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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.

Autoblog Podcast #343

George Kennedy from Boldride.com, BMW i3, NACTOY long list, Bentley SUV
Episode #343 of the Autoblog podcast is here, and this week, Dan Roth and Steven Ewing are joined by George Kennedy, Autoblog alum and Editor-in-Chief of Boldride.com. Topics include the unveiling of the BMW i3, the 2014 North American Car and Truck of the Year long list, and the green-lighted Bentley SUV. As always, we start with what's in the garage, but then answer some of your questions before diving into the week's news. For those of you who hung with us live on our UStream channel, thanks for taking the time. You can follow along after the jump with our Q&A. Thanks for listening!
Autoblog Podcast #343:

Acura recalling 76,000 TSX sedans in certain cold-weather states

Parent company Honda is issuing a recall for Acura TSX vehicles from model years 2004 to 2008, for a rather interesting fault with the electrical systems (well, kind of). It seems that TSX made between during that range have carpeting that degrades when it becomes saturated with "corrosive materials for deicing." The carpeting is in contact with each Acura's electronic control unit, which may in turn rust or become corroded as a result. All of that business could cause the engine to stall.
Acura is singling out cars registered in states that use these corrosive deicing materials (presumably road salt): Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, Wisconsin and the District of Columbia.
Owners of affected vehicles will be notified by Honda and instructed to bring their cars into the nearest Acura dealership. Dealers will inspect the ECU for damage, replace if needed, and cover with a waterproof piece; all free of charge. Check out the official recall notice below.