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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.

2.1 million vehicles recalled again over faulty airbags

Fiat Chrysler Automobiles, Honda and Toyota will recall 2.1 million vehicles to fix faulty airbag modules "after the manufacturers' original attempts to fix the defects proved ineffective in some vehicles." These vehicles had all previously been recalled, but the National Highway Traffic Safety Administration found that the airbags could still potentially malfunction. This recall will cover Acura MDX, Dodge Viper, Jeep Grand Cherokee, Honda Odyssey, Pontiac Vibe, Toyota Corolla, Toyota Matrix and Toyota Avalon models made in the early 2000s. NHTSA has reportedly received about 40 reports of airbag deployment in such vehicles, even though the vehicle had not been involved in a crash. Roughly one million of these same vehicles, all from Honda and Toyota, are also subject to recalls due to faulty Takata airbag modules, though this particular recall is for "an electronic component manufactured by TRW" that is separate from the actual airbags from Takata. According to NHTSA Administrator Mark Rosekind: "This is unfortunately a complicated issue for consumers, who may have to return to their dealer more than once. But this is an urgent safety issue, and all consumers with vehicles covered by the previous recalls should have that remedy installed. Even though it's a temporary solution until the new remedy is available, they and their families will be safer if they take the time to learn if their vehicle is covered and follow their manufacturers' instructions. A hassle is much better than a family tragedy." If you're the owner of an affected car, expect to hear more from the official automaker and government channels in short order. In the meantime, we'd suggest getting your car checked and fixed at your local dealer. The official statement and recall information can be found below. Previously Recalled Vehicle Remedies Not Working as Designed; NHTSA Announces Follow up Recall of 2.12 Million Cars and SUVs Saturday, January 31, 2015 Contact: Gordon Trowbridge, 202-366-9550, Public.Affairs@dot.gov WASHINGTON – U.S. Transportation Secretary Anthony Foxx announced today the recall of more than 2.12 million Acura, Dodge, Jeep, Honda, Pontiac, and Toyota vehicles for a defect that may cause airbags to deploy inadvertently. The recalls will provide vehicle owners with a new remedy after the manufacturers' original attempts to fix the defects proved ineffective in some vehicles.

April 2014: The ramping-up-for-summer edition

Americans appear to be gearing up for further increases in US gas prices, as green-car sales last month had their largest year-over-year gains of 2014. Domestic customers bought almost 56,000 hybrids, plug-ins and diesels in April, marking a 2.6 percent increase from April 2013. Plug-in sales were particularly strong, jumping 41 percent from a year earlier, as sales of the Chevrolet Volt extended-range plug-in and Nissan Leaf and Tesla Model S battery-electric vehicles all showed gains. April's big winner among the automakers was Honda, moving 1,442 units of its newer Accord Hybrid And April's big winner among the automakers was...Honda? Yes, Honda, which has long operated in the advanced-powertrain shadow of fellow Japanese automakers Toyota and Nissan, came up big by moving 1,442 units of its newer Accord Hybrid. And while sales of the Civic Hybrid, CR-Z and Insight all fell, the Accord Hybrid drove Honda to boost its green-car sales by 78 percent from a year earlier to 2,839 units. Per usual, Nissan and Tesla also showed year-over-year gains. Nissan boosted Leaf sales by 7.8 percent to 2,088 units. And while Tesla won't release its first-quarter results until May 7, the California-based automaker would've increased Model S sales by 34 percent to 2,300 just by maintaining its fourth-quarter 2013 sales pace. Volkswagen and low-volume advanced-powertrain vehicle makers like Audi, Porsche and Daimler AG's Smart division also fared well in April. VW increased its diesel and Jetta Hybrid sales by 25 percent to 9,583 units. Audi's diesel sales quadrupled to 2,088 units. Smart sold 203 units of its newer Smart ED battery-electric vehicle. Such gains more than offset sales declines from General Motors, Ford and Toyota, though Toyota's April was less painful than previous months. GM's big mild-hybrid sales declines more than offset the 19 percent increase in Chevy Volt sales to 1,548 units and the sales of 491 Chevrolet Cruze Diesel vehicles. All told, GM's green-car sales declined 25 percent to 3,103 units. Fusion Energi Plug-in Hybrid sales doubled and C-Max Energi PHEV sales jumped 28 percent. Ford's green-car sales were down 12 percent to 7,554 vehicles. While Fusion Energi Plug-in Hybrid sales doubled and C-Max Energi PHEV sales jumped 28 percent, Fusion Hybrid sales were little-changed while C-Max Hybrid sales tumbled 50 percent to 1,586 units.