Made in Chicago: The 2010 Ford Taurus
The view at the entrance to the final assembly line. This portion of the plant is where both the Taurus and the Lincoln MKS are finished.
Allison Shepherd explains how Ford uses 3D modeling to design an ergonomic and efficient assembly line, before implementing production. This technology, coupled with flexible manufacturing techniques allowed Ford to bring the resigned Taurus into production in only 12 months.
By meeting with front-line assembly workers before starting production of a new or redesigned model, the manufacturing process is developed to use the least amount of motion and time.
The finishing portion of the plant employs 1,200 people, working four, ten hour shifts a week. Currently, the assembly plant runs only one shift a day.
The trim portion of the vehicle, the plastic parts that seal the interior around the doors and windows, have to be heated before they can be applied. This machine keeps the parts at a set temperature, and assembly line workers apply them directly to the car, creating an instant seal.
As cars roll through the assembly line, light up boards track the status of parts and supplies, as well as the progress of the line itself. All front-line employees have the authority to stop the line during production if they encounter defects or problems. Because everyone is cross-trained in the total production of the vehicle, they can determine what defects are coming, from where, and work together to solve the problems that create them.
As one portion of the vehicle is finished, it\'s lifted up over the rest of the plant and taken to the second part of the line. By transporting semi-finished cars above the plant floor, the company can co-locate production components near where they will be used later in the process, while freeing up transportation space on the shop floor for heavy parts.
Semi-finished vehicles, awaiting the next stage of production.
A torque inspector makes sure that parts are installed correctly and that connections are secure before sending the vehicle on to the next part of the line.
Line workers install the interior parts on the 2010 Taurus.
After being fitted to a specific vehicle, doors are assembled separately from the car. They\'re installed later on toward the end of production, with the assistance of alignment machines.
The wheel is installed with the tire already fitted. A specialized machine, guided by a line worker, tightens the bolts precisely.
Finished vehicles are put through a \"water test\". The car is sprayed with a mist of water and then inspected for paint faults and seal deficiencies.
A team of line employees inspect vehicles as they come off the line for defects. The cars are started and all systems are cycled through. Any defects are flagged for repair.
Vehicles in need of minor repair or correction of defects are sent to the trim shop. Dedicated mechanics work to resolve the issue.
As a final test of the suspension, finished vehicles leave the plant driven on a custom-built quarter mile cobblestone road.
The interior of a finished, 2010 Ford Taurus.
The interior of a finished 2010 Ford Taurus.
Late last year it looked like the Big Three were circling the drain of automaker history. But while GM is trying to sprint through bankruptcy while bringing new models and cars to market, and Chrysler is hoping the Italians can finally make a high-quality mass-produced car, Ford has been quickly rolling out it's updated line of competitive, updated fuel efficient cars. Among the lineup of cars designed to compete with the auto transplants are the Euro Focus, the Transit Connect, the Fiesta, the Fusion and the Taurus. And unlike the other two American car companies, Ford went through many of the same economic and design challenges several years back. The result? A solvent, nimble company that's well positioned to launch competitive and appealing cars at a time when the auto industry is struggling to get buyers into showrooms, without having to depend on federal bailouts to keep the lights on.
Part of that strategy is Ford's flagship sedan, the Taurus. First launched in 1985, the Taurus redefined the extremely competitive mid-sized sedan market. Taurus hasn't always held the top slot in that segment, though. "We reinvented the sedan in the 1980's" says Wes Shepherd, VP of Public Relations. "But we let it languish. Starting next year, we're back in the car business. Starting with the Fusion, which is nipping at the heels of Honda and Toyota, we're back in that segment." And if the styling, features and production methods used to produce the Taurus on Chicago's South side are any indication, Ford really does seem poised to capture even more market share from the competition than it has been of late.
Chicagoist took a nearly unprecedented behind the scenes look at production of the 2010 Taurus at the Chicago Assembly Plant on 126th Street and Torrence. It's a rare look inside a well-known car that's made right here in Chicago.
Ed. note: For a more in-depth look at both the Ford Taurus and the Lincoln MKS and how the production line works, check out the Kevin's full photo set here.
