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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, Audi sweep European tin-top championships

Despite his win at the Japanese Grand Prix this weekend, Sebastian Vettel still has another race or two to go before he can claim his fourth consecutive World Championship in Formula 1. Back in Europe, however, this weekend saw several championship titles decided in a variety of tin-top racing series.
In the British Touring Car Championship, Gordon Shedden won the final round at Brands Hatch this weekend, but that wasn't enough to defend his title. Instead, the ultimate glory went to Andrew Jordan, also driving a Honda Civic, coming in ninth place to take a seven-point victory over Shedden in the final standings. Little wonder then that Honda took the constructors' championship and the Honda Yuasa Racing team took the teams' title. Four-time BTCC champion and Fifth Gear co-host Jason Plato, now driving for MG, landed third in the standings.
While Honda dominated the British championship, it was Audi that reigned supreme in mainland Europe. In the Superstars International Series - Italy's touring-car championship - Gianni Morbidelli drove the Audi RS5 to his fifth title, finishing the season's final race in a calculated third place behind the BMW racecars of Giovanni Berton and Max Mugelli. It's the second consecutive win for the RS5 in the Superstars series (Johan Kristoffersson won the title last year), and the second this year following Mike Rockenfeller's title in the RS5 DTM.

Honda recalling 405K vehicles over airbag issue

Honda is in hot water due to an airbag glitch that is causing it to recall 405,400 vehicles. According to the campaign, the supplemental restraints might fire for no apparent reason. 342,000 of the affected vehicles are 2003 and 2004 Odyssey minivans, which gels with a National Highway Traffic Safety Administration investigation we reported on in June.
Joining the Odyssey in the recall is the Acura MDX, with 63,400 units covered from the 2003 model year. Unlike the van, though, the MDX's recall covers Japan and Australia, in addition to the US and Canada. Both vehicles are suffering from an airbag control unit that is prone to malfunction when exposed to electrical noise, a condition that can cause the airbags to deploy without warning. Although no crashes have been reported in such scenarios, there have been some injuries typical of airbag deployment - abrasions and such.
Honda will be mailing recall notices to owners near the end of October, asking them to bring their vehicles into the dealership for installation of an electrical noise filter. The repair will take about an hour and be free of charge. Scroll down for the official announcement from Honda.