Flat Rock Assembly Plant

{{Short description|American auto assembly plant in Michigan}} {{Use American English|date=July 2022}} {{Use mdy dates|date=November 2023}} {{Infobox building | name = Flat Rock Assembly Plant | native_name = | native_name_lang = | logo = | logo_size = | logo_alt = | logo_caption = | image = Auto Alliance International plant Flat Rock Michigan.JPG | image_size = | image_alt = | image_caption = The plant in 2010 | pushpin_map = | pushpin_map_alt = | map_caption = | pushpin_mapsize = | pushpin_label = | pushpin_relief = | former_names = {{Plainlist| * Michigan Casting Center (1972–1981) * Mazda Motor Manufacturing USA (1987–1992) * AutoAlliance International (1992–2012) }} | alternate_names = | etymology = | status = | cancelled = | topped_out = | building_type = | architectural_style = | classification = Factory | location = | address = 1 International Drive | location_city = [[Flat Rock, Michigan]] | location_country = United States | coordinates = {{Coord|42|06|25|N|83|14|52|W|region:US_type:landmark|display=inline,title}} | altitude = | current_tenants = | namesake = | groundbreaking_date = | construction_start_date = | topped_out_date = | completion_date = | opened_date = January 1972 | inauguration_date = | relocated_date = | renovation_date = | closing_date = | demolished_date = | cost = | ren_cost = | client = | owner = [[Ford Motor Company]] | landlord = | affiliation = | height = | architectural = | tip = | antenna_spire = | roof = | top_floor = | observatory = | diameter = | circumference = | weight = | other_dimensions = | structural_system = | material = | size = | floor_count = | floor_area = | elevator_count = | grounds_area = | architect = | architecture_firm = | developer = | engineer = | structural_engineer = | services_engineer = | civil_engineer = | other_designers = | quantity_surveyor = | main_contractor = | awards = | designations = | known_for = | ren_architect = | ren_firm = | ren_engineer = | ren_str_engineer = | ren_serv_engineer = | ren_civ_engineer = | ren_oth_designers = | ren_qty_surveyor = | ren_contractor = | ren_awards = | seating_type = | seating_capacity = | number_of_rooms = | parking = | url =  | embed = | embedded = | references = | footnotes = }}

The '''Flat Rock Assembly Plant''' is a [[Ford Motor Company]] automobile assembly plant located at 1 International Drive in [[Flat Rock, Michigan]], within [[Metro Detroit]]. The facility covers 2,900,000 square feet (270,000 m²) of production space and employs approximately 3,510 hourly workers and 140 salaried workers. It currently manufactures the [[Ford Mustang]].

The plant was originally built by Ford as the '''Michigan Casting Center''' in 1972, but it closed in 1981. In 1987, [[Mazda]] took over the site and established its first U.S. manufacturing facility, '''Mazda Motor Manufacturing USA''' . In 1992, [[Ford Motor Company|Ford]] purchased a stake in the plant, and it was reorganized as the [[joint venture]] '''AutoAlliance International'''.<ref>{{cite web |title=AutoAlliance International, Inc. |url=https://www.hollingsworthllp.com/case-study/autoalliance-international-inc/ |access-date=August 28, 2025}}</ref> Mazda ended production there in 2012, after which the facility returned to full Ford ownership.<ref>{{cite news |last=Ohnsman |first=Alan |date=August 24, 2012 |title=Mazda Ends 20-Year U.S. Manufacturing Run |url=https://www.bloomberg.com/news/articles/2012-08-24/mazda-ends-20-year-u-s-manufacturing-run |access-date=August 28, 2025 |work=Bloomberg}}</ref>

== History ==

=== Michigan Casting Center (1972–1981) === [[File:FORD MOTOR COMPANY'S NEW CASTING PLANT AT FLAT ROCK - NARA - 549726 LEVELS.tif|thumb|right|Casting plant, 1973.]] The Michigan Casting Center (MCC) opened in January 1972 following three years of construction and Ford's largest single capital investment at the time. It was considered one of the most technologically advanced [[Metal casting|casting facilities]] in the world.<ref>{{cite web |date=January 20, 1972 |title=Ford Opens a Giant Casting Centre |url=https://news.google.com/newspapers?id=6GwtAAAAIBAJ&sjid=4YkFAAAAIBAJ&dq=michigan%20casting%20center%20opened&pg=2695%2C4464032 |access-date=April 11, 2013 |work=Schenectady Gazette}}</ref> Despite the investment, the facility was plagued by labor disputes, workplace injuries,<ref>{{cite web |date=November 1, 1973 |title=Detroit plant |url=https://news.google.com/newspapers?id=jTQ_AAAAIBAJ&sjid=d1EMAAAAIBAJ&dq=michigan%20casting%20center%20opened&pg=1110%2C375353 |access-date=April 11, 2013 |work=Windsor Star}}</ref> and declining demand for the V8 engine blocks it produced. Ford closed the plant in 1981.<ref>{{cite web |date=September 15, 1981 |title=Ford Will Close Unit in Flat Rock |url=https://www.nytimes.com/1981/09/15/business/ford-will-close-unit-in-flat-rock.html |access-date=April 11, 2013 |work=The New York Times}}</ref><ref>{{cite web |date=December 3, 1984 |title=Flat Rock Mayor Hopeful |url=https://news.google.com/newspapers?id=IFwiAAAAIBAJ&sjid=AasFAAAAIBAJ&dq=michigan%20casting%20center%20closed&pg=1337%2C2901659 |access-date=April 11, 2013 |work=The Argus-Press}}</ref>

On January 25, 1979, a worker, [[Robert Williams (robot fatality)|Robert Williams]], was killed by an [[industrial robot]] arm. He was the first known person to be killed by a robot.<ref name="KR-832">{{cite news |date=August 11, 1983 |title=$10 Million Awarded To Family Of U.S. Plant Worker Killed By Robot |url=https://news.google.com/newspapers?id=7KMyAAAAIBAJ&sjid=Bu8FAAAAIBAJ&pg=3301,87702 |access-date=June 8, 2018 |newspaper=Ottawa Citizen |page=14}}</ref>

=== Mazda Motor Manufacturing USA (1987–1992) === In 1985, [[Mazda]] began constructing a new assembly plant on the site of the former MCC. Production at Mazda Motor Manufacturing USA (MMUSA) began in September 1987 with the [[Mazda MX-6]] and [[Ford Probe]] coupes.<ref>{{cite web |last=Manji |first=James F. |date=June 1, 1988 |title=Building cars with Mazda quality. (Mazda Motor Manufacturing USA Corp.) |url=http://business.highbeam.com/438319/article-1G1-6458174/building-cars-mazda-quality |url-status=dead |archive-url=https://web.archive.org/web/20131210021509/http://business.highbeam.com/438319/article-1G1-6458174/building-cars-mazda-quality |archive-date=December 10, 2013 |access-date=April 11, 2013 |work=Automation |publisher=Penton Business Media, Inc.}}</ref> By 1991, the plant employed about 3,600 workers, including 250 Japanese employees.<ref name="CohenAdjust2">Cohen, Sharon. "[https://news.google.com/newspapers?nid=1346&dat=19911225&id=g7ROAAAAIBAJ&sjid=J_wDAAAAIBAJ&pg=1797,3219645 Metamorphosis in Motown]." ''Associated Press'' at ''The Ledger''. December 26, 1991. p. 7C. Retrieved from [[Google News]] on November 19, 2013.</ref>

=== AutoAlliance International (1992–2012) === On April 15, 1992, Ford repurchased a 50% stake in the facility, creating a joint venture with Mazda. The plant was renamed AutoAlliance International on July 1, 1992.<ref name="Mazda20082">{{cite web |date=July 23, 2008 |title=North American All-New Mazda6 Production Begins at AutoAlliance International |url=http://www.mazda.com/publicity/release/2008/200807/080723.html |access-date=April 11, 2013 |work=Mazda}}</ref> The factory began producing all U.S. models of the [[Mazda 626]] in 1993. The [[Mercury Cougar]] (1998–2002) and the North American [[Mazda6]] (2003–2012) were also assembled there. [[Ford Mustang]] production was added in 2005.

During this period, [[Deepak Ahuja]] served as Chief Financial Officer of the joint venture.<ref name="star-201111112">{{cite magazine |last=Star |first=Leanne |date=November 11, 2011 |title=Alumni profile: Deepak Ahuja |url=https://www.mccormick.northwestern.edu/magazine/fall-2011/PDF/alumni-profile-deepak-ahuja.pdf |url-status=dead |archive-url=https://web.archive.org/web/20160902230003/http://www.mccormick.northwestern.edu/magazine//fall-2011/PDF/alumni-profile-deepak-ahuja.pdf |archive-date=September 2, 2016 |access-date=September 18, 2018 |magazine=McCormick Magazine |page=42 |issue=Fall 2011}}</ref>

The last Mazda6 rolled off the line on August 24, 2012, ending Mazda production in the United States and concluding the 20-year joint venture. Mazda shifted Mazda6 production back to its [[Hofu (Mazda factory)|Hofu factory]] in Japan and opened a new factory in [[Salamanca, Guanajuato|Salamanca]], Mexico.<ref>{{Cite web |last=Apostolides |first=Zoe |date=2014-02-26 |title=Mazda officially opens Salamanca plant in Mexico |url=https://www.automotivelogistics.media/inbound-logistics/mazda-officially-opens-salamanca-plant-in-mexico/209507 |access-date=2025-08-28 |website=Automotive Logistics |language=en-GB}}</ref>

=== Flat Rock Assembly Plant (since 2012) === On September 10, 2012, Ford assumed full control of the facility, renaming it the Flat Rock Assembly Plant. The company spent $555 million to retool the plant for production of the 2013 [[Ford Fusion (Americas)|Ford Fusion]].<ref name="media.ford.com2">{{cite web |title=Ford Opens New Era at Flat Rock Assembly Plant, Source of 1,200 New Jobs and U.S. Production Home of All-New Fusion |url=http://media.ford.com/article_display.cfm?article_id=37067 |url-status=dead |archive-url=https://web.archive.org/web/20121112164832/http://media.ford.com/article_display.cfm?article_id=37067 |archive-date=November 12, 2012 |access-date=November 25, 2012}}</ref>

In July 2015, Ford confirmed that the 2017 [[Lincoln Continental]] would be built at Flat Rock starting in 2016.<ref>{{cite web |date=July 15, 2015 |title=Lincoln Continental to be made at Ford Flat Rock plant |url=http://www.freep.com/story/money/cars/ford/2015/07/15/ford-confirms-lincoln-continental-production-flat-rock-michigan-plant/30197835}}</ref> In January 2017, Ford announced plans to build an electric SUV by 2020 and an autonomous vehicle for commercial ride-hailing by 2021, both to be produced at the facility.<ref>{{cite web |title=Ford Adding Electrified F-150, Mustang, Transit by 2020 in Major EV Push; Expanded U.S. Plant to Add 700 Jobs to Make EVs, Autonomous Cars |url=https://media.ford.com/content/fordmedia/fna/us/en/news/2017/01/03/ford-adding-electrified-f-150-mustang-transit-by-2020.html |website=Ford Media Center}}</ref>

Declining sales of the Mustang and especially the Continental led Ford to cut the plant’s output from two shifts to one in late 2018.<ref>{{cite web |last1=Willems |first1=Steph |date=November 28, 2018 |title=Ford Cuts Factory Shifts, Comes Out Looking Like the Golden Child |url=https://www.thetruthaboutcars.com/2018/11/ford-cuts-factory-shifts-comes-out-looking-like-the-golden-child/ |access-date=October 5, 2019 |website=The Truth About Cars}}</ref> More than 1,000 workers were laid off in early 2019, including nearly 500 temporary employees.<ref>{{cite news |last1=Howard |first1=Phoebe Wall |date=February 5, 2019 |title=Flat Rock shift cut leaves more than 400 Ford workers in jeopardy |url=https://www.freep.com/story/money/cars/ford/2019/02/04/ford-layoffs-flat-rock/2771265002/ |access-date=October 5, 2019 |work=Detroit Free Press}}</ref><ref>{{cite news |last1=Laing |first1=Keith |date=February 4, 2019 |title=Ford: Flat Rock workers to be offered job transfers |url=https://www.detroitnews.com/story/business/autos/ford/2019/02/04/ford-says-laid-off-full-time-flat-rock-workers-will-be-offered-other-jobs/2771720002/ |access-date=October 5, 2019 |work=The Detroit News}}</ref>

In March 2019, Ford revised its plans, delaying production of a battery-electric vehicle at Flat Rock.<ref>{{cite news |last1=Thibodeau |first1=Ian |title=Ford Flat Rock plant shifts to electric vehicles, Mustang |url=https://www.detroitnews.com/story/business/autos/ford/2019/03/20/ford-flat-rock-plant-shifts-electric-vehicles-mustang/3221693002/ |access-date=October 5, 2019 |work=The Detroit News}}</ref>

== Products == === Current === *[[Ford Mustang]] (2005–present)<ref>{{cite web|last=Henkel|first=Karl|date=April 9, 2013|title=Ford begins hiring 1,400 for Flat Rock plant|url=http://www.detroitnews.com/article/20130409/AUTO0102/304090436/1121/auto01/Ford-begins-hiring-1-400-for-Flat-Rock-plant|access-date=April 11, 2013|work=Detroit News}}{{dead link|date=December 2017|bot=InternetArchiveBot|fix-attempted=yes}}</ref>

=== Past === *[[Lincoln Continental]] (2017–2020)<ref>{{cite news|title=New Lincoln Continental will be Michigan made|url=https://www.usatoday.com/story/money/cars/2015/07/15/ford-lincoln-contenental/30208199/|newspaper=USA Today|date=July 15, 2015|access-date=July 16, 2015}}</ref> *[[Ford Fusion (Americas)|Ford Fusion]] (2013–2016)<ref name="media.ford.com">{{cite web |title=Ford Opens New Era at Flat Rock Assembly Plant, Source of 1,200 New Jobs and U.S. Production Home of All-New Fusion | Ford Motor Company Newsroom |url=http://media.ford.com/article_display.cfm?article_id=37067 |url-status=dead |archive-url=https://web.archive.org/web/20121112164832/http://media.ford.com/article_display.cfm?article_id=37067 |archive-date=November 12, 2012 |access-date=November 25, 2012}}</ref> *[[Mazda 6]] (2003–2012)<ref>{{cite web|last=Pope|first=Byron|date=September 10, 2012|title=Ford Expects Fusion Output to Exceed Mazda6 at Flat Rock|url=http://wardsauto.com/auto-makers/ford-expects-fusion-output-exceed-mazda6-flat-rock|url-status=dead|archive-url=https://web.archive.org/web/20130902094456/http://wardsauto.com/auto-makers/ford-expects-fusion-output-exceed-mazda6-flat-rock|archive-date=September 2, 2013|access-date=April 11, 2013|work=Wards Auto}}</ref> *[[Mercury Cougar]] (1999–2002) *[[Mazda 626]] (1990–2002) *[[Ford Probe]] (1989–1997) *[[Mazda MX-6]] (1988–1997)

== References == {{Portal|Michigan|Cars}} {{reflist}}

== Further reading == * Fucini, Joseph J. ''Working for the Japanese''. [[Simon & Schuster]], June 30, 2008. {{ISBN|1439106487}}, 9781439106488. **The section starting at p. 101 discusses [[History of the Japanese in Metro Detroit|Japanese employees]] from [[Mazda]] working in the Flat Rock Assembly Plant along with Americans in the 1980s.

[[Category:Ford factories]] [[Category:Mazda factories]] [[Category:Former joint ventures]] [[Category:Motor vehicle assembly plants in Michigan]] [[Category:Buildings and structures in Wayne County, Michigan]] [[Category:1972 establishments in Michigan]]