Inside The Assembly Line Crafting The Ford Ranger At Silverton Plant

Inside the Assembly Line: Crafting the Ford Ranger at Silverton Plant

Ford’s Silverton Manufacturing Plant in Pretoria stands as one of the five global hubs producing the Ranger pickup. Known for its quality, reliability, and durability, the Ranger has cemented its place as a top contender in its segment. An exclusive behind-the-scenes video reveals the intricate production process of the new Ford Ranger at Silverton. Highlighting…

Inside The Assembly Line Crafting The Ford Ranger At Silverton Plant

Ford’s Silverton Manufacturing Plant in Pretoria stands as one of the five global hubs producing the Ranger pickup. Known for its quality, reliability, and durability, the Ranger has cemented its place as a top contender in its segment.

An exclusive behind-the-scenes video reveals the intricate production process of the new Ford Ranger at Silverton. Highlighting cutting-edge technologies and a meticulous focus on quality, the video provides an in-depth look at how this award-winning vehicle, including South Africa’s 2023 Car of the Year, is crafted. This insight offers Ford enthusiasts a greater appreciation of the expertise and dedication involved in each Ranger’s creation.

The production of the new Ranger has significantly evolved to meet global demands. In 2022, a substantial investment was made in Ford’s South African operations, enhancing supplier tooling and expanding capacity. The plant now boasts a record installed capacity, producing up to 200,000 vehicles annually, with the ability to roll out up to 720 vehicles daily through a three-shift, 24-hour production schedule, translating to one vehicle every two minutes.

The investment also modernized the Silverton operations, introducing Ford’s first on-site Stamping Plant, a new highly automated Body Shop, and advanced assembly operations on the Trim, Chassis, and Final lines. The Stamping Plant, spanning 10,320 square meters, feeds stamped body panels directly to the adjacent 44,000 square meter Body Shop, which utilizes approximately 493 robots.

The extensive 100,000 square meter Chassis Plant, located in the Tshwane Automotive Special Economic Zone (TASEZ) next to the Silverton Assembly Plant, manufactures the robust ladder-frame chassis for the Ranger. This facility ensures seamless sequencing of parts directly to the assembly line and is unique as Ford’s only owned and operated Chassis Plant globally.

Silverton also features an advanced Paint Shop, employing a fully automated process with 62 robots and a computerised Paint Defect Detection System. This system uses 21 high-resolution cameras to capture over 3,000 images in 15 seconds for each vehicle, addressing any paint issues on two manicure lines before the vehicle proceeds to the assembly line.

Detailed quality inspections are performed across all manufacturing lines, including off-line 3D scanning of parts. One of the advanced technologies at Silverton is the DeGould Auto Scan system, which replaces manual inspections with an automated system. This high-tech system captures high-definition full-body images of each vehicle in just six seconds, identifying any defects or damage smaller than what the naked eye can detect, ensuring each vehicle meets the highest quality standards before reaching customers or being shipped globally.

10 Fascinating Facts About Ford Ranger Production:

  1. A vehicle rolls off the production line every two minutes at Ford’s Silverton Manufacturing Plant.
  2. Nearly 600 robots are employed on the chassis line, with each chassis taking around three hours to build.
  3. Each Ranger body features approximately 3,000-4,000 spot welds, with corrosion protection provided by 12 chemical baths before painting.
  4. Around eight liters of Ford’s innovative 3-Wet High Solids Paint system cover each Ranger.
  5. The 3-Wet paint process ensures durability and chip resistance, reducing CO2 and VOC emissions by minimizing paint booth size and the number of paint purges and ovens required.
  6. Post-painting, each Ranger passes through a state-of-the-art paint scanner that detects coating defects as small as 0.2 mm².
  7. Each Ranger comprises over 2,700 parts and undergoes nearly 1,000 quality confirmation checks before shipment.
  8. A high-pressure Water Test sprays each Ranger for 20 minutes, simulating severe rainstorms to ensure no water ingress.
  9. Final quality checks include testing on the Squeak and Rattle Track, High Speed Track, and Rough Road Track.
  10. Daily, one Ranger variant is randomly selected for a thorough inspection involving lasers and cameras for wheel alignment and headlight checks, followed by a test on the Steering Alignment Test Track.

These meticulous processes and advanced technologies underscore Ford’s commitment to delivering high-quality, reliable vehicles, ensuring every Ford Ranger that leaves the Silverton Plant meets the highest standards.


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