Ford’s New Electric Vehicle Production System Could Be a Game Changer

How Ford’s Build Is Different

Instead of the traditional step-by-step production line, Ford’s assembly tree system builds the front, centre (including the structural battery), and rear modules at the same time. These modules are then joined together later in the process.

This method can speed up assembly by up to 15%, reduce complexity with 20% fewer parts, and cut the number of fasteners needed by 25–30%. The structural battery pack also serves as part of the vehicle’s floor, improving rigidity, freeing up cabin space, and lowering weight.

“Ford is looking at the numbers as much as the engineering. Reducing parts and simplifying the build changes the economics of making EVs. That opens the door to faster product launches, sharper pricing, and technology that still meets the expectations of UK customers.”
Ashley Passant, Managing Director – Car & Van Operations at Greenhous Group

Why It Matters

One of the biggest roadblocks to electric vehicle adoption worldwide has been price. While drivers are eager to make the switch, many simply can’t justify the cost compared to petrol or diesel models. China has taken a strong lead here, with manufacturers producing cost-effective EVs at scale. Their formula? Streamlined production and aggressive pricing, which is a combination that’s helped them dominate in several markets.
Ford is taking a different route. Instead of focusing purely on scale, they’re betting on process innovation, the kind of smart manufacturing tweaks that can be applied across multiple parts of the production line. The goal: to close the price gap without sacrificing quality or safety.
For UK drivers, that could mean a future where electric vehicles aren’t just eco-friendly, but genuinely affordable.

Safety Considerations

It’s not just where you put the battery, it’s how you build around it. Ford’s latest EV design integrates the battery directly into the floor structure, a move that does more than save space.
By making the battery part of the chassis itself, the vehicle gains extra rigidity. That means a stronger frame, which could help keep the cabin intact in certain types of collisions. There’s another bonus too: this setup drops the centre of gravity, improving stability and sharpening handling. Ford hasn’t shared crash-test results yet, but there’s good reason to be optimistic. Other EVs with a similar battery-in-floor approach have already posted impressive real-world safety records.

Looking Ahead

If Ford’s new production system delivers on its promise, it could reshape how quickly and affordably electric vehicles reach the market not just pickups, but potentially cars, vans, and SUVs.

“What makes this appealing is the combination of affordability, technology, and day-to-day usability. If Ford brings this to the UK, it could prompt many drivers to seriously consider making the switch to electric.”
Neil Gordon, Dealer Principal at Premier Motors

Stay Updated

We’ll be watching closely as Ford shares more about the Universal EV Platform and the vehicles it will produce. In the meantime, you can explore our current range of Ford cars and vans by visiting Premier Motors.