FordNews
Monthly magazine for Ford employees in the UK   July/August 2009




Dagenham: 80 years in the making
What’s different?
Ford of Britain MD Nigel Sharp shares his news and views



                  Dear all
                 ...
Scrappage scheme beginning to have impact
Figures from the Society of Motor Manufacturers and Traders show               d...
Improved service to Ireland
                                                               “The new Parts Order service is...
S-MAX awards aplenty
Ford‘s outstanding product line-up                 established in 1990 as an ethical motoring
continu...
Manitou to the
rescue
Ford and the fire service came to the rescue of a local
college by putting much-needed equipment int...
One Southampton
                                                                                                          ...
Dagenham: 80 yea
Once the most self-contained car manufacturing plant the UK has ever seen



       The early
       year...
ars in the making
n, Ford Dagenham continues to be an industry-leading facility after 80 years


                         ...
Dagenham:
 Dagenham today
                                                                Power plant
                    ...
80 years in the making
Green Dagenham
Dagenham's eco-friendly policies were recognised by Green-Car-                      ...
Going
                                             loco                                                         From left:...
From the                                                                                                     archive
     ...
YOUR                 LEISURE page sponsored by
Save up to *25% on your 2009 Warner Leisure Hotels break. Call 0800 1 388
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  1. 1. FordNews Monthly magazine for Ford employees in the UK July/August 2009 Dagenham: 80 years in the making
  2. 2. What’s different? Ford of Britain MD Nigel Sharp shares his news and views Dear all Positive sales results have provided welcome and deserved good news for Ford in a market which continues to be extremely challenging for all vehicle manufacturers. Market share is increasing, sales of models emitting less than 120 Editor FordNews contacts g/Km CO2 have more than doubled so far this year compared with the Jason Simms 01277 253946 same period in 2008, and Fiesta and Focus are first and second in the jsimms14@ford.com charts respectively. Perhaps most encouraging of all is that in May 2009 we sold almost as Bridgend many small cars as we did immediately before recession gripped the Robin Roberts 01446 742905 vr.oom@btinternet.com market. In fact, just 50 fewer Ka, Fiesta and Fusion units were sold than in May 2008 – we should all be proud of that achievement. Dagenham As the impact of the government scrappage scheme is yet to register Tig Forder 07884 288440 significantly in sales figures, we can reasonably expect improvements in sales volume to tig.forder@gmail.com continue. Daventry Our outstanding product range is the chief reason for this success but the actions of all who Peter Watt 07712 874714 work at Ford played a part in that success. From designers to accountants, assembly workers peter@pwattpr.com to transporter drivers – all are crucial players in the tricky business of profitably delivering dynamic, attractive vehicles that represent excellent value for money. Dunton Kelvin Brown 01277 252102 Achieving this in the toughest of economic climates shows how well we can manage factors kbrow139@ford.com within our control and shape them to deliver exceptional results. For example, great strides have been made in quality but we cannot afford to lose any of the Southampton ground we have gained. We have also made a big impact on reducing costs but we must Seren Boyd 01395 222303 info@splasheditorial.co.uk continue to seek out opportunities to further reduce our overheads. In addition, each Ford employee, retiree and beneficiary can help sales figures directly Classified Advertisements through the Ambassador scheme. As we are entitled to allocate three vouchers to friends and Jill Bird 01277 253947 other contacts every year, we have the potential to generate over 140,000 unit sales annually. jbird2@ford.com Awareness rather than a hard-sell is the key with such sales so I encourage you to familiarise yourself with the scheme (see page 23). Design & Display Advertisements Martin Hammond 01277 254195 mhammon5@ford.com Ford News, 1/466, Feel the difference Ford Motor Company Ltd., Eagle Way, Managing Director Brentwood, Essex, CM13 3BW email: fnews@ford.com 4 12 20 Sales: Rail reunion: Cover story: Positive figures in April Using EDAP to keep on track Dagenham’s 80th anniversary FN 3
  3. 3. Scrappage scheme beginning to have impact Figures from the Society of Motor Manufacturers and Traders show deals in Blue Oval dealerships, the remainder are chiefly for sales of Ford’s small car range returning to levels of a year ago. In May Focus. this year, new Ka, Fiesta and Fusion registrations were within 50 units Ford Britain managing director, Nigel of their 10,046 May 2008 total. Sharp, said: “We hope this Continuing the Blue Oval-dominated battle for top sales spot, new scrappage scheme will boost Fiesta remained number one with Focus second, reflecting their year- sales of new vehicles and in to-date positions. In total, 7,040 new Fiestas were registered with doing so, help secure jobs at Focus just behind on 6,693 - that’s 48,182 and 38,655 respectively in Ford and our dealer partners, 2009. and assist the environment. It is These results helped Ford outperform the total car market once early days yet but increased web traffic and again with May sales down just 16 per cent versus May 2008 showroom visits are now turning into vehicle registrations, so we compared with an industry drop of 24.8 per cent. In this reduced remain optimistic as we head into the summer selling months.” market Ford claimed 17.3 per cent of all May vehicle sales – a Sales of Ford cars under the 120g/km CO2 tax break rose by 57 per percentage point up on a year ago. The growing popularity of more cent last month – and have more than doubled so far this year economical vehicles helped the Kuga compact crossover, capable of compared with the same 2008 period. 46.3mpg and 159g/km CO2 emissions, achieve a near 50 per cent Figures were also given a boost with the delivery of more than 1,600 sales surge. vehicles to Avis as part of an innovative new daily rental service it is The Government’s scrappage scheme has started to have a positive providing for BAE Systems. The entire fleet of Ford cars was delivered effect, with more than 3,800 extra Ford registrations last month. Ka, within just two weeks to ensure the contract started on time. Fiesta and Fusion model ranges account for two thirds of scrappage See page 7 for impact of the scrappage scheme on production. Fiesta gets auto The introduction of a new, 2.0-litre, 115PS engine to its ECOnetic range has created the lowest CO2 Mondeo yet. Offered in five-door or estate derivatives, it is rated at just 139g/km CO2, furthering Ford’s The Fiesta range has been commitment to creating fuel efficient models, without sacrificing strengthened with the arrival practicality or driving characteristics. of the new Durashift automatic transmission models. Matched to the Two-litre ECOnetic Fiesta’s new 1.4-litre, 96PS Optimised with a six-speed transmission, it offers combined fuel Duratec petrol engine, economy of 54.3mpg, rising to 64.2mpg in motorway cruising, and convenience does not significantly compromise performance or gives a potential combined driving range of over 800 miles. economy, with new Fiesta automatic achieving 0-62mph in 13.9sec, Ford now boasts the 43.4mpg and a CO2 rating of 154g/km. broadest sub-160g/km Beyond core performance, development work has also refined the vehicle range of any Ford Fiesta’s accelerator pedal response and created a sporty driving manufacturer, with 185 quality, present even with the automatic transmission. models providing The 1.4-litre automatic completes the Fiesta’s UK engine and savings to company transmission line-up. Sales of the new Fiesta to the end of May 2009 car and family buyers totalled 48,182 units. alike. Growing strength in Motability Ford’s increasing strength in the Motability market has popular. Focus continues to be a strong performer. seen it reach the top of the scheme’s sales chart. According Ford Britain Motability manager, Mark Chapman, said: to Motability Operation‘s own figures, more than 1,100 Ford “Ford’s position in the Motability market is very robust. vehicles were registered than those of the next best Overall our sales are down nine per cent so far in 2009 but performing manufacturer. In total, 3,657 vehicles were we are still significantly ahead of the industry’s 16 per cent registered, down five per cent on May 2008 figures in a deficit on 2008 figures, and importantly our share is market suffering 19 per cent average decline. increasing.” May 2009 was the third consecutive month Ford was Ford Motability also welcomes a new ambassador, Motability’s most popular manufacturer. Jane Sowerby (pictured). A fall six years ago left Jane Those results contributed to a total of 17,694 vehicles paralysed from the waist down but she has since become sold so far in 2009 under the scheme. Ford’s increasing a Paralympian hopeful for the British Disabled Ski team. If share in the market is due to the wide range of cars on offer all goes to plan, Jane will be taking part in the Winter and the arrival of new Fiesta which has proved extremely Paralympics to held in Vancouver in 2010. FN 5
  4. 4. Improved service to Ireland “The new Parts Order service is good news parts, which allows dealers to submit orders for the Irish market,” said Ford Customer up to 6pm in the evening for delivery the next Service Division director for Ford Ireland, Bill morning. Noonan. “Dealers can get their stock orders Transport cost savings approaching in half the time, reducing their costs and £700,000 per year have also been achieved giving them the opportunity to offer a better by eliminating the need for air freight to Ford dealers in Ireland are receiving their service to Ford customers.” supplement road deliveries for more urgent regular service parts orders significantly The dramatic timesaving was achieved items. In addition to the parts shipped by air quicker thanks to improvements developed following a detailed analysis of the existing from the UK, this also includes parts which by the Daventry Distribution team. The delivery process. This revealed that by Daventry could not supply, which were restructured delivery service not only helps introducing additional order processing runs previously sent to Ireland by air from the parts the dealers compete more effectively and in the warehouse, selecting a quicker ferry warehouse in Cologne. attract new business but has also provided crossing and streamlining the transportation Parts from Cologne are now transported Ford’s parts operations with major reductions network in Ireland, dealers could receive the by road to Daventry, where they are in transport costs. parts much quicker. integrated with shipments from that The new service – which has cut typical In fact, parts ordered before lunchtime can warehouse and dispatched together to stock order delivery times from 90 hours to now be delivered by the following morning, Ireland. The new process takes no longer 40 hours – was designed and implemented allowing dealers to respond much more than sending by air, but ensures that the by a cross-functional team in less than three efficiently to customer requirements. This dealer receives the entire order in a single months, including all the necessary revisions new service is complemented by the delivery. to the supporting IT systems. additional ‘vehicle off road’ service for urgent “This initiative is supported by Education with professionals in delivering real life Reaching out Outreach as part of the continuum of engineering projects.” to students educational support built up over several years to encourage students to choose Dunton-based engineers have been engineering, technology or science as a working with A-level students from local career. It is delivered in partnership with the schools on projects set up by Ford and other Engineering Development Trust,” said companies including NPower, Halcrow and Education Outreach‘s David Cayton. Selex. The projects undertaken were all Dunton welcomed students and teachers engineering challenges involving several from 16 schools for an Engineering Education months of work, where the students needed Scheme assessment day when they showed to solve difficult problems, compile reports, off projects as diverse as the design of a flat- analyse the issues and deliver a convincing pack footbridge, hands-free rear door presentation. opening system for Transit Connect and a David said: “This is another high quality The team from Greensward College, Hockley, with their substitute gearchange rapid warm-up system for vehicle engines. opportunity by Ford for young people to work system for Transit Connect Choice of 35 UK Holiday Parks Up to 65 FREE activities, facilities from o & entertainment options included nly Heated pools & SplashZones * All-weather SportsZones for the wh up to Kids’ clubs from tots to teens family ole Range of daytime activities * Evening entertainment off sho rt brea ks For more information or to book please call or go online and Calls to 0871 numbers will cost no more than 10p per minute QUOTE for your special discount from a BT landline - calls from other networks may vary. Terms and Conditions: * Price/discount varies by Park, date, duration & grade booked. Save up to 50% offer applies to current brochure prices and isbased on selected dates during April/May/June/Sept/Oct 2009. Offer excludes holidays taken in July, August and all School and Bank Holiday periods where saving is up to an extra 10% off the bestcurrent public price. £99 ‘from’ price based on a family of 6 sharing Superior Self-Catering 2 bedroom accommodation at The Orchards Holiday Village, Essex, for 4 nights (Mon - Fri) on 12 October 2009 after relevant disc ount has been applied. Offers are subject to promotional rate availability, apply to new bookings only and cannot be used in conjunction with any other voucher, discount or offer, unless otherwise stated. Offer appli s to direct bookings only and cannot be booked via a Travel Agent. All details correct at e time of going to print. We reserve the right to withdraw or amend any offers at any time without prior notice. £100 deposit isdeducted from the full amount at the time of booking, leaving a balance payable no later than 37447/GS 8 weeks before the holiday start date. Bookings made within 8 weeks of the holiday start date are payable in full. All offers e 31 October 2009. Facilities, activities and entertainment vary by Park and date and maybe nd subject to a moderate extra charge. Please be aware that not all Parks, dates and accommodation types are included in this offe please check at time of booking. Pictures shown are for representational purposes only. r; Terms and conditions of the current Haven brochure and website apply. Haven Holidays is a trading name of Bourne Leisure Limite 1 Park Lane, Hemel Hempstead, HP2 4YL, Registered in England No 04011660. d, 6 FordNews July/August 2009
  5. 5. S-MAX awards aplenty Ford‘s outstanding product line-up established in 1990 as an ethical motoring continues to draw media plaudits. organisation and sustainable travel lobby S-MAX has won the large MPV class in group. the British Insurance Car Security Awards The ETA is now Britain’s largest charity for the third year in a row, with Galaxy once focused on transport and the environment. more runner-up. Supported by security Ford cars were also the top of the list of experts Thatcham, the Department for towcars, in the third annual Towcar Awards, Transport, the Home Office and UK as judged by experts from What Car?, insurers, the awards are the highest official Practical Caravan and The Camping and recognition of vehicle security in the UK. Caravanning Club. The S-MAX 1.8 TDCi has also won the The Ford S-MAX 2.2-litre TDCi Titanium large MPV category in the Environmental has been judged best in its weight class, Transport Association’s (ETA) Green Car while the Ford Kuga 2.0-litre TDCi Zetec Awards 2009. The organisation was 2WD has taken top honours in its category. Prize for Rally boss becomes mentor OBE Southampton plant stalwart Gary Appleton has marked his Ford’s world rally team director, Malcolm Wilson, has been retirement from Ford by winning a top award for his mentoring work. named in The Queen’s Birthday Honours list. Malcolm was The former paint shop senior engineer has been awarded the 2009 awarded an OBE (Officer of the British Empire) for his services to Mentor of the Year award by Southampton Solent University (SSU). British motorsport. It celebrates his work during the last year with final year business The award is one of the highest achievements bestowed by and marketing student Ellen Jones, who referred to Gary in her the British monarchy and recognises distinguished achievement nomination as being ‘a rock’ for her during the year. in any field at national or regional level. Wilson will receive his SSU mentoring co-ordinator Louise Drake, said Gary had been honour from Her Majesty The Queen at a ceremony at an exceptional mentor over the years. “We are proud to Buckingham Palace in London later this year. congratulate Gary as he has provided our students with such Malcolm, director of the BP Ford Abu Dhabi World Rally Team tremendous support,” she said. and managing director of M-Sport, which runs Ford’s world rally The award marks a new chapter in Gary’s life, as he embarks on a programme, commented: “It’s a great honour to be recognised new career in training. “I’m really far too young to retire and now I in this way. Motorsport, and particularly rallying, has been my have my plan for the next decade. It’s a complete change of life.” life.” Scrappage scheme good for Sigma UK and taking about a third of total BEP output. European Sigma units are also fitted in Mondeo, Focus, scrappage C-MAX, Focus Coupe Cabriolet and Fusion. schemes are good BEP saw Sigma production pass 55,000 news for Bridgend units in March, over 44,000 in April and Engine Plant (BEP). As the incentives are around 43,000 in May. rolled out and more buyers appreciate the Bridgend MP&L manager Colin Nower opportunities and savings to be made, the said: “Our volume for Sigma is going up Welsh plant has gone into overdrive to meet almost every day. When you look at the demand. orders you can see the additional work is Sigma production has risen over 54 per being driven by demand for the new Fiesta cent in recent months with most of those series, which is a great car, and it makes us engines destined for new Fiesta which is very proud to be part of its success.” FN 7
  6. 6. Manitou to the rescue Ford and the fire service came to the rescue of a local college by putting much-needed equipment into their workshops. The Southampton plant donated 11 items of unwanted equipment, including lathes, mills, hydraulics and workshops up to replicate an industrial environment, but when we tried pneumatic rigs, to Eastleigh College for use in the NVQ and BTEC to get quotes for lifting the equipment into our stores, we got engineering courses. nowhere.” But the equipment was so heavy and unwieldy, that college staff USAR watch manager, Lee Giffard (pictured), said the team were were unable to remove it from the flatbed transporter. Mercifully, glad to be of assistance. “We are the only department in the Hampshire Fire and Rescue Service’s Urban Search and Rescue unit Hampshire Fire Service which has this capability,” he said. “After (USAR) came up trumps, and offered to help out with their Manitou – a speaking with Ford and the college, we decided it was for a good four-wheel drive vehicle with a telescopic arm specially designed for cause and used the Manitou to move the equipment around.” lifting and moving. Ford training officer, John Powell, said the collaboration had been a “It was like Thunderbirds to the rescue,” said Eastleigh College great success. “This is a great example of team work in the learning manager Mike Driscoll. “The idea is that we try to set our community.” From left: Tracey Cashman, Joanna Papamargaritis, Dunton fundraisers run for life Anita Horwood, Boguslawa Ochab, Kelly Ridgwell, Fiona Johnson and Claire Walton Seven employees from Powertrain at Dunton raised £2,222 running the five-kilometre Cancer Research UK Race for Life in Basildon. “Quite an achievement considering some of the girls had not run before,” said Claire Walton, manual transmission supervisor in Drivetrain Systems Engineering. “We have had great support from our colleagues and have been running three times a week.” Fellow runner, application engineer Tracey Cashman, added: “We are now preparing to run a 10k race for Cancer Research with some of the Powertrain boys in October.” First aid Hospice donations Generous employees at Dunton dug deep in their pockets Bridgend Engine Plant and donated £1,350 to five local hospices, as part of the Dunton shopfloor has been given a safety Charity Committee (DCC) organised door collection. The day boost with a new rapid response was co-ordinated by DCC member Michelle Faddie, C-Car medical trolley which can carry two communications manager – no mean task considering the trained nurses, a stretcher and vital number of entrances into the Dunton site that needed to be lifesaving first response equipment. manned by Ford and hospice volunteers. With over 100,000 sq metres of Despite a cold morning the sun shone and the generosity of shopfloor it is vital that first Dunton employees matched the good weather. The five local Kelita Sikwa and occupational health responders and medical staff can practice nurse Clair Andrews check hospices to benefit were: Fair Havens, Little Havens, St Luke‘s, quickly reach locations. over the medical trolley St Francis and Farleigh. The electric trolley is stationed ambulance in most locations where “The £1,350 total raised was an increase from the £1,200 last behind the plant medical centre it could not turn around or year, a significant achievement considering the current financial and is permanently available to manoeuvre but the trolley can get climate,” said Rob answer emergency calls anywhere through the smallest gaps. With the Argles of the charity on site. Medical staff have trolley we can quickly cover the committee. undergone plant training to drive plant and get trained medical staff “The committee the vehicle. It is also available to do and vital equipment to an incident rounded the total up routine assessments and checks of or recover a casualty. to £1,500, enabling medical equipment strategically “In an emergency situation we the hospices to each placed throughout the plant for would work very closely with the benefit to the tune of emergency use and to make security staff so the medical staff £300.” workplace visits. can concentrate on treating the Clinical manager, Cheryl Barnes, patient at the incident or on the From left: Rob Argles, DCC; Debbie de Boltz, Farleigh; Matthew said: “The layout of the plant trolley before they are handed over Loynes, DCC; Lynda Head, St Francis; Dave Russell, DCC; Dave Bishop, Fair Havens/Little Havens; Sadie Jasper, DCC; Anita means it is not suitable for a regular to the public ambulance service.” Whelan, St. Luke’s; Arvinder Marway, DCC FN 9
  7. 7. One Southampton Rob Ardley, front, with from left, Shane Douglas, Martin Manley, Tony Le Grange, Dane Butten and Martin Swain Ford Southampton has been relaunched to ensure the plant remains a good place to as a one-shift plant with a new staff training be,” he said. “We want good morale and programme. Following reductions in have been rebuilding the team, albeit a production volumes and employee numbers smaller team.” (from 1,150 to 542), One Southampton is a To do this, the decision was made to scheme which builds on the company embrace the One Ford model and pick out objective of One Ford. some of the key messages that are relevant Embracing the one-shift work pattern to Southampton. “We are now smaller, all positively, the programme aims to listen to accounted for and need to pull together to be used to plan future initiatives, with 93 per staff’s concerns, boost morale and ultimately successful,” added Rob. cent saying the session was worthwhile. make the plant more effective. To implement One Southampton, plant “People understand it and there is a Human Resources manager, Rob Ardley, employees were split into ten groups of 60 for massive focus on quality right now. We are said the focus is to work with employees and a manager-developed session on SQDCME changing things and we are listening. We are suppliers. “In parallel with supporting those (safety, quality, delivery, cost, morale and getting to know the guys on the floor and it staff who were leaving, we’ve been working environment. Participants’ feedback is being feels a nicer place to be,” said Rob. Safety Especially safe behaviour by a contractor during demolition at Bridgend has earned the first ‘green cards’ awarded by Dunton’s Powertrain Operations Manufacturing Engineering (PTO ME). first Wilson Construction was awarded the Safety Culture Green Cards for their work during the demolition and strip-out phase of the EcoBoost engine programme. In fact, Wilson Construction’s method of working was considered so good it has now been incorporated into the standard PTO ME specification for similar work. “At the end of the strip-out phase of a programme it’s very important that no loose material is left in the roof space, as any items that remain at height present a hazard and the potential for an accident,” explained Mark Donnison, PTO ME facilities supervisor of plant engineering. “Wilson Construction took our standard Ford procedure for performing a high level sweep and developed it further to incorporate a detailed method of reporting, using photographs and schematic maps of the area.” These green cards are the first awarded since the scheme started in 2008. “We’ve had procedures for identifying and addressing behaviours on our sites for years but with the development of our safety culture the next step was to recognise contributions above and beyond normal business,” said PTO ME safety leader Chris Bracey. From left: Craig Wilson, of Wilson Construction, “We want to recognise safe behaviours on our sites but we want our partners to win further receives his award from Chris Bracey, Joe business off the back of their safety successes,” said PTO ME director, Paul Neighbour. “The Williams of Wilson Construction, and Mark Donnison presents an award to Jason Leeds safety of our sites gives us a competitive edge – companies want to work on our sites.” Shipping success Daventry’s overseas export customers including representatives from warehouse, are benefitting from a new process for transport operations and customer managing parts shipments from the liaison – was able to identify a more efficient warehouse which travel in large containers process which made it possible to store the via sea. The new process – which was export cases within the Daventry site, rather Lesley Holden checking the dispatches before they are shipped developed as part of a six-sigma project led than transporting them to the external by 6 Sigma Black Belt Bridget Halpin – has location. the same time providing our improved the quality and speed of deliveries, Regular weekly meetings were introduced overseas customers with a superior service.” and provided significant cost savings for to review when export shipments were Export customers should see significant Daventry’s operations. ready for release, and new invoicing and benefits from the new approach. Because Before the project team got to work, shipping processes were developed to the export cases now experience less Daventry used an external warehouse to optimise the way they were handled within handling and are stored locally within the store export deliveries which were either too the warehouse. Daventry warehouse, there is less risk that small to ship economically or which needed “Our new export processes will reduce the shipments will be damaged or mislaid. special inspections prior to shipment. This costs by £250,000 each year,” said Daventry When the cases are released for process also required extra administrative site manager Andy Blaber. “The project team transportation, the shipments can also be services provided by an external company. was able to find a solution which uses the made more quickly since the parts are The cross-functional project team – resources we already have on site, while at already on site. FN 11
  8. 8. Dagenham: 80 yea Once the most self-contained car manufacturing plant the UK has ever seen The early years On 17 May, 1929, Edsel, the son of company founder Henry Ford, was the first to dig into the low- lying marsh which the company had bought in 1924. Ford Dagenham took 28 months to build, from Edsel digging the first turf with a silver spade to its first vehicle, a Model AA truck, rolling off the production line in October 1931. Special trains moved 2,000 Ford employees and their families to their new Dagenham homes from Trafford Park, Manchester – the company's first UK plant. The move was achieved in the space of one weekend. Built on wasteland and reclaimed marshes, Ford of Britain's first chairman, Lord Perry, described Dagenham as "almost the worst possible choice" of site. Before Ford acquired the site it was part of Britain's first flying ground for experiments with early planes. Bought for £167,700 the initial site measured just 295 acres, around 150 football pitches. Because of its marshland location, 22,000 piles had to be sunk up to 80 feet into the ground to support the factory – nine million wooden blocks formed the factory floor. When first fired up in 1931, Ford's power station generated enough electricity for a town of 180,000 inhabitants. Built before the introduction of the National Health Service, employees benefited from an on-site doctor, trained nurses, operating theatre, X-ray equipment, dispensary and several first aid stations. The first vehicle, a Model AA truck, rolled off the production line on 1 October 1931 - the last was a Fiesta in 2002. Dagenham's floor space peaked at four million square feet and employee numbers hit 40,000 in 1953. 12 FordNews July/August 2009
  9. 9. ars in the making n, Ford Dagenham continues to be an industry-leading facility after 80 years Wild Dagenham Although an urban industrial site, Dagenham has its fair share of wildlife with over 50 different species of birdlife making their home there. Ford and the Forestry Commission have planted 10,500 trees as part of the environmental regeneration of the Dagenham Estate while freshwater fish are found in the on-site lake called The Breach. Five major classes of insect live alongside production including the rare Bombardier beetle and the Adonis ladybird. The war years – 1939 to 1945 During the war the Dagenham jetty was used to evacuate 17,000 local residents. May 1940 and when Churchill took over significant military vehicle orders came in the form of V8 Bren gun carriers, Fordson tractors, Ford Emergency Food Vans and Fire tenders. During the war period, Dagenham became Britain’s chief tractor supplier. Despite the factory rooftops being camouflaged to look like fields and being manned with anti-aircraft guns, 200 bombs fell on the Dagenham estate during the Second World War. 1941 Women work at Dagenham for the first time, initially 1,100 rising to approx 3,400 at war’s end. 1929 to 2009 In 1942 Dagenham Foundry workers raised £7,500 to buy a Spitfire – equivalent to over £250,000 at today's prices. Dagenham furnace slag was used to asphalt the surfaces of 56 airfields in 10 counties. 1943 Dagenham recognises the unions. Three weeks after the end of WWII, Dagenham restarted car production. Left: 1946, the millionth vehicle produced at Dagenham was a 10bhp Prefect. Dagenham’s who’s who? Sandy Shaw, Billy Ocean, Henry Akinwande, Sir Malcolm Campbell, Idris Elba and Winston George Ellis have all worked at Dagenham. The world’s oldest man and one of only two surviving WW1 veteran, 113-year-old Henry Allingham, held various engineering positions at Dagenham until he retired in 1960. Dagenham's 10 millionth car and Ford's 250 millionth worldwide, a Fiesta, was driven off the line in 1996 by retired boxing champion and local resident Frank Bruno (pictured). Alex Trotman, Ford Motor Company's first foreign-born chairman and CEO, started his career at Dagenham. FN 13
  10. 10. Dagenham: Dagenham today Power plant Engine design and assembly teams are based under one roof in Today, Ford Dagenham covers 475 acres and has DDC for maximum cooperation and efficiencies . received £800 million of investment this decade. It is Dagenham engines are shipped to Belgium, Germany, France, Ford's largest producer of diesel powerplants globally, Italy, Turkey, Russia and Japan. capable of manufacturing 1.4 million units a year: Tiger engine (1.4 & 1.6) is used by Ford, Mazda and Volvo Tooling and Stamping produce 145,000 panels every Lion engine (2.7, 3.0 V6 & 3.6 V8) is used by Jaguar, Land Rover, day. Peugeot and Citroen. Ford's Dagenham estate includes a £37 million Lynx engine (1.8) powers the UK's best selling car, the Focus, and private/public college, the Centre for Engineering and is adaptable for marine use. Manufacturing Excellence (CEME), led by Ford and the Puma engine (2.0, 2.2 & 2.4) is used by Jaguar, Land Rover and in London Development Agency. commercial vehicles from Ford, Peugeot Citroën and Fiat. Dagenham majors in diesel engine design and manufacture. The Dagenham Diesel Centre (DDC) was a £325 million investment when it was opened in 2003 and has the capacity to assemble 1.4 million engines a year. In 2008 it produced 1,050,000 units. These powerplants are fitted to 28 different Ford, Jaguar, Land Rover and Peugeot/Citroën models. Engines are taken from the production lines by on-site transport operations for onward delivery by road, rail and sea. Railway lines service the site, which boasts a deep water jetty used to load and unload vessels travelling between Ford plants. Today the site employs a total of 4,000 people in engine, stamping and transport operations. Ford engineers and production specialists work closely together on the development and assembly of diesel engines. Dagenham plant manager Dave Parker said: "Ford Dagenham is ideally positioned to give quick and easy access to our markets which continue to sustain operations here after 80 years. Today we're at the centre of Ford's fuel efficiency drive as exemplified by the 76mpg diesel engine supplied for the new Ford Fiesta. Ford Dagenham has a rich manufacturing, economic and social heritage, which has provided the foundation for its competitive position today." DDC by day ... ...and night 14 FordNews July/August 2009
  11. 11. 80 years in the making Green Dagenham Dagenham's eco-friendly policies were recognised by Green-Car- Dagenham on the move Guide.com with the Greenest Manufacturer of the Year 2008 award. An early pioneer of recycling, Henry Ford fuelled Dagenham's power Dagenham's transport operations import and export 300,000 station by burning London's waste – 2,000 tons per week until 1939. vehicles a year. They also handle the 15 million stampings, such Today, Ford is working with a renewable energy company on a plan to as vehicle body panels, bonnets and bootlids, and 1.8 million use household waste diverted from landfill turned into a synthetic gas to wheels produced by Dagenham's stamping and tooling power its Dagenham estate. Other Dagenham eco-efficient processes operations. prevent over 12,600 tonnes of waste going to landfill. Dagenham jetty can easily handle ships up to 24,000 tonnes The use of 'green' renewable vegetable oil for metal working instead while transport operations has access to a fleet of 2,000 trailers of mineral oil has resulted in over 500,000 litres of oil being saved. and uses 10 miles of railway tracks across the Dagenham estate DDC is entirely powered by two wind turbines which can each which link into the main network. generate enough energy to power 1,000 homes. Designed by award- In an average year shipments of products from Ford winning architect Sir Norman Foster, they stand at 120 metres tall, have Dagenham to customer plants will cover 50,000 nautical miles. blades measuring 35 metres in length and have avoided over 6,500 Ford Dagenham's truck trailers cover in excess of 10 million tonnes of CO2 emissions a year since they went up in 2004. The miles annually. application for a third turbine is currently going through planning Vehicle body panels are shipped to Wales, Belgium, Sweden, permission. Germany, Spain, Italy, Turkey, Poland, Russia and the Midlands in the UK. Eurostar high speed rail link between St Pancras and the Channel Tunnel travels through the Ford estate before going underground to enter London. 1929 to 2009 High tech Air in Dagenham Diesel Centre's production hall is filtered to minimise particles that could interfere with the assembly of the latest hi-tech diesel engines. Fiesta ECOnetic on DDC’s Tiger Dagenham's 2.4-litre engine is part of the hybrid technology in engine line, which supplies the 76.3mpg car’s 1.6-litre TDCi engine London's record-breaking new Wrightbus Electrocity single decker. In summary Since 1972 only four cars have topped the UK sales charts – they are all Fords. Two were built at Dagenham – Fiesta and Cortina – the others are Escort and Focus. Over 71 years, Dagenham built 10,980,368 cars, trucks and tractors and in its 80 years has produced over 37 million engines. FN 15
  12. 12. Going loco From left: With ‘The Allen’: Roman Bronka, Paul Jackson, Arthur James and Graham Garner Every boy’s dream came true for four today’s Ford locos very short distances in and out toolmakers and fitters when they spent the day of Dagenham’s central workshop where they are behind the wheel of a 77-year-old diesel repaired, maintained and serviced. locomotive once used on Ford’s Dagenham He said: “Trains used to be fun, and driving estate. Rail area maintenance fitter Arthur James, them is pretty straightforward. Once you have Future and his three friends, Engine Plant toolmakers mastered forwards, backwards, brake and Roman Bronka, Graham Garner and Paul throttle – it’s just a case of getting it all in the right Jackson, have used their educational grant order. Stations are more complicated, watching star? money from EDAP to do beginners and then advanced railway driving courses on steam engines with the Kent & East Sussex Railway for signals, but as long as you pay attention to what they are telling you to do it’s pretty easy.” The Allen was one of three locos ordered in (K&ESR). Oxford blue and gold livery in 1932 to transport You may not have heard the name In May they drove something different – the materials and waste to and from Dagenham’s but Freddie Russo is making an former Ford diesel-electric shunting locomotive new blast furnace. The locomotives worked for 34 impression on the motorbike racing Number 40, known as ‘The Allen’. They had the years, running 250,000 hours until 1966, when scene. The 18 year-old started late in run of the ten-and-a-half mile track, with an many were scrapped. The body of one and the the 2008 season after his first instructor, guard and signalman on board – and engine of another were saved by K&ESR. For experience on two-wheels, a track day, everyone got a chance to drive. more information see the charitable company’s just months before. By the time the Arthur, a keen railway historian, often drives website www.kesr.org.uk Superclub CB500 championship had closed, he was second on the leader board after 12 race wins in the series and podiums in every race he finished. The hard way down This year, the son of Ford Warley food Homicidal sheepdogs, and having to do 126 miles on services supervisor, Catherine Russo, is getting lost and all manner of the Bristol-Launceston leg. going strong. Having taken a big step ailments were part of a 900- However, the pair finally up the ladder to compete in the Metzler mile John O’Groats to Land’s arrived on schedule at Land’s Junior Superstock 600 series, which End charity bike ride for one End in 27 degrees C on a runs alongside the prestigious British intrepid pair. Dagenham sunny afternoon. Superbike Championship, toolmakers Rob Middleton and The secret of Dave’s performances have been drawing Dave Hilton set themselves the success was drinking one- attention from even those who’ve seen considerable challenge of and-a-half pints of tonic water it all before. “At Thruxton Freddie completing the epic journey in each evening to prevent and Essex Air Ambulance. qualified 9th on the grid and managed just nine days. cramp. Rob’s diet was simpler And their only photographic to go tenth, seventh, sixth and then With what they now realise – “whatever was cheap and records of the whole trip – fourth,” said Catherine. “Even the was far too little pre-planning, three pints of Stella”. except those taken by Steve commentator was getting a bit excited they started to appreciate what Two weeks on, Dave and Gowers and Macmillan‘s at this stage.” they had undertaken when the Rob’s memories of their Rachel Gascoigne – were Unfortunately, inexperience caught 16-hour journey to their start experiences differ. Dave was some shots Dave wanted of up with Freddie and he ended up unhurt point took a car, plane, two still “elated” by a sense of brown Pennines sheep. but in the barrier. However, he was only trains and a taxi. Their lowest achievement, while Rob said Rachel, who followed the beaten by a tenth of a second for fastest point was on the second day, he felt “strangely anti- last leg of their journey, said: lap of the race and was one second after Rob developed mild climactic”. He said: “It was a “Congratulations to both Rob better than the previous lap record. hypothermia after getting real test of mental as well as and Dave on their outstanding He’s now looking for sponsors to drenched in freezing wind and physical stamina, and I am effort. I saw for myself just how back his natural talent and hopes to rain in the Cairngorms along glad we stuck to it.” tough it was for them. make a career of motorsport. “Although the A9 in Scotland. Both agreed that “We are particularly grateful I didn’t finish at Thruxton, I know I have Further tests of their mettle colleagues, and even to Rob who chose to support the pace to match the front-runners and came with heavy rainfall in the strangers they met en route, Macmillan. The money that he can only hope that I can get the backing Lake District, “terrible traffic, had been “incredibly raises will help to bring Ford to prove it out on the track,” said and really bad driving” on the generous”. They have raised Dagenham ever closer to Freddie. For more, visit way to Preston, going to the almost £4,000 for the reaching its target of funding a http://www.freddierusso.co.uk wrong Marriot hotel in Bristol, Dagenham Macmillan Appeal Macmillan nurse.” FN 19
  13. 13. From the archive Last tractor off the line July 1964 and the last tractor, a Fordson Major, to roll off the Dagenham line is driven into the history books by line superintendent, Gerry Keane. After this, production switched over to Basildon. Although his face is obscured, the man behind the camera to the right is likely to be ‘Ben’ Bennett, a company photographer who pioneered in-house cine photography at Ford. He later also moved to the new Basildon tractor plant. If you have any information or stories relating to this photo, or any Ford- Standing next to the tractor with his arms related photos that you would like to share, Ford News would be delighted to folded is Jack Rushton, the then Director of hear from you. See page 3 for contact details. Manufacturing at Dagenham. Toolroom reunion a success A crowd of more than 250 toolmakers past and With the plant’s shop stewards committee Neil Spence, Brian Coleman and Brian Mead, present met up to share archive photos, swap paying for the raffle, all £1,100 from sales of were among the employees from the Forties stories and generally reminisce about the old tickets and CDs of contributed archive photos and Fifties in attendance. days. The evening, which was pronounced a went to Dagenham’s Macmillan Appeal. A follow-up reunion is planned for next year. success by organisers and guests alike will now Guests of honour were four former Details via dbrown91@ford.com or become an annual event, was the result of a apprentice instructors – Dick Thomas, 92, Stan jthomp70@ford.com story in Ford News and a Dagenham newsletter. Woodford, 90, Jack Waddle, 83, and Charlie Last November, to mark Dagenham Massie, 78. Three former Toolroom managers, Toolroom’s 50th anniversary, a Ford News story mentioned most archive photos from the plant’s past had been lost. Two toolmakers, Jim Thompson and Dave Brown, said they were researching the old days – and within weeks had been inundated by phone calls and visits from Fordies keen to bridge that gap. A thousand old photos later, the pair, with their supervisor Steve Gowers, decided to hold The oldest person present, former instructor From left: Current employees Tony Jackson, a nostalgia evening where old photos were on Dick Thomas, left, joined Ford in 1940. Former Danny Marshall, and Chris Passfield with, behind, display and new ones could be discovered. apprentice Terry Whitehead joined in 1958 Bob Eveling and Vinny Passfield got together E X C L U S I V E LY F O R A D U LT S BOOK A WARNER LEISURE HOTELS BREAK & SAVE UP TO 25%* TO BOOK CALL OUR PRIVILEGE HOLIDAY TEAM ON 0800 1 388 399 quoting code HG368 (lines open 7 days a week 9am-9pm). www.warnerleisurehotels.co.uk/phc * Save up to 25% offer excludes Bank Holidays, Christmas & New Year, Premier Starbreaks, Spa breaks and 2 night midweek breaks. Offers are off the current Warner Leisure Hotels 2009 brochure prices and cannot be used in conjunction with any other offer and apply to new bookings only. All bookings are subject to availability and terms and conditions in the current Warner Leisure Hotels 2009 brochure. All persons in your booking must be over 21 years of age. Supplements apply for room upgrades and Experience Breaks. Warner Leisure Hotels reserve the right to change or reduce these offers at anytime without prior notice. Bourne Holidays (trading as Warner Leisure Hotels) is a company registered in England and Wales with company number 01854900 whose registered office is 1 Park Lane, Hemel Hempstead, Hertfordshire HP2 4YL. 20 FordNews July/August 2009
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