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Q&A with Bryce Currie: Inside the New Ford Universal EV Production System

Sep 03, 2025
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The new Ford Universal EV Production System is a reinvention of the automotive assembly process. Combined with the Ford Universal EV Platform, the system will enable Ford to deliver a new generation of affordable electric vehicles at scale, starting at the Louisville Assembly Plant.

Bryce Currie, Ford vice president of Americas manufacturing, answers questions about what this means for Ford assembly line workers at the Louisville plant ahead of the first vehicle launch in 2027.

Q: How is the Universal EV Production System different from what Ford does today?

Bryce Currie: Simply put, we’re transforming the traditional assembly line into an “assembly tree.” Instead of one long conveyor, three sub-assemblies run down their own lines simultaneously and then join together. One sub-assembly is for the front of the vehicle, another for the rear, and the third for the structural battery, seats, consoles and carpeting.

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Q: What makes the Universal EV Production System unique?

Bryce Currie: We’re confident this is the first time a vehicle will be built like this anywhere in the world. We tore up the century-old concept of the moving assembly line, transforming it with three sub-assemblies and a process that presents the vehicle to operators as a kit. We put operators first, and we expect the ergonomic benefits of the Ford Universal EV Production System will flow through to cost and quality.

Q: How much faster is the Universal EV Production System?

Bryce Currie: The platform would allow us to assemble the new midsize electric truck 40% faster than Louisville Assembly Plant’s current products. We reinvested some of that time into insourcing and automation to improve quality and cost. That decision will give Louisville Assembly Plant the highest level of automation in final assembly across all Ford plants globally, and it means assembly of the midsize truck will ultimately net out at 15% faster than Louisville Assembly today. 

Q: How will the Universal EV Production System improve working conditions for employees?

Bryce Currie: We listened to all the things operators don’t like. Safety is our top priority, consistent with what we hear from operators. The result is that their work at Louisville Assembly Plant will be significantly more ergonomic. It’s designed to require less twisting, turning and bending.

Q: What will make work on the assembly line more efficient and ergonomic?

Bryce Currie: We want this to be the most efficient plant, assembling the most efficient product in the market. The vehicle arrives in front of the operator as a kit — with parts in the right orientation, and fasteners, scanners and power tools included in the kit. This helps them focus and keep their eyes forward with limited stock behind them. We’ve engineered an 84% reduction in reaching over the fender, as one example. The wiring harness is also more than 4,000 feet shorter and 22 pounds lighter than in our first-gen electric SUV, making it much easier to install. 

Q: How does reducing manufacturing complexity improve vehicle quality?

Bryce Currie: Less wasted movement means our employees can focus on quality. And complexity reduction will help with quality, too. We have 50% fewer connections, 50% fewer cooling hoses, and 20% fewer parts than a typical program. We’ve also eliminated Pre-Opened Pre-Positioned (POPP) clamps in favor of quick connects. It all means a lower risk of faulty connections. It’s going to be a big improvement.

Q: Will Ford implement its Universal EV Production System at any other plants?

Bryce Currie: We are focused on Louisville Assembly Plant first and making this project a success. Then we’ll determine how to take these learnings into our global manufacturing operations. We can test and learn at the leading edge, while we continue to run and refine the proven processes we’ve honed over 122 years.

Q: What technology upgrades are happening at Louisville Assembly Plant?

Bryce Currie: We know that only a high-tech plant can assemble a high-tech product. So, the digital infrastructure here will be significantly upgraded. Louisville Assembly will have the fastest network with the most access points out of any Ford plant globally – meaning we can do quality checks anywhere in final assembly. Network capability will be the latest-generation WiFi-7, which is more resilient and three times faster than what exists today, and we’re increasing the density of access points. On top of that, private 5G will help ensure reliable high-speed wireless communications for diagnostics and quality checks.

Q: How much money is Ford investing in upgrading manufacturing at Louisville Assembly Plant?

Bryce Currie: We plan to invest approximately $2 billion at Louisville Assembly Plant.

Q: What is Ford’s commitment to the Louisville community beyond the factory walls?

Bryce Currie: Since 2020, Ford and its employees have donated more than $8 million and volunteered more than 10,000 hours serving the state of Kentucky and our local communities. That doesn’t even include the impact of 48 dealers across the state, which employ 2,300 people. We’re securing the future of Louisville Assembly Plant with this new investment in manufacturing, enabling Ford and our employees to continue strengthening the Louisville community. 

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