Inside the Cologne Ford Factory: a sneak peek
Our staff writer Jack Griffiths travelled to Cologne, Germany to see how a car is made. Check out a sneak peek of his experiences on the factory floor.
Check out the full article in issue 67 of the magazine!
[COLOGNE GERMANY FORD PLANT]
Date: ca. 1903 - ca. 1954
Creators: Ford Motor Company. (Most Recent)
From: Series: Motion Picture Films Relating to the Ford Motor Company, the Henry Ford Family, Noted Personalities, Industry, and Numerous Americana and Other Subjects, ca. ca. 1903 1903 - ca. ca. 1954 1954
Collection FC: Ford Motor Company Collection
localIdentifier: FC-FC-1506
naId: 91833
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Ford Focus production at the Ford Saarlouis plant in Germany
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How to make a Ford Fiesta -- in 86 seconds!
Fiesta production at Ford's assembly plant in Cologne Germany.
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Making the world's best-selling small car is a complicated process, but it's simple when you know how. Starring some of the amazing Ford people that make it possible: Erika Tsubaki -- Ford Design Strategy and Futuring, Mario Eschweiler -- Manufacturing Engineering, Hans-Jörg Stapel -- Senior Process Engineer, Betty Cherian-Oddo -- Fiesta Trim and Final Assembly.
CAR FACTORY: Ford Co-Bots
Car workers and robots work hand-in-hand
New collaborative robots, also known as co-bots, are first being used to help workers fit shock absorbers to Fiesta cars, a task that requires pinpoint accuracy, strength, and a high level of dexterity. Employees work hand-in-hand with the robots to ensure a perfect fit every time.
The trial at Ford’s assembly plant in Cologne, Germany, is part of the company’s investigations into Industry 4.0, a term coined to describe a fourth industrial revolution, embracing automation, data exchange and manufacturing technologies. Ford sought feedback from more than 1,000 production line workers to identify tasks for which the new robots would best be suited.
Measuring a little more than 3 feet high, the new robots work hand-in-hand with the line workers at two work stations. Rather than manipulate a heavy shock absorber and installation tool, workers can now use the robot to lift and automatically position the shock absorber into the wheel arch, before pushing a button to complete installation.
Equipped with high-tech sensors, the co-bots stop immediately if they detect an arm or even a finger in their path, ensuring worker safety. Similar technology also is used in the pharmaceutical and electronics industries. Developed over two years, the robot program was carried out in close partnership with German robot manufacturer, KUKA Roboter GmbH.
Ford is now reviewing further use of collaborative robots that can be programmed to perform tasks ranging from shaking “hands” to making a coffee.
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Ford's Cologne Museum - The Backlot
A walk-around the backlot of Ford's Cologne Museum - see glimpses of cars and prototypes and more here
Made in Germany | Ford Germany holds steady
As though there were no crisis,Ford is investing 200 million euros in its Cologne works. After months of uncertainty for the 17,500 employees,the new generation of environmentally friendly 'EcoBoost' engines will now be built on the Rhine instead of Romania.Ford is expanding its Cologne site despite falling profits in the US. But what is the car maker doing differently? Thanks to the scrapping bonus,Ford Germany is working double shifts instead of short time and the Fiesta is also being made in Cologne. But Ford Europe's future lies in the US,where,with record losses of 15 Billion dollars last year,the outlook is gloomy. Its European branch faces a fight for survival in a market with powerful competitors. Report by Claudia Laszczak.
FORD MANUFACTURING: Production Ford Transit in Germany
Ford starts production of the Deutsche Post StreetScooter WORK XL van at its manufacturing site in Cologne, Germany
Based on a Ford Transit chassis, the electric delivery van is fitted with a battery-electric drivetrain and a body designed and built to StreetScooter specifications
Deutsche Post DHL Group and Ford are pioneers in the electrification of delivery traffic, the cooperation with StreetScooter offering an annual production capacity of 3,500 units
COLOGNE, Germany, Oct. 9, 2018 – Ford has begun production of the Deutsche Post StreetScooter WORK XL electric van at its European HQ in Cologne, Germany.
Based on a Transit chassis, produced at the Ford Otosan joint venture plant in Kocaeli, Turkey, the medium-sized electric delivery van is fitted with a battery-electric drivetrain and a body designed and built to StreetScooter specifications.
Around 180 Ford employees are working in two shifts to build up to 16 WORK XL models per day, providing an annual production capacity of 3,500 units.
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“Manufacturing the StreetScooter WORK XL at our plant in Cologne brings together perfectly Ford’s unrivalled expertise in commercial vehicle production along with StreetScooter’s strengths as an agile start-up company,” said Joerg Beyer, managing director, Product Development, Ford of Europe. “This joint project underlines that as well as being a volume manufacturer, we can also deliver smaller production runs.”
WORK XL is the largest delivery van in the StreetScooter portfolio, with a load volume of 20 m3, room for more than 200 packages, and a payload of up to 1,275 kg. Ford will manufacture the van with a range of electric motors and lithium-ion batteries, delivering up to 90 kW (122 PS) and a maximum torque of 276 Nm. With a battery capacity of up to 76 kWh, the WORK XL has a range of up to 200 kilometres. Compared with diesel models, each electric delivery van will offer a reduction in CO2 emissions of 5 tonnes each year and a saving of 1,900 litres of fuel.
Deutsche Post DHL is using the WORK XL to support its urban parcel delivery service in Germany, while the future availability of the electric van to third-party customers is under consideration.
“With Ford, we have found the ideal partner who understands our flexible and customer-oriented way of production. Together, we are promoting electromobility in Germany and making inner‑city delivery traffic more environmentally friendly and quieter. With the new WORK XL StreetScooter, we now have the perfect e-van for parcel delivery in metropolitan areas, which in the future will also benefit other transport companies,” said Prof. Dr. Achim Kampker, CEO and founder, StreetScooter.
Electrified powertrains will play a key role in Ford’s European product line-up. The company is investing €9.5 billion and plans to deliver 16 fully electric vehicles within a global portfolio of 40 electrified vehicles through 2022.
Recently, at the IAA Commercial Vehicle show in Hanover, Germany, Ford presented its Transit Custom plug-in hybrid (PHEV) model for the first time. Featuring an advanced hybrid powertrain system, the Transit Custom PHEV targets a zero-emission driving range of 50 kilometres (31 miles) and uses the multi-award-winning Ford 1.0-litre EcoBoost petrol engine as a range extender for total range exceeding 500 kilometres (310 miles).
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Ford in Germany
A hyper-lapse of the towns and cities where Ford builds and develops in Germany.
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Werksführung (Fiesta-Fertigung) bei Ford in Köln #forddrive
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Ford Environmental Test Centre in Cologne, Germany
Ford’s new state-of-the-art Environmental Test Centre puts all the world’s weather under one roof, enabling engineers to test forthcoming vehicles in the most demanding conditions and make whatever weather they want at any time of the day.
Altitudes higher than Mont Blanc, the tallest Alpine peak, vehicle and wind speeds of up to 250 km/h (155 mph), and snow, glaring sunlight and rain are among conditions that are a push of a button away in Europe’s most advanced automotive environmental test centre. On an area the size of a football pitch, engineers can now take vehicles around the world, from the desert heat of the Sahara, to the arctic cold of Siberia and to the heavy humidity of Costa Rica.
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Welcome to Ford’s Weather Factory
Ford’s new state-of-the-art Environmental Test Centre puts all the world’s weather under one roof, enabling engineers to test forthcoming vehicles – from a small Ford KA+ to a two-tonne Ford Transit in the most demanding conditions and make whatever weather they want at any time of the day. ????
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A look round the new Ford Design Centre extension - Cologne, Germany
Ford has opened the new 11.6 million Euro extension of their Design Centre in Germany.
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2019 Ford Focus - PRODUCTION
Produktionsstart des neuen Ford Focus: Vierte Generation des Erfolgsmodells läuft in Saarlouis vom Band
Die Ford-Werke GmbH startet Serienfertigung des Bestsellers in Saarlouis
In der Ford Focus-Fertigung feiern rund 500 Beschäftigte gemeinsam mit Vertretern der Unternehmensleitung, dem Ministerpräsidenten des Saarlands, der Landeswirtschaftsministerin und Saarlouis‘ Oberbürgermeister
Ford investiert rund 600 Millionen Euro in neue Produktionsanlagen im Saarlouiser Werk; innovative Fertigungsanlagen garantieren höchste Produktionsqualität
Zu den Händlern kommt der neue Kompaktwagen im September – der Basispreis beträgt 18.700 Euro
Die vierte Generation des Bestsellers läuft vom Band: In Saarlouis hat die Serienfertigung des neuen Ford Focus begonnen. Ford feierte den Produktionsstart am Dienstag bei einer Mitarbeiterveranstaltung in der Ford Focus-Fertigung im Werk Saarlouis mit rund 500 Beschäftigten. Zu den Gästen zählten auch Saarlands Ministerpräsident Tobias Hans, Landeswirtschaftsministerin Anke Rehlinger und Peter Demmer, der Oberbürgermeister von Saarlouis.
Gunnar Herrmann, Vorsitzender der Geschäftsführung der Ford-Werke GmbH, bedankte sich bei den Beschäftigten für den reibungslosen Anlauf der Volumenproduktion und betonte die Bedeutung der Modellreihe. „Der neue Ford Focus kann sich wirklich sehen lassen! Wir haben alles für die Fortsetzung seines Erfolgs getan und ein Auto auf die Räder gestellt, das besser, fortschrittlicher und innovativer ist als alles, was wir bisher in Europa auf den Markt gebracht haben.“
--An der Spitze des Kompaktwagen-Segments
Neben dem neuen, frischen Design und dem hohen Qualitätslevel im Interieur, beeindruckt der neue Ford Focus vor allem mit dem, was unter der Haube steckt - eine Vielzahl innovativster Technologien. Mit dem Angebot an Assistenzsystemen, die Ford von nun an mit dem Begriff „Ford Co-Pilot360“ zusammenfasst, bringt der Ford Focus Technologien in die Kompaktklasse, die man bislang nur aus der Mittel- oder Oberklasse kannte. Viele Funktionen entsprechen dabei dem Level 2 für autonome Fahrzeuge.
Zudem setzt der neue Ford Focus, als erste europäische Baureihe von Ford mit dem sogenannten FordPass Connect-Modem, neue Maßstäbe in Sachen Konnektivität. Und auch beim Antrieb bietet die vierte Generation des Kompaktwagens etwas ganz Neues: Die jüngste Generation des vielfach preisgekrönten EcoBoost-Dreizylinders mit 1,0 und 1,5 Litern Hubraum profitiert von der intelligenten Zylinder-Steuerung, die Ford als erster Automobilhersteller überhaupt für Dreizylinder-Aggregate eingeführt hat.
Doch nicht nur unter der Haube des neuen Ford Focus steckt allerhand Hightech, auch in der Fertigung setzt Ford auf innovative Technologien. „Saarlouis zählt nach wie vor zu den effizientesten und produktivsten Automobilwerken weltweit!“, sagte Gunnar Herrmann. „Damit das auch so bleibt, investieren wir kontinuierlich in dieses Werk. In der Fertigung des neuen Ford Focus haben wir rund 600 Millionen Euro für neue und optimierte Produktionsanlagen ausgegeben – einige der neuen Fertigungstechnologien kommen sogar erstmals in der gesamten Automobilindustrie zum Einsatz.“
So hat zum Bespiel in der neuen Boron-Halle auf rund 6.000 Quadratmetern – das entspricht in etwa der Größe eines Fußballplatzes in der Bundesliga – eine neue Heißverformungsanlage ihre Arbeit aufgenommen. Diese kann ultra-hochfeste und besonders leichte Komponenten aus Boron-Stahl vor Ort verarbeiten und verfügt – ein Novum für Automobilhersteller – über einen vollautomatisierten Entladeprozess. In der 40 Meter langen Ofenstraße werden die Boron-Stahlplatten über Gas- und magnetische Induktion auf 930 Grad Celsius zu einer gefügigen Masse erhitzt, bevor sie in eine 1.250-Tonnen-Presse gelangen. Anschließend schneiden Laser mit einem 3.000 Grad heißen Lichtstrahl die wassergekühlten Platten in ihre endgültige Form.
Der am besten verarbeitete Ford Focus der Modellgeschichte
Die optimierten und erneuerten Produktionsanlagen liefern die Grundlage für den qualitativ hochwertigsten und am besten verarbeiteten Ford Focus der bisherigen Modellgeschichte. Allerdings können auch die modernsten Fertigungsmaschinen die gewünschte Produktionsqualität nicht ohne die Beschäftigten abliefern, die die Neuerungen mit ihrem engagierten Einsatz umsetzen. Darauf verwies Werkleiterin Kerstin Lauer und bedankte sich ausdrücklich bei ihren Mitarbeiterinnen und Mitarbeitern: „Ich bin stolz auf Euch und auf das Ergebnis. Ihr habt in den vergangenen Wochen und Monaten alles gegeben, damit wir heute den Startschuss für die Serienproduktion geben können. Für Euren engagierten Einsatz möchte ich mich ganz herzlich bedanken!“
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Vaughn Gittin Jr. Tours Cologne Ford Museum | Ford Performance
Vaughn Gittin Jr. got a private tour of Ford's Cologne museum.
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Vaughn Gittin Jr. Tours Cologne Ford Museum | Ford Performance
Ford's ‘Weather Factory’ can simulate global weather conditions
Ford’s new state-of-the-art vehicle testing facility will simulate a huge range of demanding weather conditions – from arctic frost and desert heat to rainforest humidity.
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Made in Germany | Wie sich Ford in Deutschland behauptet
Als ob es keine Krise gäbe - Ford investiert 200 Millionen Euro in sein Kölner Werk. Nach monatelanger Zitterpartie für die 17500 Mitarbeiter steht fest: die neue Generation der umweltfreundlichen,sogenannten EcoBoost-Motoren wird statt in Rumänien am Rhein gebaut.Trotz sinkender Umsätze in den USA,baut Ford den Kölner Standort aus. Was macht der Autobauer anders als alle anderen? Dank der Abwrackprämie heißt es bei Ford Deutschland: Doppelschichten statt Kurzarbeit,in Köln wird auch der Fiesta gebaut. Doch das Schicksal von Ford Europa entscheidet sich in Amerika. Bei der Mutterfirma in den USA sieht es allerdings düster aus: im letzten Jahr gab es einen Rekordverlust von 15 Milliarden Dollar. Die europäischen Standorte müssen um ihre Zukunft kämpfen und werden dabei untereinander zu den größten Konkurrenten. Eine Reportage von Claudia Laszczak.
2017 Ford Fiesta unveiled at an event in Cologne, Germany
2017 Ford Fiesta unveiled at an event in Cologne
The all-new 2017 Ford Fiesta has arrived. Ford unveiled the new car at its 'Go Further' event in Cologne, Germany where Ford CEO Mark Fields and Ford of Europe president Jim Farley introduced us to not one but four versions of the next generation of the best-selling supermini.
The Fiesta’s gentle move upmarket should allow it to major, at least for petrol engine buyers, on the 1.0-litre three-cylinder Ecoboost engine, now available in three power levels, with the 1.5 TDCi four-cylinder unit as diesel support. The sixspeed dual-clutch Powershift auto will continue until multispeed ‘hydraulic’ autos arrive in two or three years’ time. Ford is also certain to continue with its class-beating Fiesta ST.
The clear intention is to avoid ‘frightening the horses’ with its new Fiesta when the car goes on sale in the first half of next year, with current models accounting for one-third of European Ford sales. But the company also wants to offer something new, with greater concentration on quality and better materials.
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