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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.

Acura NSX prototype gets back on track

Developing a new vehicle is not without its complications, we're sure, but usually things follow a fairly predictable progression: you develop a prototype, you test it, test it and test it again, then you put it into production. What you don't expect is that your prototype will burn to the ground, but that's what famously happened to the NSX which Honda engineers were testing a few months ago.
Fortunately, the Acura NSX prototype is back on track, both literally and figuratively, as you can see from this latest batch of spy shots snapped at the Nürburgring. This camouflaged prototype looks pretty much the same as the last one, only, you know... less crispy. Which is to say, it looks pretty much ready to hit showrooms.
The naysayers may point out that Honda chose colder and damper weather to put the NSX back into testing - thereby mitigating the risk of another fire - but we're sure the Japanese automaker has been working hard to fix the flammability issues, whatever may have caused them, over the past few months. At least, we hope they have.

Lawsuit reveals gruesome details of Takata airbag victim's death

The accident was minor. The aftermath was horrific. Carlos Solis was waiting to turn left into a Houston-area apartment complex on January 28 when oncoming traffic struck the front-left corner of his 2002 Honda Accord, pictured above. He was stopped, according to a police report of the accident. The other car traveled at under 30 miles per hour. He should have walked away from the fender-bender. Instead, the 35-year-old married man was killed when a defective airbag exploded and sent a large piece of metal shrapnel into his neck, his estate's lawyers allege in a lawsuit filed Thursday in Harris County, Texas. He bled to death while his younger brother and an 11-year-old cousin tried to save him. Solis is one of at least six motorists killed by defective airbags made by Takata, a global automotive supplier. He may also be a posthumous poster child for federal legislation introduced earlier this week that would ensure car owners receive more timely information about safety recalls. Currently, federal law does not require car dealers to tell prospective buyers about open recalls on used cars or whether defects have been repaired. Legislation introduced by Sen. Ed Markey (D-Mass.) and Sen. Richard Blumenthal (D-Conn.) wouldn't require that directly of dealerships, but it would mandate that car owners be notified of recalls when they apply for registration and at the time of registration renewal. "Important recall notices can get bogged down with legalese, and busy consumers can miss a life-saving update," Blumenthal said. "This legislation provides a common-sense avenue to ensure every driver is reminded and encouraged to make the necessary repairs." Such a law may have prevented Solis' death. Although his '02 Accord had been recalled in late 2011, his wife and lawyers say he had no knowledge of the recall when he bought the car used from All Star Auto Sales in 2014, nor did he know of the dangerous flaw when he set out to visit his parents on Jan. 18. Only one month earlier, Congress held hearings on Takata and Honda's long-standing inaction related to the defective airbags. Documents showed both companies were aware of problems with the airbags as early as 2004, and a report in The New York Times detailed secret airbag tests, the results of which alarmed Takata engineers. Yet the company withheld the information from federal safety administrators.