• Feb 20th 2009 at 9:27AM
  • 22

As of this morning, Ford's Romeo engine plant has officially produced its 10 millionth engine. That's a whole lotta V8s. Even more impressive, it only started making motors back in 1990 when it was converted from a tractor plant. Romeo now builds engines for the Ford F-150, Mustang, Shelby GT500, Explorer, E-Series van, Crown Victoria, and the Mercury Grand Marquis at a rate of 140 per hour. That's one every 26 seconds! The combined output of those engines for 2008 alone was 88,900,000 horsepower!

While the first engine produced in Romeo was a lowly 2-valve 4.6L V8, the ceremonial 10 millionth engine was a 4.6L 3-valve V8, so things have changed quite a bit. We kid, but as the engine maker for two iconic Ford vehicles, Romeo is a really important part of the Ford manufacturing scene. It employd around 1,000 workers on two lines, one making the 4.6L V8 and the other hand assembling the supercharged 5.4L V8 for the GT500. The 10 millionth engine will fittingly be installed in a 2010 Mustang GT after it's shipped to AutoAlliance International in Flat Rock, MI.

[Source: Ford]


Ford's Romeo Engine plant produces 10 millionth engine, continues to power ford icons
  • Romeo Engine Plant, produces V-8 engines for Ford F-150, Mustang, Shelby GT500, Explorer, E-Series van, Crown Victoria, and the Mercury Grand Marquis
  • Plant produces 140 engines an hour on its high-volume line, with hourly and salaried teams focusing on continuous improvement and quality basics.
  • In 2008, engines built at Romeo output 88.9 million horsepower, 2,750 times the combined horsepower of this year's starting field at Daytona.
ROMEO, Mich., Feb. 19, 2009 – After years of delivering power to two of Ford Motor Company's iconic products, the Ford F-150 and Mustang, Romeo Engine Plant has reached a historic milestone – the production of its 10 millionth engine.

The 10 millionth engine, a 4.6 liter 3-valve V-8, will be shipped to AutoAlliance International in Flat Rock, Mich., to be installed in a new 2010 Mustang GT.

The V-8 engines manufactured at the plant build on two of Ford's strengths – capability for the Ford F-150, the best-selling truck in America, and performance for Mustang, America's favorite muscle car. In 2008 alone, the engines produced at the plant generated a combined 90 million horsepower, about 2,750 times the combined horsepower of this year's starting field for the Daytona 500.

"Romeo Engine's products are powering two of Ford's iconic vehicles and we focus on quality every minute of every day," said Plant Manager Shaun Whitehead. "We deal with a great deal of complexity on our lines, and we've had very strong quality performance over a very long period of time."

The Romeo plant, converted from a tractor manufacturing facility, produced its first engine in 1990 – a 4.6-liter, two-valve V-8. Today the plant, with a thousand employees, manufactures V-8 engines along with many of their major components including cast iron blocks, crankshafts, cylinder heads, connecting rods, camshafts and aluminum blocks.

The plant operates two lines – a high-volume Line, or HVL, and a niche line, where employees meticulously hand build 5.4 liter, 4-valve supercharged engines for the Shelby GT500. The HVL builds 4.6 liter two-valve and three-valve V-8 engines and 4.6 liter 2-valve Flex Fuel V-8 engines, delivering 140 engines an hour.

"We have more than 600 purchase parts from more than 150 suppliers so we deal with a large amount of intricate processes and parts on our line," Whitehead said. "We have 11 different models on the line that we handle for seven different assembly plant customers – as well as the Ford Customer Service Division."

The engines are shipped to plants in Michigan, Ohio, Kentucky, Missouri and Canada where they are placed in the F-150, Mustang, Econoline, Explorer, Crown Victoria or Grand Marquis models.

The HVL line stretches more than 4,000 feet, with quality monitored every step of the way to deliver continuous improvement. From 2007 to 2008, combined engine warranty data on the 4.6 liter engines showed a 9 percent improvement rate year over year, based on the first three months of use.

"Quality really is our number one priority," said Quality Manager Phil Kloss. "Our Quality Operating System focuses on continuous improvement and an adherence to quality basics."

In-line testing is consistently refined and error-proofed to detect and drive prevention of variations. Periodic job observations ensure operators follow instruction sheets 100 percent of the time, and detailed management reviews of all aspects of the system are designed to monitor any changes and ensure seamless launches.

"We have hundreds of eyes throughout our machining and assembly processes," Kloss said. "Employees on the line constantly bring attention to changes in feel, appearance or test performance – even when unrelated to the task at hand."

That teamwork obviously is paying off – both in quantity and quality.

"This is a huge accomplishment for our plant," said Randy Newsom, UAW Local 400 Chairman at Romeo Engine. "We started this plant with a team concept that was really new for Ford when they converted from the tractor plant. Over the years, we've stayed consistent in our team approach, with both hourly and salaried employees working together. We strive to be the best engine builders in the world, and we'd like to build another 10 million."

# # #

Ford Motor Company
Ford Motor Company, a global automotive industry leader based in Dearborn, Mich., manufactures or distributes automobiles across six continents. With about 213,000 employees and about 90 plants worldwide, the company's wholly owned brands include Ford, Lincoln, Mercury and Volvo. The company provides financial services through Ford Motor Credit Company. For more information regarding Ford's products, please visit www.ford.com.
[Source: Ford]

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    • 1 Second Ago
      • 6 Years Ago
      I wonder if there are still parts that don't interchange between the motors produced there and the Windsor plant.
      • 6 Years Ago
      Romeo is a good plant. I have been in there many times. Congrats to them!!
      • 6 Years Ago
      That's nothing. There were 47,000,000 3800's made in roughly the same time period, and that's not counting the original 3.8L V6's we made at that site before the 3800 incarnation.
      • 6 Years Ago
      The Modular engines were such an improvement over the dinosaur Windsor engines, it's unbelievable. Congratulations Ford, and keep 'em coming with new improvements!
      • 6 Years Ago
      Why go from a 2 valve/cylinder to 3 valve/cylinder rather than the now standard 4 valve/cylinder? costs?
        • 6 Years Ago
        3-valve is still SOHC so it's cheaper, simpler and more compact than DOHC 4-valve, I believe.
        • 6 Years Ago
        A lot of people in the Mustang aftermarket feel that the 3 valve head flows as well as the 4 valve head. With fewer moving parts, there's less friction, less expense, and less weight and more room to work.

        Of course the Honda guys need their 4 valves to be happy, doesn't matter whether it's of actual benefit, they sleep better knowing their engines have 4 valves per cylinder and their VTEC is about to kick in yo.
      • 6 Years Ago
      Mercedes larger (V8) motors were 3-valve for quite some time and are still used in the supercharged AMGs (http://en.wikipedia.org/wiki/Mercedes-Benz_M113_engine). And as was pointed out above, VW/Audi's entire lineup was 5-valve for a while (none remain). The Ferrari F355 engine was also 5 valve (it's part of the reason for the name!).

      Valves are a tradeoff, more is not always better. It takes more energy to open and close more valves and that means higher fuel consumption and less power output compared to an engine that manages to flow the same amount of air with fewer valves.

      When GM can make a 2-valve pushrod motor that can flow far more air than any 4-valve motor even close to it in price, I think the case for more valves is not completely clear. I can't condemn all multiple valve motors in one fell swoop, because usually there's no motor to compare against that is similar in so many other ways. But I can speak specifically to my own 5V Audi 2.7T. It's overly complex and burns too much fuel. You could see with the 4V 3.0L that followed it that the 5V was doing nothing but adding cost and complexity. This was shown if anything even more clearly on the 4-cylinder transition from the 5V 1.8T to the 4V 2.0T and on the 8-cylinder transition from the 5V 4.2L to the 4V 4.2L (which led to the RS4/R8 motor). To me it's clear, if you can't do it with 4 valves, maybe it isn't something that's useful to do.
        • 6 Years Ago
        "When GM can make a 2-valve pushrod motor that can flow far more air than any 4-valve motor even close to it in price, I think the case for more valves is not completely clear."

        flow capability is only one thing to consider. the one thing that multiple valves gives you is a bit more flexibility. While one big valve might surely be able to flow as well as two smaller valves, one thing you're trading off is swirl/turbulence capability at lower engine speeds. If you try to make up for that by doing some tricks in the port, you end up hurting flow capability, and so on. This is less of an issue with modern fuel systems, but it's still there. It's part of the reason why on the street, the 440 6-barrel engine was a better performer than the "legendary" 426 Hemi; but on the racetrack the Hemi ran away from everyone.

        then, of course, multiple cams give you a lot more freedom to do VVT schemes.
      • 6 Years Ago
      They used a 3 valve design probably because it was cheaper, less complicated, less weight, less friction, less heat etc.. But I have been following mustang a long time and I know Ford got the 3 valve heads to flow just as good as the 4 valve cobra heads and that was the primary reason it got the go ahead along with added benefits listed above because I read the article on it in MM&FF when the 2005 Mustang just came out.
        • 6 Years Ago
        Next time your following a mustang and it goes off a cliff.... follow it.
      • 6 Years Ago
      This Motor Is Very Strong Its Only Down Side Is Its Weight..
      • 6 Years Ago
      WOW, a 3 VALVE motor.
        • 6 Years Ago
        "still, not much to be proud of"

        only if you're dumb enough to judge an engine by the # of valves it has.
        • 6 Years Ago

        still, not much to be proud of
        • 6 Years Ago
        I know
        • 6 Years Ago
        they mean 3 valves per cyl pal.
        • 6 Years Ago
        @Kitko: yes, because "more stripes, more adidas"
      • 6 Years Ago
      Kudos, Ford!

      Keep 'em comin'!
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