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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.

Inside Honda's ghost town for testing autonomous cars

On the edge of the San Francisco suburb of Concord, California sits a ghost town. Dilapidated buildings and cracked roads are framed by overgrowth and slightly askew street signs. The decommissioned five acre portion of the Concord Naval Weapons Station that once housed military personnel and their families is now home to squirrels, jack rabbits, wild turkeys and Honda's mysterious testing lab for autonomous vehicles. This former town within a Naval base – now dubbed "GoMentum Station" – is the perfect testing ground for Honda's self-driving cars. An almost turn-key solution to the problem of finding somewhere to experiment with autonomous vehicle inside an urban area. Thanks to the GoMentum Station, the automaker has access to 20 miles of various road types, intersections and infrastructure exactly like those found in the real world. Just, you know, without all the people getting in the way. While the faded lane markers and cracked asphalt might initially make it difficult for the car to figure out what's going on around it, that's exactly what you want when training a self-driving system. Many roads in the real world are also in dire need of upkeep. Just because autonomous vehicles are hitting the streets doesn't mean the funding needed to fix all the potholes and faded lane markers will magically appear. The real world doesn't work that way and the robot cars that will eventually make our commutes less of a headache will need to be aware of that. Plus, it's tougher to train a car to drive downtown than to barrel down the highway at 80 miles per hour. A company is going to want to get as much practice as possible. While semi-autonomous driving on the everyone-going-the-same-way-at-a-constant-speed freeway is already a reality, navigating in an urban environment is far more complex. If you've driven on the streets of Los Angeles, San Francisco, New York, Chicago or Seattle you know that driving downtown takes far more concentration than cruising down the interstate. With all that in mind, Honda's tricked out Acura RLX did a good job during an (admittedly very controlled) hands-free demo. It didn't hit either of the pedestrians walking across its path. It stopped at stop signs and even maneuvered around a mannequin situated in the middle of the road. The reality is, watching a car drive around the block and safely avoid stuff is boring. Not to metion, Google has been doing this for a while in the real world.

Honda patents show technology that could give you X-ray vision

A pair of patent applications from Honda appear to show technology that will bring us one step closer to augmented-reality driving. The patents involve head-up displays (HUDs) and technology that can show people and vehicles that would otherwise be obscured. It'd be like being Superman behind the wheel. The first of the patents is for pedestrian detection. Many vehicles have a version of pedestrian detection that will alert a driver of a possible collision and automatically brake. This system from Honda would go a step further. Rather than just intervening when someone steps in front of the car, the proposed system would be able to detect multiple pedestrians and display their locations on an augmented reality HUD. It would also be able to locate pedestrians that are out of the driver's field of view, whether obscured by blind spots or something else. With this system, drivers would have information that would allow them to actively avoid a situation before the car has to intervene. The second patent adds vehicle-to-vehicle communications for keeping track of cars in traffic. In the patent, Honda explains how the system would work with a line of three cars. Provided the cars were connected with a V2V system, the lead car would communicate with the middle car to calculate the distance between them. Then, the middle car would relay that information to the last car, which would display an icon representing the lead vehicle with its position and status on the augmented reality HUD. This would allow the driver to effectively see through the middle car to know where the lead car is and what it's doing. The system would also be able to keep track of when the lead car starts braking, giving the driver advance notice and more time to react to a sudden slowdown or stop. This isn't the first time Honda has looked into advanced pedestrian technology or short-range communications. A few years ago, the company experimented with a system that would allow a car to communicate with pedestrians' cell phones to see their position, even when the sensors couldn't. The detection technology described in the first patent appears to rely only on sensors. Honda also experimented with V2V communication on motorcycles, so it's possible that project laid some groundwork for the augmented reality system in the second patent.