Ford's Plant in Brazil - video.

[jonk]

Got this from a contact in the US. Caps aren't mine.

WE RECOMMEND THAT ONE TAKE THE TIME TO VIEW THIS SITE. IT GIVES A . VERY POSITIVE PICTURE OF THE AUTO INDUSTRY IN SOUTH AMERICA & WHY. DETROIT PEOPLE CAN LEARN & BAIL OUT BY THE GOVERNMENT IS NOT THE TOTAL ANSWER. ATTITUDE CHANGE IS THE BIGGEST CHALLENGE TO OVERCOME.

This may open some eyes!

This is a video of a new Ford plant in Brazil . One look at this and each of you will instantly be able to tell what is wrong with the manufacturing plants of the US car makers and why there will probably never be another one built in the US. It will also point out why more will go off shore.


Ford's most advanced assembly plant

http://info.detnews.com/video/index.cfm?id=1189

[barra240t]

Thats pretty impressive stuff.

[pertuan]

Wow.... just... Wow...

[Gobes32]

I think you will find that Ford Australia is setup the same however not as many different suppliers. The territory, falcon, falcon ute, wagon and once upon a time, fairlane, all rolled down the same line. They may be the same car essentially, but they all still count as five different body styles. People forget just how flexible and ingenious Ford Oz's operations are.

[vztrt]

Originally Posted by Gobes32

I think you will find that Ford Australia is setup the same however not as many different suppliers. The territory, falcon, falcon ute, wagon and once upon a time, fairlane, all rolled down the same line. They may be the same car essentially, but they all still count as five different body styles. People forget just how flexible and ingenious Ford Oz's operations are.

Thats what I was thinking. The problem in Australia is that its an old plant (not built in 2001) so they have constraints. But I understood at the end that the union is killing lean manufacturing improvements in the US....surprise surpsrise.

[Yellow_Festiva]

That is very impressive, and the way it should be if a car manufacture is to survive.

[irlewy86]

Guess my F250 must have come down the line of the old factory.


Taraus X has been just canned in the US and Panther platform has to go one day. Surely Falcon could go Stateside.

[SM1DY]

Its good to have an insight like that. The whole process just looks 'tight'.

[gtfpv]

Originally Posted by jonk

Got this from a contact in the US. Caps aren't mine.

WE RECOMMEND THAT ONE TAKE THE TIME TO VIEW THIS SITE. IT GIVES A . VERY POSITIVE PICTURE OF THE AUTO INDUSTRY IN SOUTH AMERICA & WHY. DETROIT PEOPLE CAN LEARN & BAIL OUT BY THE GOVERNMENT IS NOT THE TOTAL ANSWER. ATTITUDE CHANGE IS THE BIGGEST CHALLENGE TO OVERCOME.

This may open some eyes!

This is a video of a new Ford plant in Brazil . One look at this and each of you will instantly be able to tell what is wrong with the manufacturing plants of the US car makers and why there will probably never be another one built in the US. It will also point out why more will go off shore.


Ford's most advanced assembly plant

http://info.detnews.com/video/index.cfm?id=1189

i say good on them . and let them be the best if they can . cant comment on the US . but in australia , a factory like this would never exist, because corperate australia are too busy trying to keep reducing costs and cut budgets whilst charging way to much . which are all geared towards huge shareholder profits and fat cat salaries . so i appluad companies with enogh insite to reward and treat all of its staff and employees with conditions like we see here .
they deserve it / because whoever runs this plant is a very very smart cookie .

[Fordman1]

Originally Posted by gtfpv

but in australia , a factory like this would never exist, because corperate australia are too busy trying to keep reducing costs and cut budgets whilst charging way to much . .

Rubbish !!

Go visit the Broadmeadows Assembly plant and watch JIT line side delivery from all the major suppliers, and also the flexible body shop.

The only thing missing is the complete pre-assembly of the drive train and rear suspension in one module - that'll probably happen with Focus.

Suggest you learn your stuff before you 'slag off' the locals...............

[vztrt]

gtfpv, you havent been to the campbellfield plant have ya?

[gtfpv]

yeah sorry . i guess i was generalising . . ford australia do produce great cars in my opinion . i hope they are a great company as seems to be the case in brazil. no i havent been to the ford australia plant .
i'm glad some companies do have it together here .

[bob^]

Their only downfall is having the assembly plant 100km away from the manufacturing plant...
But yes, Ford Oz assembly line is impressive to watch, much like in that video.

[vztrt]

Remember Ford Australia showed up Mazda on when it was pointed out that they were wasting time in their manufacturing process.

[Gobes32]

And as impressive as all that looks, imagine if you saw a video of Toyota's Japanese operations? Makes that Brazilian plant look like a go kart factory. It is very impressive. Very smart manufacturers the Japanese.

[Mark351]

Once again, the US unions are shown to be the major roadblock to innovation in the auto sector there with regards to assembly. There will be no auto workers left before they get to a plant model like Brazil or even Australia.

[dom_105]

If Ford tried to build that plant in the US, the UAW would have a fit. This, incidentally, is what is holding back any Ford products which roll off the Broady line making their way to the States.

Unions have their place, but not to the detrement of the employers or the industry, and eventually the employees, in which they operate.

[vztrt]

Originally Posted by dom_105

If Ford tried to build that plant in the US, the UAW would have a fit. This, incidentally, is what is holding back any Ford products which roll off the Broady line making their way to the States.

Unions have their place, but not to the detrement of the employers or the industry, and eventually the employees, in which they operate.

Originally Posted by Kieron

Have a read of this about the Camacari plant and what this pro union bloke is saying -

http://willyloman.wordpress.com/2008...orate-welfare/

Underneath are some response from what appear to be auto workers/UAW members.

Well I was gonna say if Ford is smart enough they would use the credit crisis to take the huge amount of power the unions have. But I can understand the employees wanting to keep their pension plan, cause all the money that they would have paid for social security (government pension) has been spent by the government.

[Ohio XB]

Originally Posted by Mark351

Once again, the US unions are shown to be the major roadblock to innovation in the auto sector there with regards to assembly. There will be no auto workers left before they get to a plant model like Brazil or even Australia.

You are close, very close.


This Brazil plant is not just about JIT, it is about the suppliers building the vechicle. Watch the video again and listen when Bryce (I have exchanged a number of emails with him, very good reporter) states that 7 different vendors assemble the underbody and yet another vendor installs the engines and suspension.

Do you see where this is going? Did the Ford workers assemble the underbody? No. Did Ford workers install the engine? No. Did Ford workers assemble the front suspension on the chassis? No. The VENDORS are performing this work. Who is building the car? You decide.

Anyone here work at Broadmeadows or any other Oz Ford plant? Think about this please......when does it go from JIT and just "vendors in the plant" to vendors building the vehicle and you looking for another job?

It used to be the vendors dropped the parts off at the door.

Then the vendors bring the parts to the line.

Now, in some cases, you have the vendors installing their parts or sub-assemblies.

What will the Ford worker be doing? Driving them off the line? Nah, they can hire car porters that can do that for much less pay.





Please be careful when paying attention to where the line is......where there is progress and advanced assembly techniques, and where your job as a Ford worker is being eliminated while all those suppliers "install their parts" on the vehicle. Why will Ford, or any auto manufacturer for that matter, need its own employees?


Steve

[Bossxr8]

Originally Posted by Ohio XB

You are close, very close.


This Brazil plant is not just about JIT, it is about the suppliers building the vechicle. Watch the video again and listen when Bryce (I have exchanged a number of emails with him, very good reporter) states that 7 different vendors assemble the underbody and yet another vendor installs the engines and suspension.

Do you see where this is going? Did the Ford workers assemble the underbody? No. Did Ford workers install the engine? No. Did Ford workers assemble the front suspension on the chassis? No. The VENDORS are performing this work. Who is building the car? You decide.

Anyone here work at Broadmeadows or any other Oz Ford plant? Think about this please......when does it go from JIT and just "vendors in the plant" to vendors building the vehicle and you looking for another job?

It used to be the vendors dropped the parts off at the door.

Then the vendors bring the parts to the line.

Now, in some cases, you have the vendors installing their parts or sub-assemblies.

What will the Ford worker be doing? Driving them off the line? Nah, they can hire car porters that can do that for much less pay.





Please be careful when paying attention to where the line is......where there is progress and advanced assembly techniques, and where your job as a Ford worker is being eliminated while all those suppliers "install their parts" on the vehicle. Why will Ford, or any auto manufacturer for that matter, need its own employees?


Steve

Vendors only deliver sub assemblies like seats etc to Broadmeadows on conveyors from adjacent plants, they don't ever fit anything on line. The AMWU would go off their heads if the company tried to change that, thank god, but in saying that a lot of part production is being farmed out to contractors if it means the company can save money. The Barra cylinder head for example, it was cheaper to have it cast in Mexico and sent over here for machining rather than Aluminium Casting make it themselves on site.

[Ohio XB]

Originally Posted by Bossxr8

Vendors only deliver sub assemblies like seats etc to Broadmeadows on conveyors from adjacent plants, they don't ever fit anything on line. The AMWU would go off their heads if the company tried to change that, thank god, but in saying that a lot of part production is being farmed out to contractors if it means the company can save money. The Barra cylinder head for example, it was cheaper to have it cast in Mexico and sent over here for machining rather than Aluminium Casting make it themselves on site.

But when the UAW resists this it is that "militant, inflexible frigging union".


My point exactly. See how fast this went from being a detriment to Ford that the UAW is causing and killing the company, to thank god for the AMWU who does the exact same thing?

So to those that said the American UAW is the dagger in Ford's heart, I am just glad that BOTH of these unions are here. You see you have the exact same condition in Australia. This is another reason the unions need to be there.


Think Ford wouldn't have vendors build parts of the vehicle on the assembly line in a Ford plant? Did you watch this video? What is the only difference there? NO UNION to prevent it. Wouldn't not having your own employees save on cost?

How many people here would be willing to give up their jobs so that their company can be more profitable? How many times will you do that?



Steve

[Kieron]

Originally Posted by Ohio XB

But when the UAW resists this it is that "militant, inflexible frigging union".


My point exactly. See how fast this went from being a detriment to Ford that the UAW is causing and killing the company, to thank god for the AMWU who does the exact same thing?

So to those that said the American UAW is the dagger in Ford's heart, I am just glad that BOTH of these unions are here. You see you have the exact same condition in Australia. This is another reason the unions need to be there.

Actually I don't believe we do. It's my understanding that when a Ford employee retires/leaves in Aus, they don't get company pensions, health plans etc, your on your own.

From what I read of the US auto industry, the big three have huge nooses around their necks with these health/pension plans.

Think Ford wouldn't have vendors build parts of the vehicle on the assembly line in a Ford plant? Did you watch this video? What is the only difference there? NO UNION to prevent it. Wouldn't not having your own employees save on cost?

How many people here would be willing to give up their jobs so that their company can be more profitable? How many times will you do that?
Steve

If the vendors come in and assemble the vehicle, this is essentially outsourcing, exactly what many other businesses do. However, those outsourcing companies still need to employ labour in order to do the assembly.

What Ford in the USA would do is broker a deal with the outsourcing companies that would say you will take xxx number of Ford employees for component assembly and probably redeployment, tell the workers the deal, some will accept and others won't and would probably get redundancy.


Yes there will be job losses if Ford did this in the USA, but maybe some are close to retiring age anyway.

[sleekism]

Originally Posted by Gobes32

And as impressive as all that looks, imagine if you saw a video of Toyota's Japanese operations? Makes that Brazilian plant look like a go kart factory. It is very impressive. Very smart manufacturers the Japanese.

Thus why Japan has spent the last two decades in recession :

Japan is no longer the economic model to follow. Most "Japanese" cars are now built outside Japan. I suspect the profitability of the Brazillian plant has more to do with lower overheads (wages, taxes etc.) than production efficiency otherwise the Broadmeadows plant would be profitable.

[axeray]

That's very impressive.

Wow

[Bossxr8]

Its really no different to Broadmeadows, except it's newer. Ford's Business Park, on the Broadmeadows site, I think, has DANA, Venture, Autoliv and other suppliers supplying parts directly to the production line just in time.

A few years ago Fords Stamping Plant was the highest ranked plant based on the Ford Production System rankings, with the engine plant and Broadmeadows right behind it, so Ford Australia don't play second fiddle to anyone.


I had a mate who works for Toyota just come back from a plant in Thailand, and he reckons the plants are absolute dumps. He said that on some of the presses the workers had to duck down in the middle of the press, so when it cycled they wouldn't get crushed. OH&S does not exist over there. If they didn't duck every time the press cycled they would probably be killed. Unbelieveable.

[SB076]

Originally Posted by Bossxr8

I had a mate who works for Toyota just come back from a plant in Thailand, and he reckons the plants are absolute dumps. He said that on some of the presses the workers had to duck down in the middle of the press, so when it cycled they wouldn't get crushed. OH&S does not exist over there. If they didn't duck every time the press cycled they would probably be killed. Unbelieveable.

I havent been to Thailand but did have a look at some European manufacturers and the difference in things like press guarding is massive. A lot of people think wages is the sole reason why oz manufacturers cant compete in reality there are many reasons - OH&S, Enviromental, and Govt taxes and charges come to mind

Plants like that can be built anywhere, the reasons why it was built in Brasil is because its considered to be a "low cost centre" its also part of the merging BRIC countries that are tipped to be the next industrial powerhouses

[Gobes32]

Ford Australia is a very, very efficiently run operation. And is more profitable than Holden, even with all their exports. This also goes into factoring why Ford Oz will get the Focus contract and not Thailand. Bossxr8 has touched on OH&S, Ford Oz is the most safest plant to work for in the Ford world. Also, it's not the wages that make cars so expensive, it's the overheads like oh&s, taxes, training, etc.

[Kieron]

Have a read of this about the Camacari plant and what this pro union bloke is saying -

http://willyloman.wordpress.com/2008...orate-welfare/

Underneath are some response from what appear to be auto workers/UAW members.

[zetec]

Originally Posted by Kieron

Have a read of this about the Camacari plant and what this pro union bloke is saying -

http://willyloman.wordpress.com/2008...orate-welfare/

Underneath are some response from what appear to be auto workers/UAW members.

Good God...

[MAD]

Originally Posted by zetec

Good God...

Therein lies the problem with America..... Americans...lol