The first 2004 Ford F-150, a yellow SuperCab FX4, rolled off Ford’s Kansas City , Mo. assembly plant line recently using an all-new flexible manufacturing system.

                “No other product has contributed more to our success or been more important to us in recent years than the F-Series,” said Nick Scheele, Ford president and Chief Operating Officer. “We are confident the improved power, styling cues and interiors of the all-new 2004 Ford F-150 will help preserve its place as the number one truck in America.”

                The F-Series has been the nation’s best-selling truck for 26 consecutive years and the best-selling vehicle for 21 years in a row.

Flexible manufacturing start-up

                With the launch of the new 2004 Ford F-150 at Kansas Assembly, Ford also introduced its new flexible production technology at its second assembly plant in North America .

                The new system allows Kansas City Assembly to build up to eight different models off two platforms. “Kansas City Assembly now has the ability to change the mix, volume and options of products in response to consumer demand and market segmentation – all with minimal investment and changeover loss,” said Dave Savchetz, Kansas City Assembly’s plant manager.

                Over the next decade, Ford expects to save up to $2 billion because its flexible system costs 10 to 15 percent less than traditional systems, with an added 50 percent savings in changeover costs.

                Ford’s flexible body shops employ an industry-first system of 16 standardized cells, or modules, all built from about 300 components. Only product-specific tooling needs to be changed, or ...

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