Monthly magazine for Ford employees in the UK July/August 2009
Dagenham: 80 years in the making
Ford of Britain MD Nigel Sharp shares his news and views
Positive sales results have provided welcome and deserved good news
for Ford in a market which continues to be extremely challenging for all
Market share is increasing, sales of models emitting less than 120
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 email@example.com
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
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.
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 firstname.lastname@example.org
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 email@example.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 firstname.lastname@example.org
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
continue to seek out opportunities to further reduce our overheads.
In addition, each Ford employee, retiree and beneficiary can help sales figures directly
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. email@example.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
Feel the difference Ford Motor Company Ltd.,
Managing Director Brentwood,
Sales: Rail reunion: Cover story:
Positive figures in April Using EDAP to keep on track Dagenham’s 80th anniversary
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
models. Matched to the
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.
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
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6 FordNews July/August 2009
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
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.”
Manitou to the
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
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).
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.”
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.
Dagenham: 80 yea
Once the most self-contained car manufacturing plant the UK has ever seen
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
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
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
12 FordNews July/August 2009
ars in the making
n, Ford Dagenham continues to be an industry-leading facility after 80 years
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
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
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
Alex Trotman, Ford Motor Company's first foreign-born
chairman and CEO, started his career at Dagenham.
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
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
80 years in the making
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
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.
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
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.”
From the archive
Last tractor off
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
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 firstname.lastname@example.org or
become an annual event, was the result of a apprentice instructors – Dick Thomas, 92, Stan email@example.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
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