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Experience America this summer with Andrew Burmon

Before I left Chicago for points east, I had a chance to tour Ford's Chicago Assembly Plant, a complex that finishes about 1160 vehicles a day. A great majority of those are Ford Explorers, pieced together by line workers wearing safety glasses and headphones, working pneumatic tools in a hypnotizing ballet of endless repetition. Whir, whir, whir.
Walking the floor, following pedestrian pathways marked by bright yellow paint, I watched linemen and women raise engine assemblies into vehicle bodies, hang doors and bolt wheels, as conveyor belts ceaselessly inched the unfinished machines ever forward. (A tip: When touring the plant, one steps over the drive-chains running through channels in the floor.)
My tour guide Larry, a dead ringer for Jesse Ventura, even let me jump in a just-finished Explorer the moment it rolled off the line. Videographer Stephen Greenwood, who's riding along for this part of my ride, captured the mesmerizing shots after the break.
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Reader Comments (Page 1 of 1)
Jim Jun 8th 2011 6:13AM
"(A tip: When touring the plant, one steps over the drive-chains running through channels in the floor.)"
"One"? Who does Paul Brady think he is? The Queen?
An incongruous word from an, inevitably, poorly annunciating American.
And he obviously thinks that AOL members are idiots.
Phil MacAbee Jun 19th 2011 4:32PM
The production rate in that plant...1160 per day...seems a bit optimistic...but
if in fact that plant produced units all three shifts...that would amount to 48+ units per hour...or more realistic...two ten hour shifts = 58+ units per hour...I too was
in this plant in 2005 when it assembled Fairlane 500's..and the fork trucks delivering parts to the line had to go awfully fast to supply them...making a walk
through the plant somewhat dangerous for the uninitiated and unwary. Methinks in the overall real world sense...1160 per day is a bit optimistic..especially when
much of the work on this moving line is done underneath the vehicles...looking upward...which is ergonomically questionable in my opinion. Nevertheless the plant is impressive to tour...
aldera Jun 10th 2011 5:44AM
you have no clue. I used to make seats for the explorer when it was made in st. louis. We had a real time hourly count of the vehicles ford made each hour to what we made in that same hour. They could pump them out at a steady 56 vehicles per hour for 8 hours on days and when all the big whigs went home and left the night shift alone they were pumping them out at an average of 60 per hour. 1160 per 24 hr period is a very real number and is probably not even close to what that plant could do if needed. If the demand is there, they'll put more people on the line,speed the line up, extend the shift to 10 hrs and just sit back and watch a well oiled machine pump them out.
Ronn-In-CO Jun 10th 2011 1:48AM
I ordered a new Explorer in March. Still no word on when it will be built, much less delivered. I'll bet the 2012's will be being built before my 2011 arrives.
mike flynn Jun 26th 2011 1:57PM
My Explorer was ordered in February through ARI Leasing, Ford assembled May 10th and I'm still waiting delivery to Maryland. Dealer, leasing company, no one knows where it sits waiting for truck to haul ....what's up with that????????