Ford Targets $30,000 EV with Radical 40% Faster Production System

Louisville, Kentucky – Ford Motor Company is undertaking a significant overhaul of its electric vehicle manufacturing process, investing billions to introduce a new "assembly tree" system aimed at producing affordable EVs, including a midsize pickup truck with a targeted starting price of $30,000 by 2027. This radical approach, dubbed the "Ford Universal EV Production System," is designed to challenge Chinese EV makers and Tesla by prioritizing innovation in manufacturing speed and cost efficiency.

Ford CEO Jim Farley stated, "No one's ever built a car in three pieces then fit them together at the end." This new method involves independently assembling the front, middle (including the battery), and rear sections of the vehicle on separate lines before joining them. This contrasts sharply with traditional linear assembly lines and is projected to be 40% faster than current processes at Ford's Louisville assembly plant, requiring 40% fewer workstations.

The innovation extends to the vehicle design itself, with the "Ford Universal EV Platform" utilizing large single-piece aluminum unicastings for the three modular sections, replacing dozens of smaller parts. Doug Field, Ford's chief EV, digital, and design officer, explained that this "cell-to-body" approach integrates the lithium-iron phosphate (LFP) battery pack directly into the vehicle's structural floor, making it 30% cheaper and safer. This also allows for a 20% reduction in overall parts and 30% fewer fasteners.

The company's strategic shift represents a $5 billion investment, including $2 billion to retool the Louisville plant and $3 billion for a new BlueOval Battery Park in Michigan to produce LFP batteries. This move aims to secure 2,200 jobs in Louisville and create 1,700 additional jobs in Michigan, bolstering domestic EV production. Ford seeks to offset the scale advantage of competitors like BYD through manufacturing innovation and cost reduction.

The first vehicle to emerge from this system will be a four-door midsize electric pickup, expected to offer more passenger space than a Toyota RAV4 and acceleration comparable to a Mustang EcoBoost. While acknowledging significant engineering challenges, Ford believes this "unboxed" manufacturing process could give it a crucial lead over rivals, including Tesla, which has discussed similar concepts but has yet to implement them.