Archives for February 2018

Wednesday Morning Auto News, Feb 21, 2018

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Will China hold our electric future at ransom? Not if Toyota can help it

Toyota’s Akira Kato demonstrates lean neodymium. (c) Bertel Schmitt

If the supply of electric vehicles is to grow as predicted, the demand for strategic materials will increase along with it. The various oil crises of the past, and the wars that came with it, illustrate where such a dependency can lead. As far as electric vehicles are concerned, two choke points have been identified: The supply of cobalt needed to make batteries, and the supply of rare earth minerals needed to make the magnets in electric motors.

There are two ways to address the problem. We can hope it will take care of itself. Or we can do something about it. Toyota is in the second camp, and it aims to reduce the dangerous dependency on neodymium. Expensive neodymium already is the main cost driver in the production of magnets, we heard today at a meeting at Toyota’s Tokyo HQ. If electric vehicles will gain popularity as expected, shortages of neodymium could occur as early as 2025, Akira Kato, general project manager at Toyota’s R&D company, told us today. [ There is more … ]

Tuesday Morning Auto News, Feb 20, 2018

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Monday Morning Auto News, Feb 19, 2018

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Friday Morning Auto News, Feb 16, 2018

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Thursday Morning Auto News, Feb 15, 2018

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Wednesday Morning Auto News, Feb 14, 2018

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Searching For “Production Hell” At Ford’s Kentucky Truck Plant

As Tesla has blown through one Model 3 production volume deadline after another, the automotive upstart’s “production hell” has become a topic of intense scrutiny and debate. Among fans of the company, the overwhelming majority of whom have little to no exposure to automotive manufacturing, the belief that Tesla must be innovating bold new manufacturing techniques that will leave the “legacy” automakers in the dust has become an article of faith. But if you spend some time at one of the established auto manufacturing plants that currently pumps out products and profits that Tesla can only dream of, it quickly becomes clear that the Silicon Valley startup culture that fuels Tesla’s innovative design and blistering performance is more liability than asset when it comes to the difficult task of actually making cars.

A recent visit to Ford’s Kentucky Truck Plant (KTP) put the contrast between Tesla’s approach to automaking and that of the established automakers into sharp relief. Even before I set foot in the massive facility, it became clear how much more confident Ford is in its manufacturing operation than Tesla. Whereas Tesla typically only opens its Fremont factory to Tesla owners who are required to sign nondisclosure agreements, Ford’s tour took select news media through nearly every portion of the plant (including the paint shop, which almost every factory limits access too), encouraged us to speak to any worker we liked, and asked only that we keep news of a new $25 million investment embargoed for a few days. If Ford were experiencing the “production hell” that has characterized every new Tesla product ramp we would have had no problem recognizing it.

What we saw instead was the intricate ballet of modern automotive manufacturing, a complex yet precise operation involving thousands of workers, robots and suppliers. We saw the fascinating mix of humility and pride among the workers who make up the foundation of the production system, the tight choreography of a fully automated body shop that turns sheets of aluminum into vehicle bodies, the firehose of data that keeps the entire system working together and the latest 3D printing technology that Ford has brought in to continuously improve –rather than replace– the humans and robots that move tirelessly to the beat of an unseen drummer. And at the end of the line, we saw that beat made manifest in a new Ford SuperDuty pickup, Expedition, or Lincoln Navigator rolling off the line at a steady rate of more than one per minute.

In short, nothing about KTP suggested anything that might be described as “production hell,” even as it produced more vehicles every day than Tesla makes Model 3 in a week. And though it may not have looked like an illustration from a speculative SciFi novel about the factories of the deep future, KTP also gave no indication of being a laggard in production or quality that might be disrupted by Tesla or anyone else.

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