Ford Rethinking the Assembly Line for EVs

Aug. 12, 2025
Engineering and manufacturing leaders say the $2 billion investment at the Louisville Assembly Plant will make it more productive and safer for workers.

Sometimes, you just need to throw away the rulebook that you wrote a century ago.

Ford Motor Co. President and CEO Jim Farley said the company’s $2 billion investment in manufacturing in Louisville to make its next generation of electric pickups required new thinking. A company founded on the idea of the moving assembly line had to think differently when preparing for the future.

“Three years ago, we did something that no one really saw,” Farley said. “We empowered a tiny skunkworks group of people in California, one-tenth of the normal people we would hire to do this kind of work, three time zones away from Detroit. And we gave them the keys to the kingdom. We tore up the moving assembly line that you see here today. And we came up with a brand-new concept, a brand-new vehicle and a better way of making a car after 122 years.”

Bold talk from the pioneer of the mass-market vehicle. Throughout the nearly hourlong presentation, engineers and executives kept coming back to the idea that Ford's plans are radically different from anything the industry has ever done.

Here are the highlights from when people stopped talking so generally and got into the specifics of how Ford's upcoming plant will be different. 

About the Author

Robert Schoenberger

Editor-in-Chief

LinkedIn: linkedin.com/in/robert-schoenberger-4326b810

Bio: Robert Schoenberger has been writing about manufacturing technology in one form or another since the late 1990s. He began his career in newspapers in South Texas and has worked for The Clarion-Ledger in Jackson, Mississippi; The Courier-Journal in Louisville, Kentucky; and The Plain Dealer in Cleveland where he spent more than six years as the automotive reporter. In 2014, he launched Today's Motor Vehicles (now EV Manufacturing & Design), a magazine focusing on design and manufacturing topics within the automotive and commercial truck worlds. He joined IndustryWeek in late 2021.

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