TechCrunch Industry News Ford throws out Henry Ford’s assembly line to make low-cost EVs in America
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Aug 13, 2025 Ford is making headlines with an impressive $2 billion investment in its Louisville Assembly Plant. They're moving away from traditional assembly lines to embrace a new, innovative production process. This shift aims to streamline efficiency and boost their competitiveness. By 2027, the automaker plans to introduce a low-cost electric pickup priced at $30,000. It's a bold step that could reshape the landscape of affordable EVs in the U.S. and transform labor dynamics in the automotive sector.
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Big Bet On Affordable U.S. EVs
- Ford is investing $2 billion to convert its Louisville plant to build affordable EVs starting with a $30,000 pickup in 2027.
- The move abandons a century-old assembly-line orthodoxy to cut costs and compete with China.
Skunk Works Team Built The System
- A Skunk Works team of ~500 in California, led by ex-Tesla Alan Clark, developed the production system and platform.
- The team pulled talent from Tesla, Rivian, Apple, and Lucid to design the approach.
Three-Branch Assembly Tree
- Ford's universal production system replaces a single conveyor with a three-branched assembly tree to assemble major modules separately.
- The approach joins front, rear, and a structural battery module at the end to form the complete vehicle.