Supplying Ford Supplierbusiness

IHS AUTOMOTIVE Supplying Ford SupplierBusiness

2015 edition supplierbusiness.com

SUPPLYING THE OEMS Ford

Julian Buckley Principal Analyst SAMPLE IHS Automotive | Supplying Ford

Contents

Overview 5 ––Turkey 52 Global market overview 6 ––Thailand 52 Ford Motor Company (FMC) financial overview 7 Internal supply network 53 Modularisation strategy 53 Product Strategy 8 Supplier parks 54 Company history and strategy review 9 Cluster of reference 55 Major model programmes 10 Strategies for manufacturing efficiency 55 ––1. Focus 11 ––2. Fiesta 15 Purchasing Strategy 57 ––3. Escape 18 Purchasing strategy overview 58 ––4. Fusion 20 Levels of vertical integration and outsourcing 58 ––5. F-150 SuperCrew 22 ––ABF Production suppliers 59 ––6. EcoSport 24 ––ABF Non-production companies 60 ––7. Explorer 26 Purchasing organisation 60 ––8. F-150 28 Purchasing offices 61 ––9. F-250/350 Super Duty 29 Key purchasing personnel 62 ––10. Ranger 31 Purchasing budget 63 ––Honourable mention - Transit 33 Supplier Selection 64 Vehicle Platforms 34 Supply base development 65 Platform strategy 35 Major and strategic suppliers 65 Major platforms 35 Supplier evaluation criteria 66 ––1. C1 36 Working with the Ford Motor Company 67 ––2. B2E 36 ––3. PN96/T1 37 Global Sourcing 68 ––4. CD4 38 Policy and plans 69 ––5. D3/D4 38 ––NAFTA 69 ––6. P131/P356/P473 39 ––EMEA 70 ––7. V3 39 ––APAC 71 ––8. T6 39 ––LATAM 72 ––9. CD1-3 40 Pricing Policy 73 ––10. CD-EU 40 Cost reduction strategies 74 Component sharing 40 Raw material price management 74 Volume planning 41 Payment terms 75 Production Strategy 43 Quality Management 76 Production strategy overview 44 Quality level 77 Manufacturing network 45 Quality management systems 77 ––United States 46 Supplier integration into product development 78 ––Germany 48 Management of suppliers and sub-suppliers 78 ––Spain SAMPLE49 ––Mexico 49 Technology 81 ––Brazil 50 Technological positioning 82 ––India 51 Areas of focus 82

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R&D organisation 84 ––OEM level 106 R&D spending 85 Trust 106 Access to supplier technology and process ––OEM level 106 development 85 Pursuit of excellence 106 Approach to alternative fuels, electrification and fuel ––OEM level 106 cells 85 Outlook 106 Special vehicle development 86 ––OEM Level 106 SuRe by region 106 Future Models 87 ––North America 107 ––Europe 107 Interviews 89 ––Asia 107 Hau Thai-Tang, group vice-president, Global SuRe by company size 107 Purchasing, Ford 90 Stephan Presser, Vehicle Engineering Manager, Ford 97 SWOT Analysis and Production Locations 109 SWOT Analysis 110 Supplier Relationship Survey 101 Global footprint 110 Introduction to the SuRe Index 102 Methodology 102 Forward Model Programmes 111 Executive summary 102 Forward Model Programmes 112 Performance review – Ford Motor Company 103 2014 SuRe survey results 103 Major Suppliers to Recent Models 121 ––Top of the ranking: Trust and future potential drive Ford Everest (2015; Rayong, Thailand) 122 harmony 103 Ford F-150 (2014; Dearborn Truck, United States) 123 ––Middle of the ranking: OEMs push cost reduction 104 Ford Ka (2014; Camacari, Brazil) 126 ––Bottom ranking: Cost overrules quality 104 Ford Mondeo (2014; Valencia, Spain) 127 Profit potential 105 Ford Mustang (2014; Flat Rock 1, United States) 130 ––OEM level 105 Ford S-Max (2015; Valencia, Spain) 132 Organization 105

Figures

Figure 1: Global light vehicle production, 2009-2018 6 Platinum trim level 26 Figure 2: Engine installation for a Model T at the Figure 13: The Ford 2015 F-250 Super Duty - with the Highland Park, Detroit plant in 1913 9 four-door crew cab, overall length is 6,680mm 29 Figure 3: Number 0001 of the first-gen Focus RS, which Figure 14: Ford introduced the new Transit in 2014 for is now maintained by Ford UK 11 the 2015MY 33 Figure 4: For the first time, the new Ford Focus RS will Figure 15: The Ford B-MAX has had the B-pillar be available in North America 13 removed to help passenger entry and egress 36 Figure 5: The latest European facelift of the sixth-gen Figure 16: The Kentucky Truck Plant had the largest Fiesta was released in 2014 16 volumes of any Ford plant in the United States over Figure 6: The 2011 Ford Escape Hybrid 18 2014 46 Figure 7: The exterior designSAMPLE of the 2013 Ford Escape Figure 17: Saarlouis Assembly is home to production of is virtually identical to that of the European Ford Kuga the Ford Focus in Europe 48 18 Figure 18: The Ford plant in Valencia, Spain, now Figure 8: The latest Ford Fusion being unveiled at the produces six models 49 2012 Detroit motor show 20 Figure 19: Production of the new Ka started at Figure 9: The Ford F-1 pickup was introduced in 1948 22 Camacari in 2015 51 Figure 10: The 2014 F-150 SuperCrew STX with the Figure 20: Job 1 of the EcoSport at the Ford plant in Sport Package 23 Rayong, Thailand 52 Figure 11: The second EcoSport compact SUV - Ford Figure 21: Screen capture from IntoSite, an application do Brasil was heavily involved with development of which supports sharing of benchmarked build both model versions 24 processes 56 Figure 12: The 2016MY Ford Explorer in the top Figure 22: Hau Thai-Tang, Ford 62

Figure 23: Brigit Behrendt, Ford 62 Figure 30: OEM Supplier Relations - Top of the Ranking Figure 24: The rear quarter window developed by 104 Magna International for the new Mustang 69 Figure 31: OEM Supplier Relations - Middle of the Figure 25: The Ford Lightweight Concept uses a series Ranking 104 of materials to help reduce overall vehicle weight 83 Figure 32: OEM Supplier Relations - Bottom of the Figure 26: The new Ford GT was unveiled at the 2015 Ranking 105 Detroit motor show and should be available in 2017 88 Figure 33: OEM Supplier Relations - North America 107 Figure 27: Hau Thai-Tang, Ford 90 Figure 34: OEM Supplier Relations - Europe 107 Figure 28: The 2015 F-150 range uses a series of Figure 35: OEM Supplier Relations - Asia 107 aluminium parts to reduce vehicle weight 91 Figure 36: Map for Ford global assembly plant Figure 29: The all-new Lincoln MKX was introduced at locations (includes Changan-Ford) 110 the 2015 NAIAS motor show 92

Tables

Table 1: Key financial performance values for Ford Country) 2014 and 2018 31 Motor Company 6 Table 13: FMC Top 10 most-used platforms (by Table 2: Total annual United States vehicle sales Production brand) 2004-2009-2014-2019 35 and US Ford sales, with percentage values (by Sales Table 14: Comparison of annual global Ford sales and Parent) 2010-2018 7 production output (by Sales Parent) 2010-2018 41 Table 3: FMC Top 10 best-selling global models (by Table 15: Ford Ka global production (by Country) 2007- Sales brand, Global nameplate) 2004-2009-2014-2019 10 2017 44 Table 4: Ford Focus global sales (by Global Nameplate) Table 16: Ford Global production plants with annual with segment competitors 2010-2018 17 output (by Sales Parent and Country) 2014-2018 45 Table 5: Ford Escape sales in United States (by Sales Table 17: Suppliers delivering to Camacari, Brazil, for Nameplate) with segment competitors 2010-2018 19 production of Ford Ka (2014) 71 Table 6: Ford Fusion sales in North America (by Sales Table 18: Automotive sales of SuRe Index survey Nameplate) with segment competitors 2010-2018 21 repondents 108 Table 7: Ford Mondeo sales in Europe (by Sales Table 19: SWOT Analysis - Ford Motor 110 Nameplate) with segment competitors 2010-2020 21 Table 20: Suppliers and Components supplied to the Table 8: Ford F-150 SuperCrew sales in North America Ford Everest (2015; Rayong, Thailand) 122 (by Sales Nameplate) with segment competitors 2010- Table 21: Suppliers and Components supplied to the 2020 23 Ford F-150 (2014; Dearborn, United States) 123 Table 9: Ford EcoSport global sales (by Sales Table 22: Suppliers and Components supplied to the Nameplate) with segment competitors 2010-2018 25 Ford Ka (2014; Camacari, Brazil) 126 Table 10: Ford Explorer sales in North America (by Table 23: Suppliers and Components supplied to the Sales Nameplate) with segment competitors 2010-2018 Ford Mondeo (2014; Valencia, Spain) 127 27 Table 24: Suppliers and Components supplied to the Table 11: Ford F-250 and F-350 Super Duty sales in Ford Mustang (2014; Flat Rock 1, United States) 130 North America (by Sales Nameplate) with segment Table 25: Suppliers and Components supplied to the competitors 2010-2018 SAMPLE30 Ford S-Max (2015; Valencia, Spain) 132 Table 12: Top 10 global markets for Ford Ranger (by

Company history and strategy review acquisition by Ford in this buying spree was Land Rover, which was bought from BMW in 2000. What is now the Ford Motor Company (in this report also referred to as Ford, Ford Motor or FMC) was the third Less than a decade after the purchase of Land Rover, Ford automotive enterprise involving Henry Ford, after the started to unload its family of companies in a great brands self-taught engineer had left the Detroit Automobile sell-off. The official line from then CEO Alan Mulally was Company and the Henry Ford Company; the latter went that the American car giant planned to concentrate on on to become the Cadillac Motor Car Company. In 1903 its core brands. While accurate, the whole truth was that Henry Ford, together with 12 investors and 1,000 shares, the collection of companies amassed by FMC was simply incorporated the Ford Motor Company, and in July that costing too much money for even the Detroit OEM to year the new company sold the first Model A. By October, support, particularly in a declining market – a market the new FMC had recorded a profit of USD37,000. which ultimately crashed at the start of the financial crisis in North America and Europe. In 1904, FMC of Canada was incorporated in Windsor, Ontario and in 1911, the first overseas plant started In 2007, 90% of Aston Martin was sold to a consortium operations in Trafford Park, near Manchester in the United of buyers for USD848 million (original purchase price Kingdom. After having introduced the now legendary was not released), with Ford retaining a 10% or USD77 Model T in 1908, the basic elements of the first automotive million interest. In 2008, Jaguar and Land Rover, which assembly line were installed at the Highland Park, had been bought separately for a total of USD5.3 billion, Michigan plant in 1913 and in 1915, FMC reported reaching were sold as Jaguar Land Rover to Indian carmaker Tata the production landmark of one million vehicles. for USD2.8 billion. In 2010 Volvo was sold to Chinese OEM Geely for USD1.8 billion (70% less than the purchase price Figure 2: Engine installation for a Model T at the in 1999). Having been known for its premium versions Highland Park, Detroit plant in 1913 of standard Ford models (such as Crown Victoria versus Grand Marquis), the cull was completed in 2010 when the Mercury brand was discontinued, and in 2014 the final ties with Mazda were broken when the Japanese OEM took full control of the joint-venture Auto Alliance plant in Thailand.

While this liquidation of assets helped Ford weather the recession over 2009 and ’10 – it was the only US-based OEM not to require any emergency loans from the Federal government – it must be with some regret that Ford management now observes the success being enjoyed by each of these companies. After all, the streamlining of business processes across Aston Martin, Jaguar, Land Rover and Volvo was supported by investment from the American OEM, and based on this solid foundation, each is now earning considerable profits for their new owners.

Source: Ford As such, the sell-off was a painful necessity, but as Mulally The company was further expanded in 1922 with the had intended, it put the OEM in the right place to start purchase of the Lincoln MotorSAMPLE Company for USD8 the One Ford programme, now the fundamental driving million, and in 1938 production started under the new force behind the core Ford and Lincoln brands. As what had Mercury brand. FMC remained as these three brands until otherwise been a series of disparate regional divisions were 1990 when Jaguar was purchased for USD2.5 billion; in brought back under a worldwide FMC umbrella, so the 1992 the group purchased a 50% stake in Mazda Motor OEM has gone on to roll out a series of ‘global’ nameplates Manufacturing, where JV locations went on to be operated – apart from local market requirements, largely identical under AutoAlliance International. The family of companies versions of the Focus, Fiesta, Fusion/Mondeo and Transit was further expanded in 1999 with the purchase of Volvo are all now produced at Ford plants around the world. Cars for USD6.45 billion, which was then grouped with This has helped to reduce purchasing costs and further Lincoln, Jaguar and Aston Martin (which Ford took control streamline assembly processes. of in 1994) to form the Premier Auto Group. The final

Behind the global models, the One Ford strategy brings profitability by increasing profit margins, while delivering together technology developments from across various economic, environmental and social sustainability. The areas of expertise, including design, materials, safety, One Ford strategy is specifically aimed at producing best- fuel efficiency, driving dynamics and interior ergonomics. in-class vehicles on global platforms which contribute When applied to a given vehicle, the advances made in each higher margins, while developing a balanced portfolio of the specialist areas are expected to deliver a product of vehicles which deliver leading fuel efficiency in every which will appeal to any customer in any given part of the segment. world. The sharing of platforms has had its downsides – vehicles Together, these advances add up to what is referred to as produced under the premium Lincoln brand have been the company’s ‘global DNA’, delivering vehicles which are accused of being little more than rebadged Ford models unmistakably Ford. Speaking in 2012, Raj Nair, group vice- with additional equipment and luxury interiors. This came president for Global Product Development, highlighted to a head in the early 2000s when Ford elected to introduce how important this is for the successful implementation of a luxury version of the F-150 SuperCrew pickup as the the One Ford strategy: “We all need to be on the same page Lincoln Blackwood – few were convinced and unit sales so that it’s very clear what the processes and deliverables were counted in the hundreds. Some industry observers are and how we communicate our needs with one have gone so far as to say that in selling Jaguar, Ford elected another.” Where Ford had previously developed vehicles to keep the wrong premium brand. To counter this, Ford in regional isolation, this strategy has been scrapped and is now undertaking a major overhaul of the Lincoln model replaced by a system where individual vehicles are designed range with the goal of producing vehicles which have a and developed in a given region with the intention of clear differentiation from their Ford equivalents, in look, rolling out those products on a global basis. equipment and overall performance. This product offensive was kicked off with the introduction of the all-new MKX At the launch of the One Ford system in 2008, Alan SUV at the 2015 NAIAS in Detroit, and there is more Mulally had this to say: “We operate in a fiercely to follow. FMC is also planning to start selling Lincoln competitive global industry. To achieve profitable growth models in China. This should give the brand much needed we have to make best use of our human resources and take exposure to a market which enjoys large cars, with the advantage of every potential economy of scale and best hope that any success will boost flatlining sales. practise we can find.” The end goal of this is to improve

Major model programmes (rankings based on 2014 Sales brand and Global nameplate data from IHS AutoInsight)

Table 3: FMC Top 10 best-selling global models (by Sales brand, Global nameplate) 2004-2009-2014-2019 Global 2004 Global 2009 Global 2014 Global 2019 Nameplate SAMPLENameplate Nameplate Nameplate Restricted View Sample Data available in full version

Source: IHS Automotive)

1. Focus (availability by market). All variants used a transverse- mounted, front-engine, front-wheel drive powertrain with According to data provided by IHS Automotive, the a MacPherson strut front suspension. Rather unusually worldwide best-selling model produced by the Ford Motor for a volume C-segment compact car, the model used Company is the Focus. This model has been the brand’s a multilink rear suspension made up of a combination best-selling vehicle since its European introduction in 1998 wishbone and semi-trailing arm set-up. and North American launch in 1999 (model year 2000). Generally, global output has been between 800,000 and The rear multilink set-up on the Focus was marketed as the 900,000 units, except in 2004 and 2009, when output Control Blade suspension, where the ‘blades’ in question fell below 800,000 cars – this drop coincides exactly with were essentially flexible trailing arms located on either the launch of new versions the following year. In 2012, side of the suspension package. In the Focus, the pressed worldwide output of the Ford Focus exceeded one million steel trailing arms have flat edges to allow some flex; in units for the first time and numbers have remained around other applications (such as the Fusion), the trailing arms this level to date, although they are forecast to slide below have rolled edges to limit flex. In addition, the system 800,000 units in 2017 before a new model is introduced the separated the individual components used for vehicle following year, prompting a related climb in sales. handling and ride quality – separating the shock absorbers and springs resulted in a smaller overall package, which in The first-generation CW170 Focus was introduced as turn delivered more rear cabin and luggage space. To reduce the replacement for the Ford Escort, which after being costs, the hub carrier was integrated into the trailing arms, launched in Europe in 1968 had gone on to be produced replacing a pair of longitudinal locating rods and a high- around the world in various formats and bodystyles – the value cast knuckle. The set-up was still more expensive last examples of the Escort were built in 2004. The all- than the semi-independent torsion beam arrangement new Focus delivered a series of innovative features, but used by many segment competitors, but the combination arguably none was more eye-catching than the ‘New Edge’ of excellent body control and reduced road noise won over exterior design, which featured body panels with sharp both customers and the motoring press. crease lines combined with smooth surfaces. Swept back headlights gave an aerodynamic look, while the high- The Focus was offered with a variety of four-cylinder mounted rear light cluster was used to mask the otherwise petrol engines but just a single turbodiesel. Petrol variants substantial D-pillar. The design language was carried over included the 1.8- and 2.0-litre Zetec-R units shared with to the interior, where a sweeping arc on the instrument the Ford Mondeo, while 1.4- and 1.6-litre engines were panel (IP) was used to delineate the centre stack and shared with the Fiesta and its coupé derivative, the Puma. analogue instrumentation. A Zetec Rocam version which could use either petrol or ethanol in any percentage combination was offered in Figure 3: Number 0001 of the first-gen Focus RS, which is Brazil. The diesel versions originally used the 8v turbo now maintained by Ford UK Endura DI with direct injection and an intercooler – this was later replaced by a Duratorq TDCI. The standard transmission was a five-speed manual, but a four-speed automatic was available as an option.

In addition to the standard models, there were also two high-performance versions of the first Focus, both introduced following the mid-life facelift of the first- generation model – in addition to other updates, these SAMPLEversions are easy to identify as the indicators (turn signals) were relocated from the front bumper into the headlight cluster. Launched in 2002, the first of these was the ST170 (SVT in North America), where ‘ST’ stands for ‘Sports Technologies’ and the numerals refer to the increased power output of the 2.0-litre DOHC 16v Duratec engine. This was reworked by engine specialists Cosworth and featured a series of upgrades, including a high-flow Source: Julian Buckley aluminium cylinder head, a dual-stage intake manifold The first-generation Focus was offered as a three- and five- and variable valve timing. The engine was driven via a door hatchback, a four-door saloon and a station wagon Durashift six-speed manual gearbox supplied by Getrag.

Although originally offered as a three-door hatch, a wagon Like the first Focus, the second-gen model was offered as a version of the ST170 was later introduced. hatchback, wagon and saloon, but in addition to these the new car served as the basis for two new variants. In 2003, The second performance version was the Focus RS (Rallye Ford launched the C-MAX MPV. The model featured many Sport (English) or RennSport (German). In this high- positive attributes of the Focus, including the Control performance three-door hatch, a Garrett turbocharger was Blade rear suspension and the quality interior, but it was added to the 2.0-litre DOHC 16v Duratec engine increased also very late to the MPV party – by comparison, the first output to 212bhp (this was evidently a base figure and Renault Scenic was launched in 1997. In addition, the some examples had higher power). The engine was driven C-MAX was only available with seating for five, a major via a high-performance five-speed manual transmission. drawback when most competitors offered seven seats. Ford produced precisely 4,501 units of the RS through 2002 and ’03, but even when fitted with a mechanical limited The second new variant of the Focus was the Coupe- slip differential supplied by Quaife and uprated AP racing Cabriolet. Introduced in 2006, the car featured a brakes, the all-or-nothing turbo performance gave the folding steel roof which combined the open-top fun of car considerable torque steer and generally compromised a convertible with the security of a coupe. While the handling on all but the smoothest roads. chassis was more stable than other comparable models, most notably the Peugeot 307CC and Renault Megane CC, The first-generation Focus was a remarkable car. The model the roof and its electric motors added some considerable served to set a new benchmark for future C-segment weight – fitted with the 2.0-litre TDCI engine the car hatchbacks (including later versions of the Volkswagen tipped the scales at 1,626kg. On the positive side, the Golf), combining exterior design, interior ergonomics and Coupe-Cabriolet was one of the few convertibles to offer driving dynamics into an affordable package. Such was the seating for four passengers, a feature which grouped it with quality of the Focus that it represents a key turning point some rare company, such as the Bentley Continental GT in what customers expected from their vehicles, which in Convertible. essence set the future trajectory of all cars in this segment through to the present day. Petrol engines for the second-gen Focus ranged from upgraded versions of the 1.4- and 1.6-litre Zetec engines Automotive history is littered with vehicles which, after used in the first car, through to the new 1.8- and 2.0-litre delivering a ground-breaking first-generation design, failed Duratec engines. Diesels included the 1.6-, 1.8- and 2.0-litre to achieve the same level of success with the replacement Duratorq TDCI engines. These were driven through model. Introduced in 2004, the second-generation Focus either five- or six-speed manual transmissions or a four- was one of these models. Featuring a watered-down speed automatic. Yet with the introduction of the high- rework of the original New Edge design, the results were performance Focus ST in late 2005, Ford ignored these disappointing, to say the least. Yet while the exterior was four-cylinder engines in favour of a five-cylinder 2.5-litre overtly conservative, improvements were made in other turbo engine used by Volvo. Rated at 225bhp, this was areas. Using an increased percentage of high-strength more powerful than both the first-gen ST and RS, but easier steel, the chassis was 10% stiffer then the out-going car. to drive due to the smoother, low-pressure turbo. Upgrades Revised front and rear subframes resulted in improved for the new ST included stiffer springs, a new strut brace NVH (noise, vibration and harshness) characteristics, and a thicker rear anti-roll bar. while thicker glass and double seals on the doors helped to reduce cabin noise. While the IP lost its New Edge flair, After stating that there would not be an RS version of the upgraded materials and improved fit and finish delivered a second-generation car, Ford launched exactly this model far superior product. in 2009. This new high-performance car used a heavily SAMPLErevised version of the same five-cylinder 2.5-litre engine in The second Focus was larger than the out-going model, the ST, including uprated pistons, camshafts, turbocharger with the wheelbase increasing from 2,615 to 2,640mm and intercooler. This resulted in a power output of 301bhp and the overall length of the hatchback increasing from and 325lb/ft of torque. To control vehicle weight, which 4,175 to 4,340mm. Although some of this length can be ultimately totalled 1,457kg, Ford opted against using a attributed to a larger front crumple zone, the interior was four-wheel drive powertrain. Without AWD to help reduce larger in every area, including the rear passenger seats and torque steer, Ford introduced the RevoKunckle system, a cargo area. This increase in size also added weight, and the new addition to the standard MacPherson strut assembly. new model was approximately 100kg heavier than the out- In combination with the Quaife LSD, the RevoKnuckle going car. could compensate for the asymmetrical power distribution across uneven length driveshafts by reducing the distance

between the wheel centre and the steering axis. The The latest Focus is effectively the same size as the out- RevoKnuckle required additional engineering and added going car, with a wheelbase measuring 2,648mm (+8mm) expense, but despite being 100bhp more powerful than the and an overall length of 4,358mm (+18mm). While still original Focus RS, the addition made power in the second the same size, the new Focus sees the electro-hydraulic version far more accessible. steering of the previous version replaced with a full electric power steering set-up, which despite the negative After a mid-life facelift that used the ‘Kinetic’ design to reputation actually delivers reasonably good driver improve the look of the second-gen Focus, Ford went on feedback. Other new features include a torque vectoring to introduce the most recent version of the Focus over Dynamic Cornering Control system which lightly brakes 2011. Where the first two model versions were largely the inside wheels to improve high-speed cornering. region-specific, the third generation vehicle became one of the Ford’s global vehicles, with all Focus production sites Repeating the now familiar pattern, in 2012 Ford around the world producing the same model with only introduced the third-generation ST. This version uses a minor local differences. With the withdrawal of the three- high-performance turbocharged version of the standard door version, the range now comprises the five-door hatch, four-cylinder 2.0-litre DOHC 16v engine, tuned to produce wagon and four-door saloon (primarily for North America 247bhp. This is more power than developed by the and China). Variants include a new ST (and forthcoming previous five-cylinder engine, with an approximate 20% RS), together with a new version of the C-MAX MPV. improvement in fuel economy, a key factor as the car will Despite the loss of the three-door hatch, it was thought be rolled out on a global basis. The worldwide marketing possible that this could be reintroduced using the famous has also forced a simplification of the equipment list, Capri nameplate, but with the official European launch of resulting in a six-speed manual as the only available the Mustang in 2015, this is now considered unlikely. transmission, and the suspension is carried over from the standard car with only minor changes, including stiffer Based on exterior changes, the third-gen Focus looks like springs and dampers. The model also does without the the car which should have succeeded the first-gen model. RevoKnuckle system, using instead an electronic Torque A trapezoidal intake is complemented by swept-back Steer Compensation system which actively counters the headlights to create a mildly aggressive front facia. The problem. extended wheel arches remain, although with a smoother transition to the body. Narrower D-pillars have allowed Figure 4: For the first time, the new Ford Focus RS will be the rear light clusters to be moved into the rear wings, or available in North America fenders. Inside the car, the redesigned IP features a centre stack with a prominent ‘bull horn’ extension; despite upgraded materials, it is still not as well conceived as the instrument panel in the VW Golf, but better than most segment competitors.

The latest version was launched with a series of four- cylinder EcoBoost petrol and Duratorq TDCI diesel engines; following a mid-life facelift in 2014, the engine range was further extended with the addition of the all- new four-cylinder 1.5-litre Duratorq TDCI. In advance of this, in 2012 Ford elected to transplant the three-cylinder 1.0-litre 12v turbo direct injection EcoBoost engine from the Fiesta into the Focus. OfferedSAMPLE with two power outputs, 98 and 123bhp (respectively using five- and six-speed manual transmissions), the engine only weighs 97kg – approximately 30kg less than the four-cylinder petrol Source: Ford 1.6 Ti-VCT. On the down side, the economy this engine At the 2015 Geneva motor show, Ford unveiled the new, promises is compromised by total vehicle weight, which third-generation Focus RS. Based on the facelifted model is still a substantial 1,276kg. While engine performance (introduced at the same event), the variant carries over is good, vehicle weight plays havoc with the official such features as the pronounced trapezoidal radiator grille 55mpg claim, and anything over mid-throttle will see fuel of the ST, but with narrower swept-back headlight clusters. consumption fall into the mid-30s. The new RS shares the four-cylinder 2.3-litre Ecoboost turbo engine with the European Mustang, although the

version in the RS has a low-inertia twinscroll turbo and speed manual transmission. larger compressor and intercooler. Power output is rated in excess of 320bhp, possibly reaching 340bhp. Due to this This is likely to be the last version of the Focus in its power increase and to improve handling performance, current state. Speaking with IHS SupplierBusiness in Ford has elected to replace the front-wheel drive of the November 2014, Stephan Presser, vehicle engineering previous RS with an all-wheel drive (AWD) powertrain. manager for the Focus in Europe, highlighted that while The AWD set-up includes twin electronically-controlled the model has undergone a series of key changes, it is based clutch packs located on either side of the rear drive unit, on the same fundamental chassis and (power upgrades which effectively act as a limited slip differential while aside) uses the same powertrain set-up. As such, it can be also managing the front-rear power split. Based on onboard expected that the next Focus, which has a forecast launch sensors, power is delivered to the outside wheels to help date of late 2017 or early 2018, will be an all-new model with high-speed cornering. Ford states this can virtually from the ground up, possibly set up to offer a hybrid version eliminate understeer. The RS features a short-throw six- using technology from the Fusion/Mondeo twins.

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