(December 2, 2010) CHICAGO — The reinvented 2011 Ford Explorer has started rolling off the line at Ford’s Chicago Assembly Plant, marking a new beginning for both the historic factory and the iconic SUV.

The Torrence Avenue plant has been extensively renovated to accommodate production of the new Explorer, and all employees have prepared for its launch by participating in extensive training programs. 

“Ford is investing in American manufacturing, ensuring that the most important new products in the company’s lineup are built in the U.S. by UAW workers,” said Jim Tetreault, vice president of North America Manufacturing. “We are thrilled to bring 2011 Ford Explorer production to Chicago Assembly Plant along with the jobs and investment it provides to the region.

“We look forward to finding more opportunities for competitively growing our business and providing customers with capable, fuel-efficient, stylish, high-quality products.”

Ford Explorer — the vehicle that defined a segment 20 years ago with more than 6 million sold – has been reinvented for the 2011 model year, raising customers’ expectations of sport utility vehicle fuel efficiency, technology, capability and quality. The seven-passenger SUV also raises the bar on safety with a class-leading array of features including industry-first inflatable rear seat belts, Trinity front impact structure, AdvanceTrac with RSC (Roll Stability Control) and Curve Control technology.

The all-new Ford Explorer SUV offers best-in-class fuel economy from high-tech powertrains, featuring multiple enhancements to improve mechanical efficiency. Explorer comes standard with a powerful, fuel-efficient 3.5-liter V6 engine with twin independent variable camshaft timing (Ti-VCT). For customers wanting top SUV fuel economy, Explorer offers an optional 2.0-liter EcoBoost I-4 engine delivering V6 power with four-cylinder fuel efficiency.

The next-generation Explorer is built at Chicago Assembly Plant on a flexible assembly line alongside the Ford Taurus and Lincoln MKS sedans. Ford’s $400 million investment includes approximately $180 million in manufacturing investments at the Chicago Assembly and nearby Chicago Stamping Plant and about $220 million for launch and engineering costs. Ford also added 1,200 new jobs to staff a second production shift at Chicago Assembly and increase production at Chicago Stamping.

The company’s investment at Chicago Assembly allowed for renovations to accommodate the all-new Explorer, which is wider and taller than the outgoing model. This meant Ford had to rework everything from vehicle carriers to the overhead clamshells that carry unfinished vehicles from one part of the line to another. Twenty new pieces of equipment, 175 electric tools and more than 70 rearranged workstations rounded out the enhancements.

All of these renovations were done without disrupting production of Taurus and MKS. In fact, in the 2010 J.D. Power and Associates Initial Quality Survey, which measures “Things Gone Wrong,” Taurus ranked highest within its segment. Taurus also ranked highest in its segment in the 2010 J.D. Power and Associates APEAL Survey, which measures “Things Gone Right.” Both are important third-party measures of quality and customer satisfaction.  

“No details were overlooked, because we are dedicated to ensuring our plant continues to deliver the best, highest-quality products possible, and competes on the international stage in an increasingly global auto industry,” said Jan Allman, Chicago Assembly Plant manager.

Additionally, a “rough road” test track was revamped, featuring seven surfaces designed to help employees identify any squeaks and rattles on vehicles before they leave the plant.