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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.

It turns out Takata isn't willing to expand airbag recall nationally after all

There have been "approximately 0.000006 failures per air bag deployment, which is far below the failure rate" of most recalls, Takata claims. Takata has seemingly made an about face following reports that it would expand its regional airbag recall into a nationwide repair effort, issuing a scathing, four-page letter rebutting allegations by the National Highway Traffic Safety Administration and its Office of Defects while simultaneously attacking the government's handling of the situation. The Japanese supplier claims in its letter that the "currently available, reliable information does not support a nationwide determination of a safety defect," arguing that there were "approximately 0.000006 failures per air bag deployment, which is far below the failure rate in the vast majority of the thousands of recalls," The Detroit News reports. Takata then breaks down the two specific incidents mentioned in NHTSA's original recall request letter, a 2005 Honda Accord and 2007 Ford Mustang. Referencing the two crashes, NHTSA Administrator David Friedman said last month "one incident is an anomaly, but two are a trend." The supplier, though, argues the Honda issue is already being covered by that company's soon-to-be-national recall (more on that in a moment). The company then goes on to point out that neither Takata nor NHTSA has been able to analyze the Mustang's airbag inflator, saying that such a lack of examination meant there was "no way to ascertain what actually occurred during the incident, whether any inflator ruptured, and whether any inflator rupture that may have occurred was related to the incidents that led to the current regional campaigns." Takata alleges that NHTSA has disobeyed its own statutes. Takata also took the opportunity to take a few swipes at NHTSA's behavior during the airbag scandal, saying it was "very surprised to receive" a recall request letter because the ODI had yet to even receive the company's responses to a pair of special orders. It also alleged that NHTSA was disobeying its own statute, which says only manufacturers of vehicles and replacement equipment can "decide in good faith whether their products contain a safety related defect," and that the government can only "issue an initial decision that a safety-related defect exists" to those same entities.

2015 Honda Civic Type R to sire next-gen CR-Z?

Salt shakers at the ready, boys and girls. There's a rumor out of Australia claiming the next Honda CR-Z will be based on the forthcoming 276-horsepower, turbocharged Civic Type R. Apparently Honda's research and development bigwigs have been unnerved by the reception of the Scion FR-S/Subaru BRZ twins and are eager to return fire.
Now, don't get too excited - Honda isn't following the Volkswagen model of offering virtually unchanged mechanicals in a different bodyshell (Beetle Turbo and GTI, for example). Instead, the report says the future CR-Z will retain its hybrid powertrain, albeit with a serious kick in the pants. A prototype is said to already be zipping around Japan with a turbocharged, direct-injected, 1.5-liter, four-cylinder engine and the current CR-Z's electric motor and battery pack. With a reported 221 horsepower mated up to a seven-speed, dual-clutch transmission (say buh-bye to the CVT and six-speed manual) and the next-gen Civic platform underneath, the rumored CR-Z has all the makings of a hot hatch riot.
Of course, this all sounds wonderful. This is also the point where you should be enjoying that salt. We really like the idea of a properly hot CR-Z that can compete with John Cooper Works Mini models and the new Ford Fiesta ST, but the three-door hybrid has been such a slow seller for Honda in the US that it might not field a second generation here, no matter how improved it might be. Let us know what you think of an amped-up CR-Z in the comments. Is it a good idea, or is this one Honda model that's just too far gone?