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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.

Recharge Wrap-up: Honda Legend Sport Hybrid launching in Japan; driving cross-country on chicken fat

Honda will begin sales in Japan of the Legend Sport Hybrid SH-AWD in January. The Legend is Japan's answer to the Acura RLX Sport Hybrid sold in the US. Up front, the new flagship sedan uses a 3.5-liter V6 with cylinder deactivation and a seven-speed, dual-clutch transmission with integrated electric motor. In the rear, a dual electric motor unit supplies power to the wheels. The three electric motors are also used for generating electricity during deceleration. The car has three drive modes, including EV Drive, Hybrid Drive and Engine Drive. The result is a fuel economy rating of 40 mpg, according to the JC08 cycle. Read more at Green Car Congress or in Honda's press release below. While Jay Leno explains how marketing early electric cars toward women caused them to lose out to internal combustion, the same can't be said about the current era of EVs. Leno says that early EVs, like Leno's beloved Baker, appealed to women because they were quiet, clean, and didn't require cranking to start them. This led to accessorization marketed toward women, causing men - who had more buying power than women at the time - to shy away from EVs. This time around, though, EVs target a broader audience in a different culture from the early 20th century. See Leno explain the early EV culture while driving his Baker Electric in the video below and read more at Hybrid Cars. GKN's two-speed eAxle allows EVs to make the most of both acceleration and top speed. Single-speed transmissions must sacrifice top speed for acceleration, or vice versa. In addition to improving performance at all speeds and increasing range, the GKN's eAxle also performs well in terms of NVH, providing seamless shifts and low gear noise. In order to package the eAxle in the BMW i8, the unit is just 12.8 inches by 22.1 inches by 12.3 inches and weighs 60 pounds. Read more at Green Car Congress. An alternative fuels researcher at Middle Tennessee State University will drive a truck powered by chicken fat biodiesel across the country. Professor Cliff Ricketts is driving a converted 1981 Volkswagen Rabbit pickup from Key West, FL to Seattle, WA to demonstrate the viability of chicken fat as a fuel. Ricketts admits, though, that the truck's exhaust stack is loud and smells like French fries. Read more at Domestic Fuel. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings.

Vehicles awarded IIHS Top Safety Pick awards skyrockets for 2015 [w/video]

By practically every measure, passenger vehicles in the US are continuing to get safer. With the year rapidly coming to an end, the Insurance Institute for Highway Safety is releasing its annual list tallying of the scores for the latest vehicles to see how they compare to last year. Judging by the agency's evaluations, the numbers look quite positive. According to the institute, 71 vehicles earned either the Top Safety Pick or Top Safety Pick+ rating so far in its testing for 2015. Among the latest winners, there have been 33 TSP+ awards and 38 TSP medalists. That's a healthy increase over the 22 TSP+ and 17 TSP grades in 2014. The figures appear even more impressive when you consider that it keeps getting harder to earn the + designation. In the latest round of testing, a vehicle must offer some form of front crash prevention automatic braking to get the mark. Previously, just a warning to drivers was necessary. This list also illustrates the ways that automakers adapt to new testing procedures. In 2013 there were 117 TSP ratings and 13 TSP+ awards. Then, the IIHS mandated that to be a safety pick, a model had to score Good in the institute's four crash tests, plus a Good or Acceptable in the small overlap front test. That brought a plunge in 2014 to just 17 TSP grades. With the numbers climbing again, companies apparently have deciphered how to perform better. Some brands especially stood out on this year's list. The IIHS praised Volvo, Mercedes-Benz and Acura for offering standard front crash prevention systems on some models. Subaru received at least one of the awards for all seven of its models. Toyota also had seven, and the Honda brand did too – though the institute counts the two- and four-door versions of the Civic and Accord separately. Check out the full announcement below and a video about this year's winners. The full list can be viewed, here. Safety gains ground: More vehicles earn top honors from IIHS The number of vehicles earning either of the Institute's two awards has jumped to 71 from 39 this time last year, giving consumers more choices for optimum protection in crashes. The number of winners in the top tier - TOP SAFETY PICK+ - has increased by 11 for 2015, despite a tougher standard for front crash prevention. "This is the third year in a row that we are giving automakers a tougher challenge to meet," says IIHS President Adrian Lund.