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Honda's Acura NSX masterstroke: building the factory in Ohio

When Honda announced it was going to build its NSX supercar in Ohio instead of Japan, it caught everybody in the industry by surprise. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Now Honda has a supercar production facility in rural Ohio that would be the envy of any Formula One team. The people at Honda call it the PMC, but its official name is the Performance Manufacturing Center. It's a building that started out as a shipping facility for suppliers, but Honda invested $70 million to transform it into a showcase facility that will build the NSX. Honda benchmarked the assembly operations at Ferrari, Lamborghini, McLaren, and Bentley before work began on its facility. The 200,000 square-foot building will also double as a customer reception center – Honda will open the doors for customers to come see their car being built. It's also going to offer them high-speed test drives at the gigantic Transportation Research Center just down the road. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Inside, the layout is wide open and well lit. There are no stripes or lines on the floor and none of the different departments are walled off. This creates a more welcoming appearance and lets you get a comprehensive view of the entire process at a glance. And with an eye towards future lessons learned, most of the equipment is of a modular design that can be easily reconfigured or moved. The body shop and paint shop are enclosed by glass walls so that anyone can see what's going on inside. And while you'll see some automation here and there, the idea was to achieve a blend between man and machine, not to try and automate everything. This is a low-volume facility with production targeted at only eight to ten cars a day. The plant runs four days a week with one ten-hour shift. Don't expect to see rows of new NSXs parked on any dealer's lot. The car will only be built to order. Honda is obsessed with ensuring the NSX is built to the most exacting quality standards. The plant people pored over the JD Power Appeal study to determine what supercar customers care about the most, then looked at which aspects of that directly tie into manufacturing. They developed their quality control strategy with three goals in mind. First, they wanted to build everything right the first time with no adjustments.

Why Acura should build a hybrid Integra successor using NSX tech

Yes, it sounds like a heresy. Yes, the Honda CR-Z was not a good hybrid sports car. Yes, we know the RSX officially replaced the Integra here (but was called the Integra in Japan). But, no, we're not crazy. Well, maybe a little bit. But hear us out. At the moment Acura is a bit of an unfocused mess. Its line-up is thoroughly uninspiring, save for its $200,000 NSX supercar – a great mid-engined supercar with an impressive, performance-oriented hybrid AWD system. And yet few people would draw a line connecting Acura's other SH-AWD hybrids, the RLX Sport Hybrid and MDX Sport Hybrid, to the NSX. The first NSX told the world that Acura built cars with world-class technology and performance, and the Integra carried it to people with normal pocketbooks. Since the new NSX communicates a similar message as its forbearer, so too would a new Integra. Now making an entry-level sports car with hybrid technology is tricky business. As we already established, the Honda CR-Z was a colossal flop. It's balance was all off: heavy, expensive, and not very sporty – and it didn't even get very good fuel economy. However, Honda and Acura can learn from these mistakes. First, to keep costs in check, Acura can borrow from Honda's ever-improving parts bin. It would logical to borrow the excellent Civic coupe platform – something the old Integra did as well. It could also attach the proposed hybrid powertrain to the upcoming Si turbocharged four-cylinder. Some added cost will be unavoidable, since the batteries and motors will have to go somewhere. That will cost some engineering dollars, and inflate the price tag a bit. However, since Acura is a premium brand, it has some wiggle room to bump up the price without losing buyers. Weight is another potential issue this hypothetical hybrid will face, and was one of the chief complaints with the CR-Z. Looking at the RLX and the RLX Sport Hybrid, the hybrid bits weigh about an extra 340 pounds. That's not insignificant, but added to the turbocharged Civic EX-T coupe's 2,900 pound curb weight, you would have a car that would weigh 3,240 pounds. That's comparable to the very fun Mustang EcoBoost. As long as Acura keeps the weight under 3,500 pounds, the brand should have an entertaining coupe on its hands. The final piece of the puzzle is to make sure it isn't compromised. Every bit of hybrid tech in the NSX is there for performance. It helps eliminate turbo lag, and it improves acceleration and handling.

Autoblog Minute: VW finds CO2 'irregularities', Takata dropped by automakers, SEMA recap

Volkswagen's diesel emissions scandal gets a new wrinkle, US regulators hit Takata Corporation with a substantial fine, and we head to Las Vegas for a look at tuner paradise at the 2015 SEMA show. Autoblog senior editor Greg Migliore reports on this edition of Autoblog Minute Weekly Recap. Show full video transcript text [00:00:00] Volkswagen's diesel emissions scandal gets a new wrinkle. US regulators issue a significant fine to Takata Corporation. And we take a peek inside tuner paradise at the 2015 SEMA show. I'm senior editor Greg Migliore and this is your Autoblog Minute Weekly Recap. The VW diesel emissions scandal, first brought to light in September, gets a new wrinkle, as an internal investigation by the German automaker revealed [00:00:30] irregularities in CO2 emissions that could affect approximately 800,000 vehicles. VW estimates the issue could pose a 2-billion euro economic risk. VW claims that most of the vehicles affected have diesel engines, but industry analysts say a 1.4-liter gas engine is also affected. VW says that fuel consumption figures were set too low during the CO2 certification process. During all of this, sales of some diesel-powered Volkswagen, Audi, and Porsche models [00:01:00] have been halted. Takata Corporation is back in the news in connection with its deadly airbag scandal. Federal regulators fined Takata $70 million. If the parts supplier does not comply, the fine could balloon to $200 million. Takata was also dropped this week by its biggest customer, Honda. And now, Toyota and Mazda will be following Honda's lead in dropping Takata. We're also hearing that Mitsubishi and Subaru are considering a switch in air-bag inflator suppliers. SEMA 2015 [00:01:30] came and went. We saw offerings from Mopar, like the AWD Challenger concept. Honda unveiled a Ridgeline that it will race at the Baja 1000, which gives us a hint at what future production model could look like. The celebrity presence was also felt in Vegas as it always is. Kid Rock brought a Duramax Diesel Chevy Silverado, and Acura restored and presented Ludacris with his now famous 1993 Acura Legend. Those are the highlights from the week that was. Be sure to come back on Saturday for my full recap, [00:02:00] where I'll have some added insight into Hyundai's foray into the luxury sector. For Autoblog, I'm Greg Migliore. Autoblog Minute is a short-form video news series reporting on all things automotive.