2005 Mustang Launch Celebration: AAI Plant Tour
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More from This Show:
Dinner at La Shish | Camouflaged 2005 Mustangs | AAI Plant Tour | 2005 Mustang Launch Celebration | MRT Headquarters | Detroit Tigers Game | Ford World Headquarters | Edsel Ford Estate

Before the Launch Celebration I got to tour the new Mustang plant. The facility is awesome, and I'll never forget watching those Mustangs being built. John LoPorto, 2005 Mustang Launch Coordinator, was the tour guide. There were five topless Mustangs in different stages of production throughout the plant. Since Ford hasn't officially announced plans to built a convertible, we were asked to ignore the "defective roofless cars."

Inside and Around the Plant
Scott Hoag, Me,
and Tony Alonso
 Eating Lunch With
Hau Thai-Tang
 2005 Mustan
 Launch Coordinator
John LoPorto and Me

2005 Mustang Production
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AutoAlliance's Stamping Operations has 38 new stamping dies that stamp 52 critical Mustang parts. Operators on the skillet conveyor inspect vehicles as they install parts. Christina Slomba installs a door latch to the interior door frame of a 2005 Mustang. Mustang bumpers are pressed and painted in the plastic mold shop before being transported to the assembly line for just-in-time delivery. A new enamel spray process paints each car with little overspray, reducing paint waste.
Quality inspector Larry Chapman inspects Mustang sheet metal fit in the plant's Body Dimensional Control area. AutoAlliance's skillet conveyor allow employees like Nikole Mooney to program the working height of the body for her workstation. This reduces ergonomic concerns caused by reaching overhead, excessive bending and walking. Brian Harvey and Ted Szenborn review instructions before operating the training robot. Operators Shirley Cosby and Steven Lingar guide the engine as it is installed into the new Mustang. AutoAlliance's Technical Training Laboratory
Quality inspectors Larry Chapman and Sherry Casey verify gap measurements on the new Mustang in the Body Dimensional Control area. Operators remove doors from assembly vehicles to provide easier access for interior parts installation. The doors are sent on a separate conveyor to a sub-assembly area where door windows, weather stripping, door handles and other parts are installed. The doors then reunite with the correct vehicle body later in the production process.
Mustang body panels are welded together on the line by weld robots. Windshield is prepared for installation on the 2005 Mustang. Paint inspector Zowanna Quin inspects the newly painted Mustang to ensure a world-class finish. Thomas Dance drives a brand-new 2005 Mustang off the line. Francisco Liwag, a plastics paint inspector, ensures a perfect finish on bumpers.
UAW worker Valerie Stewart completes a final inspection of a 2005 Mustang as the all-new model is launched at its new home, AutoAlliance International. A new Mustang undergoes testing Sharon Ferris and Luann Peacock inspect the car's interior after water testing.