At Ford's assembly plant at Camaçari in north-eastern Brazil, instrument panels made by Visteon in one part of the factory are carried on overhead conveyors to be lowered neatly into car bodies passing by underneath.
The plant makes three models – Ford's Fiesta hatchback, Fiesta saloon and EcoSport sport utility vehicle – each to various specifications, all passing together along the same assembly line, all receiving components from Ford itself and from 13 suppliers inside the final assembly building and a further 11 suppliers in other parts of the 4.7m square metre site.
“This is more than just-in-time,” says Cícero Melo, plant manager. “It's sequential delivery. Each component is made for a specific car on the line. By making several different models simultaneously we can maximise efficiency and supply the mix of products the market demands.”