Ford Flatrock – Front Decking and Engine Dress Pallets

Ford required the modification 64 front decking pallets with the addition of new adaptive tooling to accommodate the mixed-model introduction of a new Lincoln MKS vehicle together with a current Fusion vehicle (the North American version of the Mondeo). Due to increased complexity of the vehicles’ power train lineups, the scope of the project included design, manufacture and supply of 140 new engine dress pallets for the adaptive tooling system. More than 500 adaptive tools were delivered for the project.

Our adaptive tooling system, as well as being agile and flexible, created space on the pallets by replacing the old “flip” unit. This allowed Ford to add extra processes to its engine dress line and better balance its labor force. Members of our project team attended the prototype build stage in North America to make further refinements to the tooling.