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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.

Honda opening first new motherland plant in almost 50 years

Despite opening dozens of overseas plants in the past several decades in locations all over the globe, Honda Motor Co. has not expanded its car manufacturing capabilities in its home market of Japan since opening a facility in Sayama back in 1964.
But all of that is set to change this July when Honda opens the doors to a new assembly plant in Yorii, about two hours north of Tokyo. According to Bloomberg, the new facility has a projected annual capacity of 250,000 vehicles. The plant is part of the automaker's reorganization efforts, plans that include scaling back its older Sayama plant and bringing Yorii online with more efficient and innovative technology. There are additional benefits, too, as the Yorii plant is expected to create 3,800 jobs, both on-site and at its suppliers, and boost the local economy as other businesses ramp up to accommodate the influx of new workers.
While the automaker has not released specifics about which models will be produced at Yorii, Honda is expected to consolidate production of models including the Fit, a best-seller in its domestic market.

Honda recalling 100k more vehicles to replace airbag inflators

Additional recalls surrounding Takata's faulty airbag inflators seemed to be at an end, and the major issue was getting all of the affected models promptly repaired. However, Honda is voluntarily expanding its safety recall to include another 100,000-plus vehicles. The automaker is adding 88,549 examples of the 2008 Pilot, 10,868 units of the 2004 Civic and 5,454 vehicles of the 2001 Accord to replace the driver's side front inflator. According to documents submitted to the National Highway Traffic Safety Administration, Honda found these vehicles through its process of matching Takata part numbers to individual VINs to make sure every potentially affected vehicle was found. Both model years of the Accord and Civic are already included in the campaign, but the 2008 Pilot is new to the list. The company is clear in its announcement that there are no reports of inflator ruptures in the crossover, though. This expansion takes Honda's airbag-related recall total to roughly 5.5 million vehicles in the US. When these airbags rupture, they can spray metal fragments with enough force to injure or even kill people. The automaker also has an advertising campaign to get the word out to owners that having this problem repaired is vital to their safety. Statement by American Honda Regarding Expansion of National Safety Improvement Campaign: Driver's Front Airbag Inflator Supplied by Takata Mar 19, 2015 - TORRANCE, Calif. 2008 Pilot and certain 2001 Accord and 2004 Civic vehicles added under new NHTSA campaign number 15V-153 Honda will voluntarily expand its December 2014 national Safety Improvement Campaign (NHTSA No. 14V-351) affecting certain 2001 through 2011 Honda and Acura vehicles in the United States to include 88,549 Pilot vehicles from the 2008 model year, 10,868 specific 2004 Civic vehicles and 5,454 specific 2001 Accord vehicles. While certain 2001 Accord and 2004 Civic vehicles were previously included in 14V-351, no 2008 Pilot models were included before this addition. Honda has not received any claims of airbag inflator rupture in 2008 Pilot models. Since this expansion of the national Safety Improvement Campaign is taking place in a new year, it will be identified separately by the NHTSA as No. 15V-153, but the same repair, replacement of the driver front airbag inflator, free of charge, will apply to these additional vehicles nationwide. With this expansion, a total of approximately 5.5 million vehicles will be covered by 14V-351 and 15V-153 combined.