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A look inside Honda’s “Safety For Everyone” research and development operation

RAYMOND, Ohio—As part of its long-running “Safety for Everyone” campaign, Honda has established the audacious goal of what it calls a “zero-collision society.” But rather than making big claims about developing a fully-autonomous vehicle, which Honda hasnÂ’t done, the company is trying to chip away at the more than 37,000 vehicle-related fatalities that occurred in the U.S. in 2017 with a multi-pronged approach. Here in central Ohio, engineers are working with state-of-the-art facilities and equipment to boost active safety systems like its HondaSensing suite of safety technology with old fashioned passive systems like structural steel frames or new airbag designs that protect passengers in a crash. Honda provided members of the press with a rare tour inside its Honda R&D Americas headquarters this week. Honda officials say that increasingly, safety — and specifically, third-party ratings from the likes of the National Highway Safety Traffic Administration and the Insurance Institute for Highway Safety — figure into the top three factors consumers weigh when purchasing a vehicle. Honda and Acura have 10, 2019 models that have earned IIHSÂ’s Top Safety Pick or Top Safety Pick+ ratings, and all 15, 2019 model-year Honda and Acura vehicles that have undergone NHTSA crash testing have earned a 5-star overall rating. And Honda prides itself on its growing list of safety firsts, including the first upward-deploying front passenger airbag, in 1990 in the Acura Legend; first omni-directional crash-test facility, in 2000; and the first autonomous braking system, in the 2006 Acura RL. It hopes its new three-chamber airbag goes industry-wide and joins that list. “ItÂ’s part of our companyÂ’s culture,” said Art St. Cyr, business head unit and vice president of auto operations for American Honda Motor Co. “We have a philosophy at Honda that we want to be a company that society wants to exist. That means we have to protect our customers. ThatÂ’s part of the whole mantra of doing this.” Opened in 1984, the 1.6 million square-foot Honda R&D Americas facility, located in the countryside about 45 miles northwest of Columbus, employs around 1,600 people and is HondaÂ’s largest research-and-development facility outside of Japan. Its Advanced Safety Research facility opened in 2003.

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 CEO says we shouldn't expect any new sports cars

It wasn't so long ago that Honda was known for its sporty two-door models, with models ranging from the Civic del Sol to the Prelude and from the Acura Integra and RSX to the Honda S2000. But look at its range today and all you'll see are the Civic and Accord coupes. Honda has essentially let competitors like the Scion FR-S/Subaru BRZ and Nissan 370Z take the place it once claimed as its own. But if you were hoping Honda would fight back with a new coupe or convertible of its own, we're afraid you're going to have to downgrade those hopes to pipe dreams.
While in Japan ahead of the Tokyo Motor Show, Autoblog had a chance to sit down with American Honda CEO Tetsuo Iwamura (pictured at right). When we asked about the potential for a new sports coupe or convertible in the Honda or Acura lineup, he pointed to the current Civic and Accord coupes - not to mention the upcoming new NSX - but said that Honda has no replacement for any of the aforementioned models (or a rival for the FR-S or 370Z) in the pipeline, saying only that the company is monitoring potential demand.
What Iwamura-san did note was that he's a personal fan of the new S660 roadster (pictured above) set to be unveiled tomorrow, and he is pushing (or at least hoping) that it will come to North America. Given that he's head of both Honda's American office and its global automobile operations, one might think that the only person he would have to persuade is himself (well... himself, and potential buyers), but the sporty droptop looks to be about kei-sized, which sadly suggests that it may be too small for American tastes and perhaps not designed with US crash-test standards in mind anyway.