Ford Bronco - Michigan Truck Plant - Wayne (1994)

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29/09/2024

Construite en 1957, l'usine Ford de Wayne (Michigan) produit le Ford Bronco depuis 1966

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00:00Michigan truck plant. First in quality. First in pride. Building the best-selling

00:08vehicle in the world, the F-Series truck, along with the full-size Bronco, has been

00:13a long, hard journey. A journey involving a skilled workforce of 1,900 hourly and

00:23190 salaried employees working together to implement the systems. To meet the

00:29highest quality standards. With total customer satisfaction, the ultimate goal.

00:43Yes, it's been a long, but rewarding journey. For it's a very special vehicle

00:49that travels America's roadways bearing this emblem. Michigan truck plant. First

00:55in quality. First in pride. Back in 1957, on a road connecting Detroit and Chicago,

01:05a factory opened up on the edge of a small town. People came from miles around

01:11hoping to gain employment at the Michigan truck plant, located in Wayne,

01:15Michigan. At the time, its sole purpose was to build station wagon bodies for

01:20the Lincoln-Mercury division. By February of 1964, the plant was producing light

01:27and medium trucks, as well as parcel trucks. 17 units an hour rolled off the

01:32line with a workforce of 492 hourly and 132 salaried employees. From that time

01:39forward, the plant increased in size, workforce, and product diversity to

01:43include buses and the introduction of the 1966 Bronco. The fall of 1972 began

01:52production of the all-new 1973 F-Series and the all-new 1978 Bronco soon

01:58followed. January 11th, 1988 proved to be a monumental day, as the three millionth

02:06truck, an F-150 XLT Lariat, rolled off the assembly line. The special edition

02:12Silver Anniversary Bronco was built in 1991. In 1992, Michigan Truck was selected

02:19as the only location to build the new and exciting limited edition Lightning.

02:23And in April 1993, the Michigan truck plant team was awarded Ford Motor

02:29Company's coveted Q1 Quality Excellence Award. Today, Michigan Truck is the home

02:35of the Bronco and one of five plants in North America that build the best-selling

02:40vehicle in the world, the F-Series truck.

03:10♪ MUSIC ♪

03:41The people at Michigan Truck are proud of their plant's history and the products

03:47they build. Innovative manufacturing technology and dedication to continuous

03:53improvement are ways of life at Michigan Truck. The UAW-represented team is a key

03:59part of the system, working together with management, using every ounce of energy

04:04and skill to do whatever it takes to be the best. Joint meetings are held

04:10frequently to discuss items important to the success of the plant, including

04:15ergonomics, productivity, safety, and quality. Thirteen different quality

04:21subsystem teams identify and resolve concerns using warranty data, new vehicle

04:26quality studies, and other customer indicators. In addition to the subsystem

04:31teams, there are variability reduction teams, or VRTs. They meet daily to discuss

04:38quality issues and review statistical process control data. Every decision made

04:43by the various teams is based on data gathered from the plant floor each day.

04:49The process begins in the body shop, where the Bronco body, the F-Series cab,

04:54and the F-Series box are built up. The Bronco body and the F-Series cab join the

05:00main line and move along to the door hang area. As the cabs move through the

05:07body shop, the quality and integrity of the robot's performance is verified by

05:12the employees on the line. The welding is finished off manually in the wire weld

05:19area. In the metal finish loop, operators finesse, sand, and polish the surface of

05:27each vehicle in preparation for paint application. The F-Series boxes are built

05:32up and routed to their own metal finish line. Quality checkpoints are built into

05:37the system throughout every stage of the process. For example, here in the body

05:42shop, units are randomly selected on a daily basis and taken aside for a

05:47dimensional integrity check. Significant dimensional points are verified even at

05:52this early stage of production. Next, the cabs and boxes are sent to the paint

05:58department, where they are submerged in an e-coat bath, providing excellent rust

06:02protection for the entire unit, inside and out. After the bath, the units are

06:08baked and cooled. Body sealer is then applied to make sure each vehicle is

06:13watertight. Initially, sealer is applied by this robot, which was designed and

06:19installed by the Michigan Truck Plant Skilled Trains. A secondary sealer is

06:25manually applied and smoothed out at the sealer deck. The vehicle bodies, complete

06:33with fenders, hood, and other front-end structural components, are lifted by

06:37elevator and travel through this tunnel to Michigan Trucks' world-class paint

06:42facility. Here, primer is applied and computerized controls designate the

06:48proper enamel color for each vehicle in either a solid or two-tone base coat.

06:53The paint facility also provides the capability to apply a state-of-the-art

06:58clear coat finish. Michigan Truck employees were involved in advanced

07:02planning, design, installation, and subsequent facility prove-out, resulting

07:07in a total team effort to create world-class capability in the Michigan

07:12Truck paint operation. The final area of assembly has two starting points. The

07:19chassis portion of the build-up begins on the frame line. At the same time, the

07:24vehicle bodies are transferred from paint to the trim shop, where various

07:28components are installed on five individual lines. Employee input has

07:33shaped the design of a number of workstations in the trim shop, improving

07:37ergonomics and quality. For example, on trim line one, the vehicle goes down the

07:43line on this sidewinder, resulting in a more efficient build-up of front and

07:48rear components. Knee pits were put in, allowing operators to install lower

07:53exterior trim in a more ergonomically satisfying position. These knee pits were

07:58conceived and designed by the Michigan Truck Plant ergonomics team. On trim line

08:06three, the instrument panel is installed with the assistance of an articulating

08:10arm. This technology provides ergonomic relief to the operator and significant

08:15quality improvements at the same time. The vehicles continue to move through

08:20the trim shop, where various components are installed along the way. The Bronco

08:25roof is installed on trim line five.

08:30At the windshield deck, an operator prepares the windshield for installation.

08:40Then, a robot applies urethane sealer consistently and accurately. The

08:48operators then install the windshield into the vehicle. While the bodies have

08:54been moving through the trim shop, the chassis portion of the build-up has been

08:58taking place on the frame line. The frame starts out upside down to facilitate

09:04installation of the underbody components, such as the shocks, rear axle, driveshaft,

09:09and fuel tank, among others. The engine is built up on a separate line. This

09:16synchronous parts carrier on the engine line moves at the same speed as the line,

09:21carrying the operator and the parts, which are all within reach. As a result,

09:26the operator is given additional time to perform his required tasks, assuring that

09:31a quality job is sent to the next station. The engine is then sent via overhead conveyor to

09:38the frame line, where it is installed on the chassis, which has been turned right

09:42side up to facilitate the remainder of the production process. Upon completion of the

09:49frame build-up, the units are transferred to the final assembly line, where they meet

09:53the finished body at the body deck. Here, the vehicle is temporarily lifted off the

09:58moving assembly line to a stationary platform. After the body is accurately positioned on the

10:04chassis, the vehicle is returned to the line, where the finishing touches are put into place.

10:09The bumpers are aligned and secured. The seats are installed, and the vehicle heads

10:20toward the end of the assembly line for initial startup. After the vehicle is driven off the line,

10:26additional quality inspection and alignment procedures are performed. Dynamometer testing

10:33verifies transmission shifting, speedometer accuracy, emissions controls, and anti-lock

10:38brake function. The headlamps are properly aligned and aimed. There is also a five-minute

10:46water test to make sure there are no leaks in the vehicle body. And squeak and rattle

10:53testing is performed on randomly selected units in the Burke Porter room. Each morning,

11:00at 9 a.m. sharp, several units are randomly selected and audited for overall quality. The

11:06plant manager, plant chairman, assistant plant manager, area managers, superintendents,

11:12and production managers all join in the quality process. The vehicle is then given final quality

11:20approval and shipped to our customer. Yes, it has been a long journey, a journey that won't soon be

11:31forgotten. You see, at Michigan Truck, we not only believe in continuous improvement, we live it.

11:42Our goal is to be the highest quality producer of trucks in the world. That's what we mean when

11:49we say the best never rests. Michigan Truck Plant, first in quality, first in pride. Commitment would

11:58have to be the word to get quality. You've got to have a commitment from both sides, union and

12:02management. And it's got to be from top to bottom, and it works. Quality is very important to the

12:10plant here. Without quality here, we don't have jobs. It's very simple. Being number one in quality

12:16secures our future. If we are building the best truck, if it says that we have less things going

12:23wrong with our truck than any other truck in Ford Motor Company, it makes our plant number one.

12:27That's where we want to stay, amongst the plant. Our quality in the future, based on the plan that

12:33this management has and the union has, is going to take us far beyond Q1. Quality is job one at

12:40Michigan Truck, no doubt about it. I think it makes all of us here proud. You know, you want to go out

12:47there and say, hey, I built the best truck in the world. And if you get one order from my plant,

12:53because I know it's going to be okay.

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