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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.

2015 Honda Civic Type R prototype

With a name like Earth Dreams, you'd be forgiven for assuming that Honda's new family of turbocharged VTEC engines is more about environmental credentials than performance. And to a large degree they are - particularly in 1.0- and 1.5-liter forms. But the 2.0 is another beast altogether.
Thanks to a high-output turbocharger, direct injection, a high-performance cooling system and, of course, variable valve timing, Honda's new 2.0-liter four produces upwards of 280 horsepower while still complying with upcoming Euro 6 emissions standards. Although actual output has yet to be confirmed, that preliminary figure already compares favorably with the Ford Focus ST (252 hp) and Mazdaspeed3 (274 hp) and rests comfortably in between the Volkswagen GTI (270 hp) and Golf R (296 hp).
Although Honda has already shoehorned the smaller 1.5-liter turbo four and 1.0-liter turbo three-cylinder engines into an Acura ILX and another Civic hatchback, the home it gave the 2.0 betrays more than an engine swap. What you see here is essentially the next Civic Type R, following a long line of Honda hot hatches. With this latest model, the Japanese automaker is targeting the front-drive lap record at the Nürburgring that belongs to the Renaultsport Megane Trophy and before that, to the lightweight Megane R26.R. A tall order, to be sure, so we headed to Honda's R&D center in Tochigi, Japan, to take it out for a ride.

Honda Vezel is the Fit crossover we've been waiting for

"Vezel" may sound like the latest miracle cure from Big Pharma, but in truth it's the long-awaited Fit-based crossover from Honda. Unfortunate name aside, this four-door CUV looks ready for production, because it is.
Shown here in hybrid guise, the subcompact Vezel looks quite sporty, with boldly upswept sheetmetal contours, an aggressively raked backlight, "hidden" rear doorhandles borrowed from the JDM Civic hatchback, and an expressive face with LED headlamps.
Honda is presently confirming that the Vezel will go on sale in both hybrid and gas-only guise in Japan, but it isn't offering anything in the way of specifications other than to say that both models will make use of a 1.5-liter direct-injected engine, the "Sport Hybrid i-DCD" powertrain of course getting a "high-output motor" of unspecified power and what could be a dual-clutch transmission. Honda has declined to make clear whether this is the new 1.5-liter turbocharged VTEC engine we told you about yesterday, but it's a good bet that it is indeed the same new Earth Dreams powerplant. Critically, there's no mention of whether all-wheel drive will be offered.