Ford Motor Company is fundamentally restructuring its manufacturing process, moving away from the traditional linear assembly line it pioneered over a century ago. The automaker announced it is adopting the “Universal EV Production System” to manufacture a forthcoming, affordable midsize electric pickup truck, expected to launch next year with a target price of approximately $30,000.
Instead of a single, continuous conveyor belt, Ford’s new system utilizes an “assembly tree” design. In this model, the assembly process is split into three independent branches where sub-assemblies—including front and rear unicastings and structural battery packs—are completed simultaneously before being joined at the final stage. According to Bryce Currie, Ford’s vice president of Americas Manufacturing, this approach aims to reduce complexity, eliminate unnecessary parts, and improve ergonomic conditions for plant workers.
The shift is closely tied to Ford’s new Universal EV Platform, which the company claims significantly boosts efficiency. Compared to current manufacturing standards, vehicles built on this platform require 20% fewer parts, 25% fewer fasteners, and 40% fewer workstations. Ford anticipates the assembly process for the new truck will be 15% faster than current production methods at its Louisville Assembly Plant.
Doug Field, Ford’s chief EV, digital and design officer, noted that the project applies first-principles engineering to reach mass-market affordability. The new electric truck will feature a zonal electrical architecture and lithium iron phosphate (LFP) batteries, which the company says will enhance durability and interior space while lowering total ownership costs.