The assembly line is one of those key inventions without which the modern automotive industry simply would not exist in its current form. Ford was responsible for introducing the conveyor belt-type assembly line we’re all familiar with today. Over a century later, it is replacing it with something different.
This new approach to vehicle production takes some elements of the traditional assembly line and adapts them to the world of electric vehicles. The first Ford model built using this process will be with us next year; let’s find out more about the unique way it’s being brought into the world.
The Universal EV Production System: Ford’s New Approach To Vehicle Assembly
Ford Universal EV Production SystemFord
The EV revolution is not just affecting the type of cars we drive; it’s also affecting the way these vehicles are put together in the factory. Ford may have been the earliest brand in history to use the “conveyor belt” assembly line we’re used to seeing, but today it is completely changing that model by adopting what it calls the Ford Universal EV Production System.
The problem with traditional assembly lines isn’t just speed — it’s that they were designed around combustion engines. Ford’s new system starts from a blank page, and the result looks nothing like what you’d expect. Rather than a traditional assembly line, the Universal EV Production System uses an “assembly tree”. The single, long line is split into sub-assemblies, where components are installed simultaneously. The three branches of the tree are then joined together towards the end to create the finished vehicle.
Components travel down the assembly tree as part of a kit, which also contains all fasteners, scanners, and power tools the workers need to complete the relevant assembly step. The tools are already organized in the orientation they’re going to be used: this maximizes speed and efficiency at every step, as well as dramatically improving the ergonomic aspect, since workers do not need to bend or reach to use the necessary tools.
Ford Universal EV platformFord
Smaller components are replaced by large single-piece aluminum unicastings, meaning the front and rear sections of the vehicle are assembled separately in the first two lines. The third line, on the other hand, takes care of the structural battery as well as seats, consoles, and carpeting.
The Universal EV Production System is closely connected to Ford’s brand-new Universal EV Platform: the innovative assembly system is set to be used for vehicles built on this platform, including an as-yet-nameless upcoming electric pickup truck. Ford is expecting the assembly process for this truck to be around 15% faster than that of other vehicles currently produced at the Louisville Assembly Plant, where the new system is going to be pioneered.
To understand why this change is so radical, you have to go back to where it all started — and to a popular piece of automotive history that turns out to be only half true.
“We put our employees at the center and re-created the factory from scratch […] We live and breathe continuous improvement, but sometimes you need a dramatic leap forward. We expect ergonomic breakthroughs and complexity reduction – through elimination of parts, connectors and wire – will flow through to significant quality and cost wins.” – Bryce Currie, Ford vice president, Americas Manufacturing
History and Myths: Ford’s Role In The Birth Of The Automotive Assembly Line
1903 Oldsmobile Model R Curved Dash Front Angled ViewRM Sotheby’s
Ford’s latest innovation in the world of vehicle assembly echoes another important achievement in the company’s history, one that goes back to the very start of its journey. However, not all is quite as it seems. Most people, aside from a few dedicated lovers of pre-war cars and early automotive history, are under the impression that Ford was responsible for the invention of the car assembly line at the start of the 20th century.
Ford was, in fact, the first brand to use the modern moving assembly line, with a conveyor belt carrying the partially assembled car while workers remained at their individual stations. An earlier form of assembly line had been pioneered by Oldsmobile a few years earlier. This assembly line was static: each car remained in one place, with workers moving between them to add and assemble components. The first model in history to have been put together on an assembly line was the Oldsmobile Model R, also known as the “Curved Dash”.
Super Duty pickup trucks on the factory line.Ford
Due to Ford’s introduction of the moving assembly line, Oldsmobile’s system quickly fell out of fashion, and automakers soon adopted Ford’s model, which became the default for automotive assembly. Today, Ford has the chance to set another trend, revolutionizing the world of car manufacturing once more.
If Ford’s bet on the Universal EV Platform pays off the same way the moving assembly line did, it could reshape manufacturing for decades — and deliver a $30,000 electric truck in the process. Here’s what that platform actually is.
The Core Of Ford’s New EVs: The Ford Universal EV Platform
Ford Universal EV platformFord
The creation of the new Universal EV Production System happened in tandem with the development of the Universal EV Platform. Like the new assembly system, the platform is all about efficiency and reducing waste: the numbers speak for themselves. Vehicles built on this platform have 20% fewer parts, 25% fewer fasteners, 40% fewer workstations in the plant, and the assembly time is 15% faster.
The new platform does not just improve things from the automaker’s point of view, but also from that of the customer: according to Ford, vehicles built on this platform will have lower ownership costs over five years than a three-year-old used Tesla Model Y.
If all of these features sound interesting to you, you’ll be glad to know that the first model built on the Universal EV Platform will be with us fairly soon. Ford has recently announced that an affordable, all-electric midsize pickup truck will be released next year. Although details about this model are still scarce, we do know Ford’s push for innovation has had a tangible impact: the wiring harness on the new truck will be over 4,000 feet shorter and 22 lbs lighter than the one used in the Mustang Mach-E, Ford’s first electric SUV.
Ford Universal EV platformFord
The platform also makes use of lithium iron phosphate (LFP) prismatic batteries, which contain no cobalt or nickel; this type of battery saves a considerable amount of space and weight, while also increasing durability and reducing costs for vehicle owners. The battery pack also serves as the vehicle’s floor, a layout which has multiple beneficial effects such as maximizing interior space and reducing cabin noise.
The resulting low center of gravity also means the vehicle’s handling is improved. Although EVs are associated with efficiency and eco-friendliness, driver engagement and performance are also an important part of the equation for Ford, which is making the most of electric powertrains’ advantages to create an enjoyable driving experience.
An Affordable EV Pickup: Ford’s As-Yet-Unnamed Creation
Ford Universal Vehicle EV Pickup Testing In The Snow CloseupFord
Ford’s new pickup truck will be the very first vehicle produced by the Blue Oval to use the Universal EV Platform, but it does not yet have a name. We do, however, know it will be a midsize truck with a highly affordable price tag, around $30,000. The combination of affordability and innovation calls back to the very start of Ford’s history, in the words of Ford’s Doug Field:
“We took inspiration from the Model T – the universal car that changed the world […] We assembled a really brilliant collection of minds across Ford and unleashed them to find new solutions to old problems. We applied first‑principles engineering, pushing to the limits of physics to make it fun to drive and compete on affordability. Our new zonal electric architecture unlocks capabilities the industry has never seen. This isn’t a stripped‑down, old‑school vehicle.” – Doug Field, Ford chief EV, digital and design officer
The few pieces of information available so far regarding the truck are highly promising. In terms of performance, the new model is targeting a 0-60 mph time on par with that of the EcoBoost Mustang, but will generate more downforce. The model also performs well in terms of passenger- and cargo-carrying capabilities: it will have more passenger room than the latest Toyota RAV4, and its bed will allow drivers to secure bulky sports gear such as surfboards, with no need for a roof rack or a trailer hitch rack.
Ford Universal Vehicle EV Pickup Testing In The Snow tireFord
Ford’s approach to testing its new model is another area where the company has decided to do things differently. Rather than keeping things as closely under wraps as possible, with a few grainy spy shots being the only evidence of the truck’s existence, the brand decided to incorporate a QR code into the vehicle’s camouflage.
For those who have caught sight of one of the trucks on the road, scanning it leads to a page titled “Congrats, You Spotted A Unicorn”. This page contains a few videos that offer a glimpse of the truck and its assembly process, providing a fascinating insight into how Ford is revolutionizing EV manufacturing and vehicle manufacturing as a whole.
Sources: Ford
