Ford is investing $2 billion to reinvent its Louisville Assembly Plant, transforming it into a next-gen electric vehicle hub that will debut in 2027 with a $30,000 mid-sized pickup. The upgrade isn’t just about new models, it’s a total rethink of the century-old moving assembly line pioneered by Henry Ford.
The new “universal production system” replaces the single conveyor with a three-branch assembly tree, allowing vehicles to be built with 20% fewer parts and 15% faster. Ford’s redesigned EV platform will use large single-piece aluminum castings and lithium iron phosphate batteries from its upcoming $3B BlueOval Battery Park in Michigan.
The first model, roughly the size of a Ford Maverick but roomier inside, will be built with fewer cooling hoses, fasteners, and dock stations. The changes will reduce Louisville’s workforce from 2,808 to 2,200, but Ford says it has worked closely with the United Auto Workers to ensure buy-in and improve ergonomics.
Ford CEO Jim Farley calls it a “bet” on making affordable U.S.-built EVs competitive with China, even as the company’s EV division faces falling sales and steep losses. The overhaul, developed by a California-based skunkworks team led by ex-Tesla talent, could set a new benchmark for automotive manufacturing.
