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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.

2017 Acura NSX First Drive [w/video]

The 2017 Acura NSX is heavy. It outweighs the original 1990 car by more than 800 pounds and is over 300 heavier than a Chevrolet Corvette Z06. The NSX is insanely complicated, with an assist motor between the twin-turbo V6 and the nine-speed dual-clutch transmission, plus two torque-vectoring electric motors at the front axle. And the NSX is expensive. It will probably cost $170,000 when it goes on sale in Spring 2016. Commence trolling. If you hadn't guessed, the new NSX isn't much like the first generation built from 1990 to 2005. But the two cars share a common philosophy. Both are Acura's interpretation of what a modern, everyday supercar should be. Based on the new car, things have changed a lot in the last 25 years. For project leader Ted Klaus, the original NSX was one reason he started working at Honda. At the 1990 Detroit Auto Show, "I sat watching that car for a while. A really long while. Even just looking at that car I could see the deep, advanced, functional beauty." The most difficult thing with the new NSX, says Klaus, is to explain how a heavier and more complicated car can outperform other cars in a way that feels like traditional lightweighting. View 33 Photos This is not the way the NSX was supposed to be at first. The original plan was a transverse-mounted, naturally aspirated engine just like the first car. The NSX has a giant bag of neat tricks, but to understand them takes a lengthy explanation that starts with the Sport Hybrid SH-AWD powertrain. Behind the cockpit is a 75-degree, twin-turbocharged, 3.5-liter V6, made specifically for the NSX. On its own it puts out 500 horsepower and 406 pound-feet of torque. The rest of Honda's lineup uses a 60-degree layout, but the wider angle here lowers the center of gravity. Behind the engine is the rear assist motor, with 47 hp and 100 lb-ft. Hanging off the rear of that is the nine-speed dual-clutch, developed in-house. In between the front wheels is the Twin Motor Unit (TMU), a pair of 36-hp, 54-lb-ft electric motors that add or subtract forces to their respective sides. The Power Drive unit manages the electronics, and sits in the center spine of the car like a traditional prop shaft. A lithium-ion battery pack is behind the pair of seats, on the cold side of the firewall. Total system output is 573 hp and 476 lb-ft. This is not the way the NSX was supposed to be at first. The original plan was a transverse-mounted, naturally aspirated engine just like the first car.

These are the top luxury cars bought by people entering the segment for the first time

Let's say you just got a big promotion at work or the kids are moving out of the house, and you finally have some extra money. You decide to blow it all at once and treat yourself by upgrading your ride. Naturally, you look to a luxury automaker. What do you choose?
Models like the Audi A3 and Mercedes-Benz CLA-Class may be tailor-made to introduce buyers to the premium segment, but a new study finds that they don't garner the highest rates of non-luxury customer conquests. It turns out that a Volvo leads among folks moving up to a premium brand, and it isn't even one that's made anymore, at that.
A recent study by Polk and IHS Automotive looked at what models had the highest rates of buyers upgrading from a non-luxury segment. The information comes from its new vehicle registration data through April 2014. All ten top models boasted conquest rates of over 50 percent, but the Volvo C70 led the field with 68.01 percent of its customers coming from non-premium brands.