Ford is deploying its 3-Wet paint process in facilities around the world—both in greenfield and brownfield sites. The process not only provides environmental benefits through the reduction of emissions, but requires significantly less energy, reduces the footprint of the paint shop, and accelerates vehicle throughput, all without sacrificing anything in the
way of quality paint finishes.
One technology that is experiencing growth at Ford, says Bruce Hettle, director of manufacturing engineering, is laser brazing. Note what you don’t see on the roof of this 2013 Fusion: a piece of trim covering the ditch that ordinarily exists when the body side and the roof are joined. Rather, there is a smooth surface. Hettle says that there will be the deployment of lasers for other assembly applications rolling out in the future. There will also be an increase in the use of structural adhesives, particularly as they reduce the gauge of sheet metal in order to address fuel economy requirements.
Ford is working to provide manu-facturing flexibility in its assembly plants. A prime example is the Michigan Assembly Plant, where they are building the Focus, Focus ST, Focus Electric, C-MAX Hybrid, and C-MAX Energi—gasoline-powered, electric, hybrid, and plug-in hybrid vehicles—all on the same production line. It is the only plant in the world that is doing so. (Photo: Sam VarnHagen/Ford).
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