Ford Launches Small EcoBoost Engine

This is Alan Mulally.

This is Alan Mulally. He is the president and CEO of Ford Motor Company.

M

Mr. Mulally is shown with a model of the smallest Ford engine that was put into production last Wednesday, the 1.0-liter, turbocharged, direct-injection EcoBoost.

It went into production at the Ford Cologne Engine Plant, which has the capacity of producing up to 350,000 units annually.

The engine, which will first debut in Europe in 2012 and then make its way around the world, was developed by UK powertrain engineers at Dunton and Dagenham.

Ford invested approximately $200-million in Cologne to produce the engine. This includes approximately 100 machining centers and a 1,903-ft long assembly line. To create the production layout, the Ford Manufacturing Engineering team in Dunton used Ford’s Virtual Manufacturing lab to simulate the line before it was built.

The production operation includes 55 automated and 14 semi-automated processes. The machining accuracy that can be achieved in 10 microns. Minimal coolant is used in the aluminum machining: previous operations required up to 2 liters of fluid per component; now they use no more than about 0.005. There are 90 work stations for the assembly operation.

Next year production operations for the 123-hp engine will start in a new engine plant in Craiova, Romania, then possibly in other parts of the world.

Mulally obviously loves this engine.