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577 Posts
If that really is how its going to look, I'm a little disappointed in Ford. Its no where near as good looking as other current Fords (fiesta, mondeo and current focus). Thought it may have more in common with the current Fiesta and Mondeo (Iosis concept), the front bumper, headlamps and taillights are way off.

1,901 Posts
I'm not completely sold yet, but I reckon after it's received the usual styling etc when the ST/RS variant comes out I'm sure it'll look pretty impressive.

It'll just be lacking the beloved 5-pot growl
Will take some doing to top that

1,209 Posts
I like it as a family car, looks a lot like the new Kuga which I also like.

I like the interior, reminds me of our Civic which is more space age compared to the current Focus.

Doubt I would buy one as a fun car though unless they do an ST/RS version in 3 door which apparently won't be happening.

14,669 Posts
Press release:


DETROIT, Jan. 11, 2010 - The next-generation Ford Focus makes its worldwide debut providing customers with more affordable technologies and features than ever in this segment, as well as detailed craftsmanship, outstanding fuel economy and a new standard for driving quality.

Sleek, stylish and sporty, both the four-door sedan and five-door hatchback body styles of the next-generation Focus are previewed prior to their production start for Europe and North America late in 2010 and market launch early in 2011.

The new Focus will be nearly identical in all markets, with 80 percent parts commonality around the world.
"The new Ford Focus is a clear demonstration that our ONE Ford strategy is providing global consumers with great products that harness the best of Ford Motor Company," said Alan Mulally, Ford's president and CEO.

"The efficiencies generated by our new global C-car platform will enable us to provide Ford Focus customers with an affordable product offering quality, fuel efficiency, safety and technology beyond their expectations," he added.

Simultaneous launch in Europe and North America
Production of the next-generation Ford Focus will begin simultaneously in Europe and North America in late 2010, with individual market launches starting early in 2011. Launches in Asia, Africa and South America will follow. Initial production will be concentrated at the Saarlouis (Germany), Michigan (United States) and Chongqing (China) Assembly Plants.

The new Focus will be one of up to 10 unique models to be built from Ford's new C-car platform, which is expected to generate total sales in all regions of 2 million units annually by 2012. The first of these will be the new Ford C-MAX and Ford Grand C-MAX - unveiled at the 2009 Frankfurt Motor Show - for launch in Europe in the second half of 2010.

"Global customers increasingly want smaller cars with outstanding fuel economy, but without sacrificing any of the style, technology, connectivity and driving quality they demand from larger vehicles," explained Derrick Kuzak, Ford's group vice president of Global Product Development.

"Our next generation of C-cars - led by the exciting new Focus - will clearly show that Ford is ready to meet that challenge," said Kuzak.

Engineered without compromise
The new Ford Focus has been developed by a global team, led from Ford's European small and medium vehicle center of excellence in Merkenich, near Cologne, Germany, with powertrain development led by a similar team at Ford's technical center in Dunton, England. The vehicle has been engineered without compromise to meet all customer and legislative requirements of the major worldwide markets.

In developing the vehicle for global markets, the product team in Europe was able to call on the experience acquired from recent programs like the much-acclaimed new Ford Fiesta, and was supported by the expertise of vehicle and powertrain technology specialists located in Ford's engineering center in Dearborn, Mich.

Ford's global development and sourcing strategy made it possible to provide a level of performance and feature content that is unrivaled for this vehicle segment and surprising even to drivers of larger, more premium vehicles.

Taking kinetic design to the next level
The no-compromise approach to the new Ford Focus is immediately evident from the striking exterior design of the four-door sedan and five-door hatchback models that take center stage at the 2010 NAIAS.

"The all-new Focus is at the center of convergence for automotive trends," said J Mays, Ford group vice president of Design and chief creative officer. "We've designed it with an acute understanding of global customers, yet it's tailored for each individual region. Focus combines the best from Europe, North America and Asia to deliver a level of emotional driving enjoyment never before experienced in a car this size."

The two models share a sporty and dynamic character, marking the next evolution of Ford's acclaimed kinetic design form language, which has contributed to the growing popularity of the company's latest small and medium cars.

The kinetic design approach uses bold vehicle designs to capture the feeling of energy in motion, so that cars look like they are moving - even when they are standing still.

With its striking front end, sleek profile, dramatic rising beltline and athletic stance, the new Focus clearly telegraphs the rewarding driving experience that awaits customers when they take to the road.

This dynamic quality is reinforced by the distinctive design of the interior. The new Focus has an extremely modern, ****pit-style interior, with the stylish center console wrapped around the driver and providing outstanding access to the vehicle's major controls and display panels.

A key element of the interior is the quality of craftsmanship. The cabin's bold and contemporary graphics, the sculptured shape of the soft-touch instrument panel and the choice of superior trim materials all help to give occupants the feeling that they are traveling in a premium-class car.

Unmatched driving quality
When it was introduced in 1998, the original Ford Focus brought new levels of agility and responsiveness to the C-segment. The all-new Focus plans to raise the benchmark once more, targeting class-leading driving quality that blends outstanding steering precision and road feedback with significantly improved refinement and ride control.

To deliver this performance, engineers have updated the innovative suspension concepts from prior models, developing optimized new designs for the "control blade" multilink rear suspension and the semi-isolated front and rear subframes.

The chassis design is complemented by a completely new Electric Power Assist Steering system, which has been carefully tuned to deliver pure and precise responses at high speed while remaining light and maneuverable for parking.

Ford's European driving dynamics specialists have also enhanced cornering stability and agility with the introduction of an advanced Dynamic Cornering Control system, which uses "torque vectoring" techniques to transfer power between the drive wheels to deliver reduced understeer, improved traction and better turn-in.

All global customers will benefit from the same quality of dynamic performance in the new Focus. Identical chassis and suspension architecture is being used for all markets, except for minor regional tuning differences, such as local tire specifications.

Efficient powertrains deliver performance with outstanding economy
The engaging driver appeal of the new Ford Focus is magnified by a powertrain range that delivers spirited performance and targets outstanding levels of fuel economy and CO2 emissions.

The global powertrain lineup for the new Focus will include a range of state-of-the-art Ford EcoBoost™ four-cylinder turbocharged direct injection (DI) engines - including the 1.6-liter unit in Europe and a choice of advanced and improved Duratorq TDCi common-rail diesel engines, all of which offer reductions in fuel consumption of between 10 and 20 percent compared to the outgoing models.

For the NAIAS preview, Ford is showing a completely new 2.0-liter gasoline engine for the North American market that features DI and Twin Independent Variable Camshaft Timing (Ti-VCT) for enhanced performance and fuel efficiency. The new 2.0-liter DI Ti-VCT engine is up to 20 horsepower more powerful than the current 2.0 Duratec I-4 unit while contributing to projected fuel economy gains of more than 10 percent.

To maximize the performance and economy advantage enjoyed by the new Focus, the 2.0-liter DI Ti-VCT engine is mated with the latest dry-clutch six-speed Ford PowerShift automatic transmission. This transmission uses an advanced dual-clutch design, which alone can help to reduce fuel consumption by up to 9 percent compared to a traditional four-speed automatic.

The dry-clutch PowerShift transmission is based on more efficient manual gearbox technology, and does not require the additional weight and complexity of torque converters, planetary gears and oil pumps used in conventional automatics. Electronically controlled twin clutches shift gears quickly and smoothly, providing the seamless flow of torque plus the refinement and ease of operation customers expect from a premium automatic transmission.

Ford also has confirmed plans to begin building a full, battery electric vehicle in 2011 at its Michigan Assembly Complex, for sales in North America. It will be the company's first battery electric passenger vehicle.

Intuitive technology enhances convenience and safety
The next-generation Focus will bring C-segment customers around the world an exciting array of advanced technologies generally found in larger, more premium vehicles. The global scale of Ford's C-car program makes more technologies and features economically viable than ever before for cars in this segment.

The technology package of the new Focus promises not only clear leadership in the C-segment, but also includes features customers in larger, more premium segments would find surprising.

The new technologies have been designed to be simple and highly intuitive to use, while enhancing both convenience and safety for the vehicle occupants.

Within the ****pit, the most significant innovation is the company's next-generation driver connect technology, MyFord, which provides the driver with a state-of-the-art combination of controls and display screens to operate the key vehicle features. On high series vehicles, the MyFord system includes an 8-inch touch screen, allowing the driver to control a wide range of functions via a clear and intuitive color display.

MyFord is complemented by a new generation of Ford's powerful SYNC® connectivity package, which includes a sophisticated voice control system, Bluetooth and satellite navigation, along with connection points for a wide variety of external devices and media players.

Other available safety and convenience technologies include keyless entry and "Ford Power" start button, a rearview camera and a semi-automatic parallel parking system that automatically steers the vehicle into a parking spot.

Strength and safety
The Focus platform provides an incredibly strong and stiff structure, which not only benefits vehicle dynamics and refinement but also provides the basis for enhanced crash performance.

High-strength steels are used extensively in the next-generation Focus body shell. High-strength steels comprise 55 percent of the body shell, and more than 26 percent of the vehicle's structure is formed from ultra-high-strength and Boron steels - significantly more than any other Ford product. These advanced materials help the structure meet the most stringent crash legislation across world markets, while minimizing the vehicle's weight.

The structural integrity of the body shell is also reflected in its torsional rigidity, which is 25 percent greater than the current North American Focus.

Quality and craftsmanship in every detail
With global customers now demanding a more premium experience from small- and medium-sized vehicles, achieving outstanding levels of quality and craftsmanship was a primary objective for the new Focus.

The new Focus will make significant strides in reducing cabin noise, promising a quiet cabin environment. This refinement complements the fresh new interior design and higher craftsmanship levels to create a premium feel akin to larger vehicles.

Each component in the vehicle that the customer will touch, see, hear or even smell has been subjected to rigorous analysis to ensure that it will exceed an owner's expectations. Particular attention has been given to the quality of interior trim materials, and the color matching, gaps, flushness and tolerances where one part meets another.

Across the majority of vehicle attributes, Ford has developed a global DNA standard that defines the exact attributes a part should have to meet the quality requirements of the brand. Examples include the sound the door makes when it is closed, requiring special attention to the door structure and latch mechanism, and the design of a steering wheel, right down to the thickness of padding and size of stitching on the rim.

This meticulous attention to detail is also reflected in Ford's global manufacturing strategy for the Focus, with consistent standards and processes being applied in every one of the assembly plants, wherever they are located in the world.

"We believe the new Ford Focus will provide consumers with an unmatched driving experience, together with an unrivaled ownership experience," said Jim Farley, Ford group vice president, Global Marketing. "The Focus brand always has been very special to Ford, and this new global model shows our commitment to developing another generation of exciting and appealing cars."

14,669 Posts


DETROIT, Jan. 11, 2010 - The next-generation Ford Focus debuting today at the 2010 North American International Auto Show is more than Ford's first truly global product created under its ONE Ford approach - it also marks the first worldwide application of a new global brand DNA that will help Ford cars establish a unique visual and driving appeal that is consistently recognizable around the world.

Like the genetic code that defines human beings and makes each person unique, Ford's global DNA is comprised of specific product attributes that sit at the heart of all new products, defining the character and performance of every vehicle, while providing customers with an unmistakable style and driving experience.

"Our global DNA will ensure that future Fords have the same dynamic and engaging personality - a character that will hit the driver within moments of getting behind the wheel," said Derrick Kuzak, Ford's group vice president of Global Product Development.
"The new Focus is the perfect expression of this DNA. Consistently applied throughout the world, this will provide customers with a car that is striking to look at, great to sit in and great to drive," he added.

Unique Ford character
Establishing a clear and consistent brand DNA was an important step in ensuring the success of Ford's global product strategy, providing customers worldwide a selection of vehicles that are not only desirable to own, but that also have a unique Ford character in the way they look, feel and sound.

The global DNA encompasses all the attributes that have a direct impact on a customer's experience in the vehicle - from the way it drives to the comfort and quality of the interior and the layout and function of its controls.

Each of these attributes - such as the response to the accelerator pedal or the sound a door makes when it's closed - is carefully defined using precise technical descriptions, so that engineers can ensure each new product delivers that unmistakable Ford feel, wherever it may be sold.

Natural evolution from latest Ford products
Ford's global DNA marks a natural evolution from the character of the latest European and North American products, bringing them together and capturing the same dynamic and engaging qualities found in recent vehicles like the Fiesta and Taurus.

Global teams of product specialists worked together to develop the specific requirements for each product attribute, ensuring that the chosen solution delivered the desired character in the optimum way, while fully satisfying the needs of customers in all regions worldwide.

In many cases, special clinics were held with a range of global customers to gain direct feedback on the proposed solutions before they were finalized.

Common design language reinforces DNA character
The Ford DNA also extends to the exterior and interior design, which plays a critical role in establishing a vehicle's personality. For the next generation of global products, the vehicles will share a common design language that will reinforce the character established by the other elements of the DNA.

At the heart of the design DNA is the latest evolution of the Ford kinetic design form language that has been developed by the team at the company's Merkenich design center near Cologne in Germany, under the leadership of Martin Smith, executive design director.

Ford kinetic design is an expressive styling language that gives a visual representation of energy in motion, giving customers a clear message about the dynamic driving experience provided by the vehicle.

As exciting new products like the new Ford Fiesta and all-new Focus demonstrate, kinetic design themes can be applied inside the cabin as well as to the exterior, so that the core values of the marque are consistently reflected throughout the vehicle.

Consistent DNA character offers significant benefits
This consistency and clarity of character is one of the most significant benefits for vehicles - like the new Ford Focus - engineered to embody precisely prescribed attributes of the new brand DNA.

In defining the final DNA, each product attribute - there are eight precisely defined gene sets for driving dynamics alone - has been developed with exactly the same vision in mind. This ensures that every aspect of the vehicle works harmoniously together, providing the customer with a well-balanced product that delivers outstanding performance with a unique Ford character.

"When customers see and get to drive the new Focus for the first time, they will immediately appreciate the unique Ford personality that is captured in our DNA," said Kuzak. "By applying that same DNA in all our future products, we can be confident that those exceptional qualities will be enjoyed by consumers in all the markets we serve worldwide."

14,669 Posts
and more:


DETROIT, Jan. 11, 2010 - The reveal of the next-generation Ford Focus at the 2010 North American International Auto Show includes the first in a series of powertrain technology developments coming from Ford that give its new global C-segment leader a combination of power, exhilarating performance and unsurpassed fuel economy.

Ford has disclosed that North American models of the new Focus will be equipped with a responsive, fuel-efficient combination of a 2.0-liter I-4 engine with Twin Independent Variable Camshaft Timing (Ti-VCT) and direct injection (DI) plus a dual-clutch PowerShift transmission.

"Combining a direct-injected engine and the dual-clutch PowerShift transmission will help Focus redefine fuel economy and flexibility in the C-car segment," said Barb Samardzich, vice president for Ford's global powertrain development. "The refinement and sheer fun-to-drive nature of the new Focus will surprise a lot of drivers."
The new engine is designed to deliver an estimated 155 horsepower and 145 ft.-lb. of torque to give customers ample performance and a refined driving experience.

The 2.0-liter Ti-VCT I-4 also serves as another example of Ford delivering fuel economy leadership by using advanced technologies to produce surprising power from minimal displacement. The engine can deliver outstanding fuel economy and emissions along with the throttle response, performance and flexibility expected from a world-class engine.

"Using direct injection and Ti-VCT, and coupling that to a dual-clutch transmission, we've been able to make a quantum leap in fuel economy and performance," said Derrick Kuzak, group vice president, Global Product Development. "We're meeting the goals of our global powertrain strategy, and we now have another key powertrain for use around the world."

Core engine technologies
As a DOHC design, the 2.0-liter I-4 uses two camshafts: one to open the intake valves and one to open the exhaust valves. Traditionally, camshafts have only been able to open the valves at a fixed point, defined during engine design and manufacture. But with modern variable cam timing systems, the camshafts can be rotated slightly relative to their initial position, allowing the cam timing to be advanced or retarded.

Ti-VCT takes this technology and applies it to both the intake and exhaust camshafts of its DOHC design, using electronic solenoid valves to direct high-pressure oil to control vanes in each of the camshaft sprocket housings. By using one oil control solenoid per camshaft, controlled by the Electronic Control Module, each intake and exhaust cam can be advanced or retarded independently of the other as engine operating conditions change, providing an exceptional degree of valve timing control.

"The overlap control via Ti-VCT helps us eliminate compromises in the induction and exhaust systems," said Jamie Hanshaw, Ford VCT technical specialist. "Drivers will notice improved low-end power and better fuel economy. And there are benefits they won't notice too, like reduced emissions overall, especially at part-throttle."
Fuel metering duties on the 2.0-liter I-4 are handled by a DI system that precisely delivers a fine mist of fuel directly into each cylinder for optimal performance, economy and emissions. Unlike port fuel injection (PFI) engines that spray fuel into the intake system, the direct injection system puts the fuel in the combustion chamber, exactly where it needs to be for combustion. Thanks to DI, the engine can safely operate at a high 12:1 compression ratio (compared with the current engine's 10:1 ratio), further enhancing power and efficiency. And unlike most competitive direct injection systems, the engine will be E85 flex fuel-capable.

The high-pressure fuel injectors are positioned to the side of each cylinder, aiming the fuel directly into the cylinder adjacent to a high-intensity spark plug and alongside the intake and exhaust valves. Fuel is sprayed into the cylinders at pressures of up to 2,150 pounds per square inch, which is about 35 times more intense than PFI injection.

"The DI system creates an incredibly fine spray of gasoline that's injected directly into the combustion chamber at the precise moment it's needed, eliminating a lot of the compromises on traditional fuel systems," explains Scott Makowski, I-4 engine manager. "It sounds simple, but months of testing and computer simulation went into finding the exact injector spray pattern, where in the cylinder to aim the spray, and even the piston dome design."

The Denso high-pressure fuel injectors use internal solenoids to precisely switch the flow of fuel on and off. Fuel flows through six tiny outlets - like pinholes - in each injector, and each spray is positioned to provide benefits in fuel economy and emissions. A sophisticated electronic control system varies the timing and intensity of the fuel delivery according to engine operating conditions.

Attention to detail yields fuel economy improvements
Complementing the efficiencies introduced by Ti-VCT and DI, every aspect of the proven 2.0-liter I-4 was examined to identify ways fuel economy could be improved. Key strategies focused on reducing internal engine friction and reducing overall weight.

Computer modeling indicated areas where friction reduction strategies would pay the most dividends. The valvetrain received a fine surface treatment to present the smoothest surface possible. Piston skirts are treated with a special low-friction coating, and the oil pump and its drive ratio are sized for the exact capacity requirements of the new 2.0-liter engine.

Accessory drive friction was also reduced through a series of actions. Electric Power Assist Steering eliminates the drag of an engine-driven power steering pump, while the use of so-called stretchy belt technology removes friction in the form of a belt tensioner on the air-conditioning compressor drive system.

Additionally, an overriding alternator decoupler - essentially a special pulley that reduces certain types of vibrations - allows the alternator and water pump drive belt to operate at a much lower tension than is typically used, further reducing frictional losses.

To keep overall powertrain weight as low as possible, the block, cylinder head and oil pan - traditionally the heaviest engine components - are aluminum castings. To increase rigidity, these elements are ribbed for additional strength and durability. Pistons are cast aluminum as well, with the light weight helping to reduce reciprocating mass.

Composite material is employed to keep intake manifold weight to an absolute minimum, while allowing for induction routing to increase thermal efficiency and improve low-end torque characteristics.

PowerShift: A different kind of automatic
An all-new PowerShift six-speed automatic transmission that combines the responsive performance and fuel economy of a manual gearbox with the convenience of a traditional automatic transmission promises to be another key Focus powertrain technology.

"PowerShift is a transmission that changes the game," said Samardzich. "Our fuel economy leader is now a PowerShift automatic. Previously, a C-segment driver needed a manual transmission and a clutch pedal to enjoy the greatest fuel efficiency."
Twin internal clutches keep the PowerShift in constant mesh, continuously optimizing for maximum responsiveness and fuel efficiency, depending on engine speed, vehicle speed and input from the driver's foot on the accelerator pedal. The new technology provides significant fuel economy improvement, and for the driver, it retains the operational ease of an automatic with noticeably quicker and smoother shift quality.

PowerShift is a dual dry clutch transmission, operating with sealed internal lubrication, reducing friction and contributing to Focus fuel economy improvements. The lack of pumps and hoses reduces complexity, saves weight and contributes to fuel efficiency.

An additional feature is Hill Start Assist functionality. This sensor-based system will "hold" the brakes for an instant (2.5 seconds) to prevent rollback when stopping or starting from rest on an incline. Employing a digital accelerometer to measure slope incline, the system activates automatically when the incline exceeds 3 percent.

Simpler, more responsive and more fuel-efficient than a conventional automatic transaxle, PowerShift represents an innovative small car breakthrough.

Continuing refinement on the global stage
Using the 2.0-liter Ti-VCT engine and PowerShift dual-clutch transmission in the North American market, combined with state-of-the-art common-rail diesels for global customers, Focus is poised to claim a leadership role in fuel economy from the moment it's launched. This powertrain will not be marketed in Europe.

The global powertrain lineup for the new Focus also will include a range of state-of-the-art Ford EcoBoost™ four-cylinder turbocharged direct injection engines - including the 1.6-liter unit in Europe and a choice of advanced and improved Duratorq TDCi common-rail diesel engines, all of which offer reductions in fuel consumption of between 10 and 20 percent compared to the outgoing models.

"When the new Focus launches in late 2010, it will be among the global leaders in fuel economy and CO2 emissions," said Kuzak. "We will continue to pioneer new technologies beyond launch, including a true zero-emission model launching in North America in 2011. Throughout its life cycle, Focus in all forms, in all regions, will demonstrate the Ford commitment to deliver unsurpassed fuel economy on a truly global scale."

1,287 Posts
Ok so that explains the styling then. We have to put up with this due to the yanks lack of taste. seriously i went to new york for Christmas and there cars are pretty bad looking
I think ford have dropped the ball with this one IMO, But as before i will not give my final opinion until i see the ST version.

Oh and those alloys are from an SRI astra!

14,669 Posts
last one.................


DETROIT, Jan. 11, 2010 - Taking advantage of huge advancements in virtual manufacturing technology, teams of engineers, manufacturing specialists and assembly plant workers around the world gathered in front of large projection screens in North America, Europe and Asia to build the first next-generation Ford Focus virtually piece by piece, operation by operation, down to its high-quality, high-tech paint finish more than a year before its market debut.

The event was a major milestone on the way to kicking off a truly global manufacturing operation to produce up to 10 different C-sized models from one highly flexible platform. The new Focus is the first of a portfolio of global products promised by Ford through the ONE Ford strategy championed by Ford Motor Company President and CEO Alan Mulally.
Building the first new Focus on the computer was an important step toward Ford's new global manufacturing capability. That's because plants around the world will build the new-generation global cars using shared processes, tools and technologies - a move that opens up significant opportunities for higher levels of product commonality, major strides in economies of scale and advancements in quality.

"It was an exciting moment," said Bruce Hettle, executive director, Global Manufacturing, Ford Motor Company. "We built the car part by part from start to finish, from the first piece of sheet metal. And with every step, each plant - here in North America, in Europe and in Asia-Pacific - raised its hand to say, 'Yes, we confirm we can do that.' And it wasn't just engineers and executives. It was also the people who will build the cars on the plant floor."

Major advancements in computer modeling allow Ford to verify its new global manufacturing approach is feasible, whether production takes place at Michigan Assembly, Chongqing (China), Saarlouis (Germany) or in other plants around the world - even one that is not yet built.

The virtual tools - part of Ford's powerful Global Product Development System - help Ford optimize the assembly process, make best practices more universal, and facilitate ergonomics to ensure assembly workers are able to do their best and deliver consistently high quality.

Advancements in launch quality and sustained overall product quality - already tangible in Ford's new-generation products around the world and a key brand pillar for Ford products - can now be leveraged globally.

Ford's digital manufacturing test-build confirmed the potential for a new global "bill of process" approach that prescribes the way Ford vehicles will be built from start to finish. Aligning each plant around the world in this way generates huge economies of scale for Ford, helping the company further leverage its product development investment.

Aligning processes also helps Ford achieve significant savings in tooling development costs, and allows for smarter manufacture of key components for the global operation. It's one of the benefits of the stronger global teamwork driven by the ONE Ford approach, as regional differences dissolve into a truly global product development force for the blue oval.

Global plant footprint for global cars
The digital build of that first new Focus made going global look easy. But this wave of global products from Ford Motor Company is being achieved through intensive efforts to build the scale of Ford's manufacturing operations and align them around the world to produce the new Ford Focus - and the other models based on the new global C-car platform - with universally high levels of craftsmanship, quality and efficiency.

The efforts build on the experience from the staggered global launch of the new Ford Fiesta.

Ford has already revealed an initial list of key plants around the world that will contribute to the high-volume C-segment output plans:

WAYNE, Michigan - One of three North American truck plants being retooled to build fuel-efficient global small cars, the Michigan Assembly Plant is being transformed with Ford's $550 million investment to be the lean, green and flexible manufacturing complex for Ford C-cars in North America. Approximately 3,200 employees will build Ford's next-generation Focus global small car along with a new battery-electric version of the Focus for the North American market. Ford is consolidating its operations from Wayne Assembly Plant in the same manufacturing complex in suburban Detroit into the new Michigan Assembly operation.

SAARLOUIS, Germany - Lead European assembly plant for the Ford Focus since its debut in 1998, Ford's Saarlouis Body and Assembly Plant will continue its role as the initial European production source for the third-generation model. The 3.1-million-square-foot plant with approximately 6,000 employees has produced more than 11 million vehicles since it was built in 1970. According to international research studies, the plant's lean and flexible manufacturing processes make it one of the most efficient both within Ford and the European automotive industry.

VALENCIA, Spain - The Valencia Assembly Plant, built in 1976, holds a special place in Ford's heritage of small car production expertise. Originally configured for production of the then-newly introduced Ford Fiesta, the plant has evolved into a flexible manufacturing source for Ford Fiesta and Focus models for Ford of Europe. It will become the European source for the next-generation Ford C-MAX, which goes into production this year. The 2.7-million-square-foot plant employs about 6,300 people.

ST. PETERSBURG, Russia - Built in 2002 as the first assembly plant for a foreign automaker in Russia, the St. Petersburg Assembly Plant has played a pivotal role in establishing the Ford Focus as a major brand in this growing European car market. The 2,100-employee plant in Russia's Leningrad Region currently produces the Ford Focus and Ford Mondeo, having undergone incremental investments to grow its annual capacity to 125,000 vehicles.

CHONGQING, China - Ford Motor Company and its successful joint venture in China - Changan Ford Mazda Automobile (CFMA) - broke ground in September 2009 for a new, state-of-the-art and highly flexible passenger car plant in Chongqing, China, scheduled for completion in 2012. The $490 million plant will be the production home in China for the Ford Focus, with an initial production capacity of 150,000 units. It is Ford's second in Chongqing and third in China under its CFMA joint venture.

Partnering with global suppliers
Just as Ford's plan to produce a new generation of C-segment cars for the world requires a global manufacturing resource, Ford's global assembly operations for the new family of Focus-size vehicles depends more than ever on a truly global supply base.

Establishing a robust global supply base for the new C-car product portfolio has been a primary objective for Ford's Purchasing organization around the world as the company shifts from regional to global business relationships. Instead of working with suppliers individually on different continents, Ford gathered key suppliers for global meetings early in the development process. Ford then provided suppliers a much greater level of detail on product features and manufacturing volumes and locations than was previously the case.
"The global scale of our C-car program gives us an opportunity to tap into the numerous benefits offered by an international supply base," said Tony Brown, group vice president, Global Purchasing. "By coordinating our efforts at an earlier stage, suppliers can drive potentially huge cost efficiencies. They also contribute significantly to ensuring consistent levels of excellent quality whether we're building cars in the United States, Germany or China."

Strong global supply relationships do not happen without a basis of collaboration and information transparency. The principles of Ford's 4-year-old Aligned Business Framework (ABF), which sets down guidelines for Ford and suppliers to work together, paved the way for Ford to work effectively with suppliers on a global basis.

Brown explained that the higher volumes of a global program like Ford's make it attractive to the leading suppliers of every category.

"If we can place our business with one or two of the industry's leading suppliers in each category, we're assuring them significant volume," Brown said. "That means Ford, and our suppliers, will be able to reap the financial benefits of better scale. And this directly supports our ONE Ford goal of creating a viable company that delivers profitable growth for all - including our suppliers."

The introduction of the new C-segment platform - the first of Ford's global products - is a key step forward in Ford's growing emphasis on global suppliers.

Top 100-plus commodities
Trying to stretch its resources as far as possible in the capital-intensive automotive business, Ford has a plan for the top 112 commodities in terms of value that go into a modern automobile. These 112 commodities, from chassis control arms to brake discs, represent 80 percent of the total production cost of the vehicle, excluding powertrain components.

Cross-functional teams of procurement and product development engineering specialists have undertaken detailed studies of each top 112 commodity to create what Ford calls a "commodity business plan" for it.

The commodity business plan approach was started three years ago and intensified under the collaboration model of ONE Ford. Each plan features detailed assessments of technology developments, cost drivers, sourcing strategies and global supplier assessments.

"We want to pick the best," said Paul Stokes, executive director of Ford Purchasing, who is responsible for global vehicle commodity buying. "We want the best quality and technology at lower costs, through higher volumes, increased commonality and reduced complexity so we can build appealing, affordable vehicles that customers want. These plans are our road map to get there."

This approach paid off with the new C-segment platform. Parts commonality on the new C-car increased significantly from prior vehicle programs, reaching 80 percent.

Moreover, instead of asking for multiple bids from suppliers on components, a practice known as market-testing, Ford pre-sourced more than 75 percent of the commodities for the new Ford Focus with its preferred suppliers, consistent with ABF principles.

"Pre-sourcing - telling suppliers they've got our business - might seem like sticking our neck out," Stokes said. "But we know who we want to work with because we believe they are best-in-class, and we have a very clear idea on cost, which means we can set cost targets and work with suppliers through the design and engineering process to achieve those targets."

Pre-sourcing not only saves time and money for Ford and its suppliers, it also drives longer-term relationships between Ford and the suppliers who typically provide 65 to 70 percent of vehicle components. Pre-sourcing helps provide suppliers an ongoing flow of business, which gives them assurance to invest in new facilities around the world to support Ford globally.

That's important because few automotive suppliers are truly global. Like Ford in the past and other full-line automobile manufacturers, many suppliers operate regionally. Many operate in two regions of the world, but not three. Ford has been working with its supply base to encourage global growth. For some suppliers, it means expanding to become global or entering into licensing agreements or joint ventures to extend their reach.

Just as C-cars are the first in a wave of global Ford products, the global supplier commitments for their production are the beginning of a tidal flow as Ford and its suppliers reap the benefits of global scale.

It has already driven efficiencies that have allowed Ford to reduce development costs more than 60 percent compared to vehicles developed as recently as 2006.

"Part of achieving better quality and better scale is to have fewer suppliers," explained Derrick Kuzak, group vice president of Global Product Development for Ford. "That quality and efficiency pays off, not just for Ford, but also for the extended enterprise with our supplier partners."
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