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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 adopts English as its official language in meetings worldwide

Japanese was clearly the language of operation while we visited Honda's global headquarters in Tokyo last week, as well as its newest factory and principal test track. Chief executive Takanobu Ito (pictured above) spoke to us through an interpreter. But according to the latest reports, the Japanese language is being phased out at Honda in favor of English.
This according to Bloomberg, which points out that tire manufacturer Bridgestone and rival automaker Nissan have implemented similar measures, as have Japanese retail giants Fast Retailing Co. and Rakuten Inc. Honda's shift from Japanese to English comes as part of a shift in focus from central decision-making to a more regional model, but while English has clearly emerged as the international language of business, it's no coincidence that it's also the dominant language here in America. Bloomberg points out that over the 12-month period that ended this past March, North America accounted for a massive 47 percent of Honda's revenues worldwide.

Honda's new hybrid will cut use of rare-earth metals

Honda will start selling a hybrid vehicle later this year that will reduce the use of rare-earth metals in the hybrid-electric motor's magnets. The Japanese automaker worked with Japanese metal supplier Daido Steel Co. to develop a process that eliminates the use of rare-earth elements such as terbium or dysprosium. The first vehicle to feature this process will be the Honda Freed subcompact minivan, which is based on the platform of the Fit and will go on sale in Japan later this year. The new technology will help free Honda from its dependence on China, which produces about 90 percent of the world's rare-earth metals. The new process uses what's called the "hot deformation method" to eliminate the need for the heavier metals and likely reduce hybrid-engine costs. Honda's new hybrid motors use a lighter rare-earth material called neodymium. With both electric and hybrid vehicle production forecast to grow within the next few years, rare-earth metal demand is forecast to rise by 14 percent a year to more than $9 billion by 2019, Automotive News says, citing an estimate from technology-research company Technavio Research. Honda estimates that the new process cuts the cost of making the motors' magnets by about 10 percent while reducing their weight by about eight percent, Reuters says. Additionally, neodymium is found in Australia and North America, as well as China. Honda has been selling a gas-powered version of the Freed in Japan since 2008. Three years later, Honda started selling a hybrid version of the minivan, which was rated to get 51 miles per gallon on the Japanese driving cycle. Related Video: This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. Daido Steel and Honda Adopt World's First Hybrid Vehicle Motor Magnet Free of Heavy Rare Earth Elements – Honda Freed, on sale this fall, will be the first hybrid vehicle to adopt new magnet – Daido Steel Honda TOKYO, Japan, July 12, 2016 - Daido Steel Co., Ltd. and Honda Motor Co., Ltd. became the world's first companies to achieve practical application of a hot deformed neodymium magnet containing no heavy rare earth*1 and yet with high heat resistance properties and high magnetic performance required for the use in the driving motor of a hybrid vehicle. This heavy rare earth-free hot deformed neodymium magnet will be applied first to the all-new Honda FREED, scheduled to go on sale this fall.