substantially low.

Meanwhile, our Chennai plant has begun to garner media space as well, with Mint reporting that the factory would cater to the Asia Pacific and Africa region and the installed capacity for vehicle production has doubled from one lakh to two lakh units. Keep reading this blog for more on the plant and its transformation.

The Ford Figo, which we unveiled last month, garnered much attention in India and around the world. From the common man to the world’s leading news publications — everyone is talking about it. For this fabulous new car, we have a fabulous factory — our rejuvenated integrated manufacturing plant in Maraimalai Nagar, Chennai.

The plant has undergone a comprehensive transformation in the past 21 months. This makeover is part of a $500 million investment, and has shaped the factory into an expanded and state-of-the-art automobile manufacturing facility. And why not? After all, the plant is readying for volume production of the Ford Figo. What’s more, the new facility is poised to become a strategic production hub for the Ford Motor Company.

The plant was originally set up in 1999 with a manufacturing capacity of 100,000 vehicles a year.  Post-expansion, the capacity has doubled to 200,000 units. The manufacturing footprint will also house a new engine manufacturing facility to make Ford India a production hub for low-displacement engines, coming up to an installed capacity 250,000 units, due next year. We have enlarged the plant complex from 250 to 353 acres, with 60 percent of built-up area. The remaining acreage comprises lawns and a green belt.

Here’s what else has changed at our plant:

• We move from manual assembly to 30 percent automated assembly, thanks to a flexible body shop that can produce different types of car bodies on one line
• There’s a new paint line featuring the high-tech three-wet high-solids finishing process
• We now have a dedicated testing facility with a 3.2-kilometre quality testing circuit, a squeak-and-rattle testing track for finished vehicles and dynamic water wading test-bed
• New stamping press line with automated crossbar technology
• Extension of the trim and chassis assembly line for flexible assembly of different models.
• New lean manufacturing techniques that are enabled by multiple computer systems, especially useful for build-to-order production of parts and components from the adjacent 35-acre supplier park.

Over the next few posts, we will take you through some of the best features of our plant. Stay tuned!