# Flat Rock Assembly Plant

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American auto assembly plant in Michigan

Flat Rock Assembly Plant The plant in 2010 Interactive map of the Flat Rock Assembly Plant area Former names Michigan Casting Center (1972–1981) Mazda Motor Manufacturing USA (1987–1992) AutoAlliance International (1992–2012) General information Classification Factory Location 1 International Drive, Flat Rock, Michigan, United States Coordinates 42°06′25″N 83°14′52″W / 42.10694°N 83.24778°W / 42.10694; -83.24778 Opened January 1972 Owner Ford Motor Company

The **Flat Rock Assembly Plant** is a [Ford Motor Company](/source/Ford_Motor_Company) automobile assembly plant located at 1 International Drive in [Flat Rock, Michigan](/source/Flat_Rock%2C_Michigan), within [Metro Detroit](/source/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](/source/Ford_Mustang).

The plant was originally built by Ford as the **Michigan Casting Center** in 1972, but it closed in 1981. In 1987, [Mazda](/source/Mazda) took over the site and established its first U.S. manufacturing facility, **Mazda Motor Manufacturing USA** . In 1992, [Ford](/source/Ford_Motor_Company) purchased a stake in the plant, and it was reorganized as the [joint venture](/source/Joint_venture) **AutoAlliance International**.[1] Mazda ended production there in 2012, after which the facility returned to full Ford ownership.[2]

## History

### Michigan Casting Center (1972–1981)

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 [casting facilities](/source/Metal_casting) in the world.[3] Despite the investment, the facility was plagued by labor disputes, workplace injuries,[4] and declining demand for the V8 engine blocks it produced. Ford closed the plant in 1981.[5][6]

On January 25, 1979, a worker, [Robert Williams](/source/Robert_Williams_(robot_fatality)), was killed by an [industrial robot](/source/Industrial_robot) arm. He was the first known person to be killed by a robot.[7]

### Mazda Motor Manufacturing USA (1987–1992)

In 1985, [Mazda](/source/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](/source/Mazda_MX-6) and [Ford Probe](/source/Ford_Probe) coupes.[8] By 1991, the plant employed about 3,600 workers, including 250 Japanese employees.[9]

### 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.[10] The factory began producing all U.S. models of the [Mazda 626](/source/Mazda_626) in 1993. The [Mercury Cougar](/source/Mercury_Cougar) (1998–2002) and the North American [Mazda6](/source/Mazda6) (2003–2012) were also assembled there. [Ford Mustang](/source/Ford_Mustang) production was added in 2005.

During this period, [Deepak Ahuja](/source/Deepak_Ahuja) served as Chief Financial Officer of the joint venture.[11]

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 factory](/source/Hofu_(Mazda_factory)) in Japan and opened a new factory in [Salamanca](/source/Salamanca%2C_Guanajuato), Mexico.[12]

### 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](/source/Ford_Fusion_(Americas)).[13]

In July 2015, Ford confirmed that the 2017 [Lincoln Continental](/source/Lincoln_Continental) would be built at Flat Rock starting in 2016.[14] 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.[15]

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.[16] More than 1,000 workers were laid off in early 2019, including nearly 500 temporary employees.[17][18]

In March 2019, Ford revised its plans, delaying production of a battery-electric vehicle at Flat Rock.[19]

## Products

### Current

- [Ford Mustang](/source/Ford_Mustang) (2005–present)[20]

### Past

- [Lincoln Continental](/source/Lincoln_Continental) (2017–2020)[21]

- [Ford Fusion](/source/Ford_Fusion_(Americas)) (2013–2016)[22]

- [Mazda 6](/source/Mazda_6) (2003–2012)[23]

- [Mercury Cougar](/source/Mercury_Cougar) (1999–2002)

- [Mazda 626](/source/Mazda_626) (1990–2002)

- [Ford Probe](/source/Ford_Probe) (1989–1997)

- [Mazda MX-6](/source/Mazda_MX-6) (1988–1997)

## References

- [Michigan portal](https://en.wikipedia.org/wiki/Portal:Michigan)
- [Cars portal](https://en.wikipedia.org/wiki/Portal:Cars)

1. **[^](#cite_ref-1)** ["AutoAlliance International, Inc"](https://www.hollingsworthllp.com/case-study/autoalliance-international-inc/). Retrieved August 28, 2025.

1. **[^](#cite_ref-2)** Ohnsman, Alan (August 24, 2012). ["Mazda Ends 20-Year U.S. Manufacturing Run"](https://www.bloomberg.com/news/articles/2012-08-24/mazda-ends-20-year-u-s-manufacturing-run). *Bloomberg*. Retrieved August 28, 2025.

1. **[^](#cite_ref-3)** ["Ford Opens a Giant Casting Centre"](https://news.google.com/newspapers?id=6GwtAAAAIBAJ&sjid=4YkFAAAAIBAJ&dq=michigan%20casting%20center%20opened&pg=2695%2C4464032). *Schenectady Gazette*. January 20, 1972. Retrieved April 11, 2013.

1. **[^](#cite_ref-4)** ["Detroit plant"](https://news.google.com/newspapers?id=jTQ_AAAAIBAJ&sjid=d1EMAAAAIBAJ&dq=michigan%20casting%20center%20opened&pg=1110%2C375353). *Windsor Star*. November 1, 1973. Retrieved April 11, 2013.

1. **[^](#cite_ref-5)** ["Ford Will Close Unit in Flat Rock"](https://www.nytimes.com/1981/09/15/business/ford-will-close-unit-in-flat-rock.html). *The New York Times*. September 15, 1981. Retrieved April 11, 2013.

1. **[^](#cite_ref-6)** ["Flat Rock Mayor Hopeful"](https://news.google.com/newspapers?id=IFwiAAAAIBAJ&sjid=AasFAAAAIBAJ&dq=michigan%20casting%20center%20closed&pg=1337%2C2901659). *The Argus-Press*. December 3, 1984. Retrieved April 11, 2013.

1. **[^](#cite_ref-KR-832_7-0)** ["$10 Million Awarded To Family Of U.S. Plant Worker Killed By Robot"](https://news.google.com/newspapers?id=7KMyAAAAIBAJ&sjid=Bu8FAAAAIBAJ&pg=3301,87702). *Ottawa Citizen*. August 11, 1983. p. 14. Retrieved June 8, 2018.

1. **[^](#cite_ref-8)** Manji, James F. (June 1, 1988). ["Building cars with Mazda quality. (Mazda Motor Manufacturing USA Corp.)"](https://web.archive.org/web/20131210021509/http://business.highbeam.com/438319/article-1G1-6458174/building-cars-mazda-quality). *Automation*. Penton Business Media, Inc. Archived from [the original](http://business.highbeam.com/438319/article-1G1-6458174/building-cars-mazda-quality) on December 10, 2013. Retrieved April 11, 2013.

1. **[^](#cite_ref-CohenAdjust2_9-0)** Cohen, Sharon. "[Metamorphosis in Motown](https://news.google.com/newspapers?nid=1346&dat=19911225&id=g7ROAAAAIBAJ&sjid=J_wDAAAAIBAJ&pg=1797,3219645)." *Associated Press* at *The Ledger*. December 26, 1991. p. 7C. Retrieved from [Google News](/source/Google_News) on November 19, 2013.

1. **[^](#cite_ref-Mazda20082_10-0)** ["North American All-New Mazda6 Production Begins at AutoAlliance International"](http://www.mazda.com/publicity/release/2008/200807/080723.html). *Mazda*. July 23, 2008. Retrieved April 11, 2013.

1. **[^](#cite_ref-star-201111112_11-0)** Star, Leanne (November 11, 2011). ["Alumni profile: Deepak Ahuja"](https://web.archive.org/web/20160902230003/http://www.mccormick.northwestern.edu/magazine//fall-2011/PDF/alumni-profile-deepak-ahuja.pdf) (PDF). *McCormick Magazine*. No. Fall 2011. p. 42. Archived from [the original](https://www.mccormick.northwestern.edu/magazine/fall-2011/PDF/alumni-profile-deepak-ahuja.pdf) (PDF) on September 2, 2016. Retrieved September 18, 2018.

1. **[^](#cite_ref-12)** Apostolides, Zoe (February 26, 2014). ["Mazda officially opens Salamanca plant in Mexico"](https://www.automotivelogistics.media/inbound-logistics/mazda-officially-opens-salamanca-plant-in-mexico/209507). *Automotive Logistics*. Retrieved August 28, 2025.

1. **[^](#cite_ref-media.ford.com2_13-0)** ["Ford Opens New Era at Flat Rock Assembly Plant, Source of 1,200 New Jobs and U.S. Production Home of All-New Fusion"](https://web.archive.org/web/20121112164832/http://media.ford.com/article_display.cfm?article_id=37067). Archived from [the original](http://media.ford.com/article_display.cfm?article_id=37067) on November 12, 2012. Retrieved November 25, 2012.

1. **[^](#cite_ref-14)** ["Lincoln Continental to be made at Ford Flat Rock plant"](http://www.freep.com/story/money/cars/ford/2015/07/15/ford-confirms-lincoln-continental-production-flat-rock-michigan-plant/30197835). July 15, 2015.

1. **[^](#cite_ref-15)** ["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"](https://media.ford.com/content/fordmedia/fna/us/en/news/2017/01/03/ford-adding-electrified-f-150-mustang-transit-by-2020.html). *Ford Media Center*.

1. **[^](#cite_ref-16)** Willems, Steph (November 28, 2018). ["Ford Cuts Factory Shifts, Comes Out Looking Like the Golden Child"](https://www.thetruthaboutcars.com/2018/11/ford-cuts-factory-shifts-comes-out-looking-like-the-golden-child/). *The Truth About Cars*. Retrieved October 5, 2019.

1. **[^](#cite_ref-17)** Howard, Phoebe Wall (February 5, 2019). ["Flat Rock shift cut leaves more than 400 Ford workers in jeopardy"](https://www.freep.com/story/money/cars/ford/2019/02/04/ford-layoffs-flat-rock/2771265002/). *Detroit Free Press*. Retrieved October 5, 2019.

1. **[^](#cite_ref-18)** Laing, Keith (February 4, 2019). ["Ford: Flat Rock workers to be offered job transfers"](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/). *The Detroit News*. Retrieved October 5, 2019.

1. **[^](#cite_ref-19)** Thibodeau, Ian. ["Ford Flat Rock plant shifts to electric vehicles, Mustang"](https://www.detroitnews.com/story/business/autos/ford/2019/03/20/ford-flat-rock-plant-shifts-electric-vehicles-mustang/3221693002/). *The Detroit News*. Retrieved October 5, 2019.

1. **[^](#cite_ref-20)** Henkel, Karl (April 9, 2013). ["Ford begins hiring 1,400 for Flat Rock plant"](http://www.detroitnews.com/article/20130409/AUTO0102/304090436/1121/auto01/Ford-begins-hiring-1-400-for-Flat-Rock-plant). *Detroit News*. Retrieved April 11, 2013.[*[permanent dead link](https://en.wikipedia.org/wiki/Wikipedia:Link_rot)*]

1. **[^](#cite_ref-21)** ["New Lincoln Continental will be Michigan made"](https://www.usatoday.com/story/money/cars/2015/07/15/ford-lincoln-contenental/30208199/). *USA Today*. July 15, 2015. Retrieved July 16, 2015.

1. **[^](#cite_ref-media.ford.com_22-0)** ["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"](https://web.archive.org/web/20121112164832/http://media.ford.com/article_display.cfm?article_id=37067). Archived from [the original](http://media.ford.com/article_display.cfm?article_id=37067) on November 12, 2012. Retrieved November 25, 2012.

1. **[^](#cite_ref-23)** Pope, Byron (September 10, 2012). ["Ford Expects Fusion Output to Exceed Mazda6 at Flat Rock"](https://web.archive.org/web/20130902094456/http://wardsauto.com/auto-makers/ford-expects-fusion-output-exceed-mazda6-flat-rock). *Wards Auto*. Archived from [the original](http://wardsauto.com/auto-makers/ford-expects-fusion-output-exceed-mazda6-flat-rock) on September 2, 2013. Retrieved April 11, 2013.

## Further reading

- Fucini, Joseph J. *Working for the Japanese*. [Simon & Schuster](/source/Simon_%26_Schuster), June 30, 2008. [ISBN](/source/ISBN_(identifier)) [1439106487](https://en.wikipedia.org/wiki/Special:BookSources/1439106487), 9781439106488. - The section starting at p. 101 discusses [Japanese employees](/source/History_of_the_Japanese_in_Metro_Detroit) from [Mazda](/source/Mazda) working in the Flat Rock Assembly Plant along with Americans in the 1980s.

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Adapted from the Wikipedia article [Flat Rock Assembly Plant](https://en.wikipedia.org/wiki/Flat_Rock_Assembly_Plant) by Wikipedia contributors ([contributor history](https://en.wikipedia.org/wiki/Flat_Rock_Assembly_Plant?action=history)). Available under [Creative Commons Attribution-ShareAlike 4.0 International](https://creativecommons.org/licenses/by-sa/4.0/). Changes may have been made.