Ford Cleveland Engine Plant #1 to Build Popular Duratec Engines
Ford Cleveland Engine Plant #1 to Build Popular Duratec Engines
New Program to Modernize Plant, Bring Jobs and Investment * Projected annual production of 325,000 units * Approximate employment to be 650 * More than $350 million investment in facility and tooling BROOK PARK, Ohio, July 18 Ford Motor Company announced today that it will reopen the Cleveland Engine Plant #1 in late 2003. The plant is being modernized to accommodate new production of the Duratec V6, a sophisticated dual overhead cam (DOHC) aluminum engine. Increased use of lightweight, advanced aluminum engines will help Ford meet its environmental commitments. Annual production is projected to be 325,000 units a year. More than $350 million is being invested in new equipment and tooling. Over time, employment will return to 650, the level of employment before it closed. Today, over 250 workers are involved in the facility's modernization efforts. "This program will give the Cleveland Engine Plant #1 a new lease on life," said Roman Krygier, vice president - Ford Powertrain Operations. "The plant's future is assured due in large part to the teamwork and dedication of all of the parties involved." Cleveland Engine Plant #1, which turns 50 in December, was idled late last year when the legendary 5.0-liter V8 was phased out of production. Since that time, a radical facility redesign and modernization effort has been underway. "Cleveland Engine Plant #1 has literally 'raised the roof' to accommodate this new production," Krygier said. "The roofline over a 372,000 square foot section has been raised by four feet in height -- the construction industry's largest roof-raising of its kind -- to allow for the installation of material handling equipment." New ergonomically designed equipment will offer enhanced flexibility for small-batch production in both engine assembly and component machining operations. This permits the plant to improve responsiveness to customer demand and reduce inventory levels. Cleveland Manufacturing Site - Global Supplier of V6 Aluminum Engines "We're extremely pleased to have been awarded this engine production," said Kevin Bicking, plant manager - Cleveland Engine Plant #1 and #2 and Cleveland Aluminum Casting Plant. "To win the business, we had to demonstrate a high degree of teamwork, quality and flexibility in our operation." The 1.9 million square foot Cleveland Engine Plant #1 was opened in December 1951. The facility has produced more than 32 million engines, including the 221/260/289 V8 and the 240/300 (4.9-liter) I6. "The Duratec V6 has been a mainstay at the Cleveland Manufacturing Site since its introduction in 1994," said Willie Hubbard, president - UAW Local 1250. "We're glad to see that Cleveland's Duratec production will continue to grow. This decision is a tremendous vote of confidence in the Cleveland site by the company." The Cleveland Manufacturing Site's dual engine facilities -- Cleveland Engine Plant #1 and #2 -- will have the capacity to produce over one million units a year once CEP1 opens in 2003. Duratec - DURAble TEChnology The DOHC Duratec V6 -- available in 2.5-liter and 3.0-liter displacements -- is offered in the Ford Taurus, Escape, Mercury Sable, Cougar, Mazda MPV and Tribute. The engines feature durable, advanced technology and provide an outstanding value to consumers. The modular design delivers smooth, responsive power-on-demand for added confidence and security. The additional production will allow Ford to meet increasing customer demand for the engines. "The Duratec V6 engine is popular with our customers, who value its durability, refinement and best-in-class fuel economy benefits," Krygier said. "The increased availability of this lightweight aluminum engine will help Ford satisfy its customers and meet its environmental commitments." Cleveland Engine Plant #1 - Lean by Design Design of the production area is based on industry-leading lean manufacturing principles from the Ford Production System (FPS). Output, quality levels and efficiency will be improved while reducing line-side inventory and waste through the implementation of just-in-time delivery and other best practices. The use of value stream mapping and Six Sigma problem- solving methods will result in reduced equipment operating costs and improved quality. In keeping with the FPS team-driven approach, hourly employees will be organized into functional workgroups, empowered to set their own goals as needed to ensure continuous improvement in the key areas of employee safety, customer satisfaction and labor productivity. "The Ford Production System works largely because of the participation of our workforce," said Krygier. "Leveraging the skills of all of our people is critical for our success as a lean, competent and responsive manufacturing system that delivers greater satisfaction and value to consumers." Lean-by-Design principles being applied at Cleveland Engine Plant #1 include: * Use of strategically-located "marketplaces" to minimize the distance parts need to travel, reducing a source of waste in the assembly process. * Visual Factory techniques to simplify the manufacturing process management. * Reduction of inventory both lineside and dockside to reduce carrying costs.