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Ford idling Michigan Assembly Plant to trim Focus, C-Max supply

Ford will be putting the brakes on production at its Michigan Assembly Plant in Wayne, MI, idling production during the weeks of October 28 and December 16. Ford is citing the first drop in US sales in 27 months, a 4.2-percent dip in September, as the impetus for trimming their supplies, according to Automotive News.
Ford's deft management of its supplies has been part of its success over the years, and seeing supplies of Focus and C-Max, the two vehicles built at MAP, rise from 58 and 108 days, respectively, to 71 and 122 days over the span of a month was apparently all that was need to justify the trimming. As AN points out, the rule of thumb for many automakers is to maintain a 60-day supply of vehicles.
"Ford has been focused on keeping their pricing in check. Their operating margin is in double digits. Nobody else is there and they're obviously very proud of that," Alan Baum, an auto analyst with Baum & Associates told AN. Keeping the supply chain operating smoothly and not increasing supplies too much is crucial to that healthy profit margin. After all, a large supply lowers prices ,which, in turn, cuts profit. So while this news might not be great for employees at MAP, who now have an extra two weeks of vacation time, it's far from a sign of problems in Dearborn. Quite the opposite, actually.

Ford adding second supplier for F-150 frames

Metalsa, the company that builds steel frames for the aluminum-bodied Ford F-150, is still having trouble providing enough frames to supply the two factories that build the pickup. The snafu is preventing Ford from selling as many of the country's best-selling truck as it could, and eating into profits - even though the bottom line is still breaking company records. According to The Wall Street Journal, Ford has picked Michigan company Tower International as a second frame supplier and expects to have inventory up to a proper level at the beginning of Q4 of this year. Neither Ford nor Tower would confirm the development - Automotive News got comments from a source and pieced together bits of info from Tower's financial statements and local press reports. Tower currently builds body structures for several vehicles, including the F-series, and the Bellevue, Ohio factory that will build F-150 frames previously manufactured frames for the Ranger and Econoline. According to a story in the local Sandusky Register, Tower will add one production line at the end of next month to begin shipping frames in October, and another line in April 2016. Something like 138 full-time workers and 364 robots are expected to carry out the work. Tower's most recent financial statement said that capital investment will be necessary to get everything set up, but the contract will be worth $140 million in yearly revenue.

Ford's new Focus RS hatches hot and heads for America

The hot hatch market is heating up, and heating up fast. What you see here is Ford's new challenger for pocket-rocket supremacy, the third iteration of the breed and the 30th model to wear the Rallye Sport designation. But perhaps best of all, it will be the first time Ford will offer a new Focus RS in America. Following yesterday's leak, the latest Ford Focus RS is now ready to step out into the light and light up its tires. Answering the call is the same 2.3-liter EcoBoost turbo four as you'd find in the new Mustang, but upgraded with a new low-inertia twin-scroll turbocharger, larger compressor and intercooler, freer-flowing intake, large-bore dual-pipe exhaust with electronically controlled valve and upgraded internal components. The result is a 6,500-rpm redline (closer to that of Ford's atmospheric performance engines) and an output quoted as "well in excess of 315 horsepower" – which is already 5 more than the EcoBoost Mustang and a good 63 more than the existing Focus ST. Power is transmitted to the tarmac through a new performance-focused all-wheel drive system with torque vectoring that can send as much as 70 percent of available twist to the rear wheels (and as much as 100 percent between them). The system works in tandem with the brake-based torque vectoring system and stability control, and will even divert torque to the outside rear wheel under cornering to keep it flat and under control while reducing understeer. Those still suspicious of dual-clutch gearboxes will also be pleased to read that Ford has stuck with a conventional six-speed manual. We'll reserve judgement on the inclusion of the electric power steering until we get a chance to drive it, though. Of course the small team of global Ford Performance engineers who developed the new Focus RS – and the Gymkhana legend Ken Block who consulted on the project – didn't just tinker with the powertrain and leave it at that. The suspension features stiffer spring rates, bushings and anti-roll bars than the Focus ST, augmented by two-mode switchable dampers. 19-inch alloys wear Michelin Pilot Super Sport rubber, with optional Pilot Sport Cup 2 semi-slicks for track-day enthusiasts. Ford has yet to detail the brakes on its new hot hatch, but you can bet they've been upgraded as well.