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Honda's Acura NSX masterstroke: building the factory in Ohio

When Honda announced it was going to build its NSX supercar in Ohio instead of Japan, it caught everybody in the industry by surprise. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Now Honda has a supercar production facility in rural Ohio that would be the envy of any Formula One team. The people at Honda call it the PMC, but its official name is the Performance Manufacturing Center. It's a building that started out as a shipping facility for suppliers, but Honda invested $70 million to transform it into a showcase facility that will build the NSX. Honda benchmarked the assembly operations at Ferrari, Lamborghini, McLaren, and Bentley before work began on its facility. The 200,000 square-foot building will also double as a customer reception center – Honda will open the doors for customers to come see their car being built. It's also going to offer them high-speed test drives at the gigantic Transportation Research Center just down the road. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Inside, the layout is wide open and well lit. There are no stripes or lines on the floor and none of the different departments are walled off. This creates a more welcoming appearance and lets you get a comprehensive view of the entire process at a glance. And with an eye towards future lessons learned, most of the equipment is of a modular design that can be easily reconfigured or moved. The body shop and paint shop are enclosed by glass walls so that anyone can see what's going on inside. And while you'll see some automation here and there, the idea was to achieve a blend between man and machine, not to try and automate everything. This is a low-volume facility with production targeted at only eight to ten cars a day. The plant runs four days a week with one ten-hour shift. Don't expect to see rows of new NSXs parked on any dealer's lot. The car will only be built to order. Honda is obsessed with ensuring the NSX is built to the most exacting quality standards. The plant people pored over the JD Power Appeal study to determine what supercar customers care about the most, then looked at which aspects of that directly tie into manufacturing. They developed their quality control strategy with three goals in mind. First, they wanted to build everything right the first time with no adjustments.

Honda issues 'do not drive' order for older cars with recalled Takata airbags

Honda and Acura instructed owners of more than 8,000 cars built from 2001-2003 to park them until they can have their Takata airbags replaced as part of the ongoing global campaign to eliminate millions of deadly inflators. Honda says the "Alpha" generation Takata inflators can fail at rates as high as 50%, causing potentially fatal injuries from flying shrapnel in the event of a collision.  Honda and Acura models with the "Alpha" generation Takata airbags include:  2001-2002 Honda Accord  2001-2002 Honda Civic  2002 Honda CR-V  2002 Honda Odyssey  2003 Honda Pilot  2002-2003 Acura 3.2 TL  2003 Acura 3.2CL "Approximately 8,200 Honda and Acura vehicles with the most dangerous airbags are still being driven today. Honda has replaced or accounted for more than 99% of Alpha inflators, but it is absolutely critical that these remaining vehicle owners act now to protect themselves and their loved ones," Honda's announcement said. "These vehicles are 20 to 22 years old now, and the risk to vehicle occupants is dire. Alpha air bags are some of the oldest under recall, and they have a 50% failure rate. If the inflators rupture, the metal fragments ejected toward the driver’s face could kill or leave them with devastating, life-altering injuries." Honda and Acura are far from the only brands whose models were built with defective inflators. A campaign has been underway for the better part of a decade to replace millions of the devices worldwide as drivers continue to die from injuries caused by exploding inflators.  All such repairs are free of charge to customers. Acura/Honda Customer Service can be reached at 888-234-2138 or by visiting their Takata website.   Recalls Acura Honda Ownership Safety Takata airbag recall

Honda recalling 871,000 SUVs and minivans over rollaway fear

Honda is recalling 871,000 SUVs and minivans for an issue in which the vehicles may roll away after the key has been removed from the ignition. Ninety-two percent of the recalled vehicles, or 807,000 vehicles, are in the US. According to a report from Reuters, the effected vehicles include certain numbers of the Honda Odyssey and Pilot, as well as the Acura MDX. Here are the recall figures:
2003-2004 Honda Odyssey: 318,000 vehicles
2003-2004 Honda Pilot: 259,000 vehicles