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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.

Carmakers, NHTSA to unveil auto-emergency braking agreement tomorrow

Happy St. Patrick's Day Eve. Tomorrow, there will be green beer, corned beef and cabbage, and automatic emergency braking for all. Weird combo, we know. But on St. Patty's we can expect an official announcement from a pact of automakers making auto-braking systems standard equipment by 2022. That's per a report from Reuters, which cites three sources familiar with the plans. Originally announced in September 2015 by 10 automakers and the National Highway Traffic Safety Administration, the agreement is expected to be even larger when the details are unveiled tomorrow. According to Reuters, the manufacturers of 99 percent of the US domestic market's vehicles will be represented by the new agreement. It's believed that standard AEB systems could prevent thousands of accidents across the country. Expect more on the official announcement when it's made. Related Video:

Takata allegedly hid failed airbag rupture tests in 2000

New evidence suggests Takata engineers knew about the dangers of the supplier's ammonium-nitrate-propelled airbag inflators as early as 2000, but employees hid or even destroyed test results. The allegations came out in a pre-trial hearing in a civil suit from a woman who claims that a forcefully deploying airbag in her 2001 Honda Civic paralyzed her. The pre-trial hearing included an examination of a deposition from Thomas Sheridan, a former Takata airbag engineer, to see if the evidence was admissible for the case, according to the New York Times. Sheridan alleged that Takata created a report for Honda in June 2000 that showed the parts failed, but the supplier hid the testing data. The company also reportedly got rid of the ruptured components so that there was no physical evidence. "But when I went to look for the parts, because some of the parts had come apart, they were no longer available. They had been discarded," he said in the deposition, according to the Times. Takata disputes these allegations, and one of the company's lawyers asserts the inflators in the 2001 Civic are safe. "None of them have ruptured, zero," attorney David M. Bernick told the Times. "We have no evidence, in fact we have evidence to the contrary, that this inflator was defective at the time of the accident." However, Honda has recalls for the driver's side airbag in the 2001-2005 Civic. Previous reports also indicated some Takata employees allegedly knew the inflators were dangerous. For example, an investigation by the Wall Street Journal in 2015 cited internal memos from US employees in 2000 that complained that their counterparts in Japan altered or hid the results of failed validation tests. The New York Times also found evidence of engineers joking about manipulating results. The first Takata inflator recall came on Isuzu models in 2001, and automakers have recalled millions of vehicles around the world since then. Several companies, including Honda, have pledged to stop using Takata's inflators, and he US government fined the supplier $70 million last year. Related Video: