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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 could halve its US lineup without crimping its sales much [w/video]

Taking a detailed look at the Honda lineup in the US, it isn't hard to see the strength of some models and the weaknesses of others. A recent report on Autoline Daily points out that its five core models - the Accord, Civic, CR-V, Odyssey and Pilot - make up a full 93 percent of Honda's sales in the US. Through April, Honda has sold 419,798 vehicles, and 389,474 of them were from these core models; not to mention the fact that the Accord was the top-selling car in the US last month.
This means that Honda could technically cut six of its 11 models and only lose about 5,000 sales per month. Of course, this is just some data crunching and there is no reason to believe that Honda is planning to kill off any of its models in the near future. In fact, it seems to be committed to the Ridgeline, while Japanese-made models that may actually lose money for Honda still fill unique voids. Scroll down for the video report - fast-forward to the 1:43 mark for the Honda info.

Honda Fit, Vezel Hybrids recalled in Japan; US vehicles not affected

Honda has announced a good-sized recall of two popular Japanese-market hybrids: the Fit Hybrid and the Vezel Hybrid are both headed back into the garage. The problem this time around lies in the software program that controls the 7-speed dual clutch transmission (DCT) that could "cause a delay in the ability to begin driving or the inability to move at all." In total, 81,353 units are affected (70,929 Fit Hybrids and 10,424 Vezel Hybrids) and all were made in Japan between July 2013 and February 2014. There were two previous recalls for the new Fit Hybrid's DCT, and you can find the details of them below. Jessica Fini, assistant manager of PR for Honda North America, told AutoblogGreen that this recall will not have any impact on US Honda vehicles. For one thing, the US Fit has a continuously variable transmission (CVT) instead of a DCT, so the upcoming launch of the new Fit here (the US doesn't get the Fit Hybrid) will not be delayed. Honda's upcoming small SUV in the US (based on the Vezel, but will arrive with a different name) isn't going to launch here until the end of the year, so there is time to fix any problems before launch. She also said that the Acura RLX, despite being a DCT, does not use the same transmission as the Fit Hybrid does, since the Fit transmission is specific to the one-motor hybrid system and the RLX uses three electric motors. Recall of All-New Fit Hybrid and Vezel Hybrid ref. # C14-009 TOKYO -- February 10, 2014 – Honda Motor Co., Ltd. today announced a voluntary recall of the all-new Fit Hybrid and Vezel Hybrid produced in Japan from July 2013 through February 2014 due to a problem with the software program controlling the 7-speed dual clutch transmission (DCT) which could cause a delay in the ability to begin driving or the inability to move at all. Honda today notified the Ministry of Land, Infrastructure, Transport and Tourism of the recall with a total recall population of 81,353 units. Honda conducted two recalls in October and December 2013 due to a defect with the software program controlling the 7-speed DCT which could have caused a delay in the ability to drive the vehicle or the inability to drive. This will be the third recall related to the defect of the 7-speed DCT.