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Ford’s Spanish Mega-Plant Launches S-MAX, Galaxy, and Mondeo Vignale
Flexible Factory Now Builds Six Models
Ford | May 20, 2015

VALENCIA, Spain – Ford today announced the volume production start of two all-new models at its plant in Valencia, Spain – the S-MAX multi-activity vehicle and the Galaxy seven-seat people-mover – plus the Ford Mondeo Vignale, the first of the Ford Vignale models which is the highest expression of the Ford brand in Europe, bringing together award-winning design and a unique ownership experience.

The mega-plant now produces six nameplates - and multiple body styles and derivatives - off a single production line and has become one of the world’s most advanced, flexible and productive auto plants.

Ford has invested €2.3 billion since 2011 to expand and upgrade the plant. In addition to the three new models, the plant builds the Mondeo wagon, five-door, and four-door - including the Mondeo Hybrid - Kuga sport-utility vehicle, Transit Connect light commercial vehicle and Tourneo Connect people-mover.

“Our Valencia operation has become truly state of the industry in terms of flexibility, productivity and the innovation in manufacturing quality,” said Barb Samardzich chief operating officer, Ford of Europe. “It’s incredible and virtually unprecedented to see a luxurious Ford Mondeo Vignale going down the same line with a Kuga SUV and Transit Connect commercial vehicle.

Valencia is among Ford’s most efficient facilities globally, and with new assembly line process introduced the plant now manages the increased complexity of producing more models and derivatives than any Ford facility in Europe. Highlights include:

It will enable the plant to manage a much higher number of parts required for building the new models and handle 18,000 components compared to 7,000 before

Valencia is expected to yield a 40 per cent production increase this year to about 400,000 vehicles – equivalent to one new Ford car rolling off the production line every 80 seconds – and will have the capacity to potentially build up to 450,000 vehicles a year in the future.

Since 2011, more than 900 new robots have been installed in the Valencia body shop, and 34 in the final assembly area to help deliver the highest quality standards. Nearly 600 highly skilled engineers are involved in supporting the high-tech production processes in Valencia.

This month, the new Vignale Quality Centre was opened in Valencia to support Ford’s new upscale Vignale product and ownership experience. Every Vignale model is hand-finished by a dedicated team of craftspeople, where vehicles receive 100 additional quality checks.
Valencia is today one of Spain’s top automotive exporters, with 80 per cent of its production destined for 70 countries worldwide, including North America.

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This kinda pales in comparison to Nissan's mega factories in the US. I don't think anybody else is operating at this sort of scale and complexity under one roof and it makes you wonder why.

Smyrna, TN: 640,000 Annually
Nissan Altima
Nissan Maxima
Nissan Pathfinder
Infiniti QX60
Nissan LEAF
Nissan Rogue

Canton, MS: 450,000 annually
Nissan Altima
Nissan Armada
Nissan Titan King Cab
Nissan Titan Crew Cab
Nissan Frontier King Cab
Nissan Frontier Crew Cab
Nissan Xterra
Nissan NV Cargo
Nissan NV Passenger
Nissan Murano

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I would not say that those two Nissan US plants pale Valencia, I'd say they have similar capabilities.
Unless your referring to the point that these two factories can pump out over a million units.

It would be interesting to see a Nissan's media report regarding these two flex plant details.
Reading that Nissan USA 2014 sales were just over 1,2 million, are they over supplying from these two plants,
or are bunch of these models being exported?
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