Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Michigan Assembly Plant
  • Ford Focus Electric Range
  • Ford Focus Electric Range
To coincide with the announcement Ford made yesterday about the Focus Electric getting an estimated 100 miles per gallon equivalent (MPGe), the automaker invited a group of journalists to the Michigan Assembly Plant where it will build the EV alongside the gas-powered Focus and other vehicles. In fact, the MAP has already begun building Focus EVs, since the car goes out for its first deliveries in January. You can go on a visual tour through the plant in the gallery below.

While there, we got a few more details about the new EV, including that it will use a modified version of the leaves in the SmartGuage cluster from the first Fusion/Milan hybrids from 2008. This time, instead of leaves, the car will show drivers butterflies. What they mean, in general, is how much "surplus" range the driver has. "Surplus" here isn't some magic battery genie who grants you three wish miles whenever you rub his lamp. It's simply a graphical representation of how many EV miles you have after reaching your destination, should you input that into the navigation system. What's interesting is that the number of butterflies will vary for a particular number of miles depending on the particular car's history. Thus, careful drivers will see more butterflies to indicate 20 miles beyond the destination than someone who regularly jackhammers the go pedal.

Also, once you're arrived at your destination, the dashboard will show the driver what the efficiency results of the previous drive were, and there is a recapturing energy coach to give you instant feedback about how much of the potential braking energy you actually recaptured when you come to a stop. So, the car itself will offer a lot of information about how much range you have left in the battery and how to "get" more.

But here's the kicker: Ford isn't talking about official range estimates for the Focus Electric quite yet. Still, there were hints sprinkled around the press event yesterday, from a display showing a charging battery with the "full" coming at the 80-mile mark (pictured above, right. The image on the left was meant to illustrate how handy the 6.6 kW on-board charger will be to drivers who top off during the day) to an iPhone app demo that showed "full" being 96 miles (see this pic). We heard a rumor that Ford is predicting a 70-mile EPA range, but no one will say anything official. Remember, the Nissan Leaf is officially rated at 73 miles from its 24-kWh battery pack, so 70 miles seems about right, given the Focus' 23-kWh pack.
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Ford Introduces Gas-Free Focus Electric with 100+ MPGe Expected; Nearly a Third of Lineup Now Offers 40-mpg Model

Ford introduces gasoline-free 2012 Focus Electric, expected to be the first five-passenger electric vehicle with a 100 miles per gallon equivalent (MPGe)

Nearly one-third of Ford's vehicle lines will feature a model with 40 mpg or more in 2012

Focus Electric is the first all-electric vehicle to offer faster charging technology, allowing it to charge in half the time of a Nissan Leaf using 240-volt outlets

C-MAX Hybrid is projected to achieve better fuel economy than Toyota Prius v and C-MAX Energi plug-in hybrid projected to achieve better miles per gallon equivalent in electric mode than Toyota Prius plug-in hybrid.With the C-MAX lineup, Ford becomes the largest hybrid transmission producer in North America

WAYNE, Mich., Dec. 14, 2011 – Ford's world-class Michigan Assembly Plant is starting production of the 2012 Focus Electric, expected to be the first five-passenger, all-electric car to achieve more than a 100 miles per gallon equivalent (MPGe) fuel efficiency rating.

Focus Electric also is the first of its kind to feature faster charging, which will halve Nissan Leaf's time to fully recharge the battery and help drivers to more than double the expected single-charge range in a busy day of driving and recharging.

The car headlines Ford's transformed lineup, one-third of which will feature a model with 40 mpg or more in 2012, building on the company's commitment to give fuel-efficiency-minded customers the Power of Choice.

"The Focus Electric is a shining example of the leading fuel economy Ford is offering for each new vehicle," said Derrick Kuzak, group vice president, Global Product Development. "Whether people want a hybrid, plug-in hybrid or full battery-electric vehicle, we have a family of vehicles for them to consider, providing a range of options to best meet their needs and support their driving habits and lifestyles."

Even with relatively stable gas prices, fuel economy is the top purchase consideration for new vehicles. Nearly 45 percent of customers say fuel economy is their top consideration based on a Ford survey of Americans in 36 cities this fall. Styling is the next consideration, with only 16 percent of study participants saying it is their top purchase driver.

Ford's rollout of electrified vehicles began in December 2010 with the 2011 Ford Transit Connect Electric – a small commercial van built in collaboration with Azure Dynamics. Ford's other 40-mpg vehicles include:

Focus SFE
Fiesta SFE
Focus Electric
C-MAX Hybrid
C-MAX Energi
Three vehicles yet to be announced

With 20 years of Ford research and innovation behind the software and hardware technology, the company offers proven engineering and design with Focus Electric. Ford holds approximately 500 patents on the hybrid technology used in the new Focus Electric and its other electrified vehicles.

Faster charging
Focus Electric is designed to offer enough range to cover the majority of daily driving habits of Americans. Its expected 100 MPGe is better than Chevrolet Volt and all electric vehicles with seating for five.

It will be the first electrified vehicle to offer faster charging with 240-volt outlets, which can be installed in customer homes. The battery can be recharged in just more than three hours using a 240-volt charging station, about half the charging time of the 2012 Nissan Leaf.

Faster charging with 240 volts also can extend range as drivers can more quickly recharge between stops – up to 30 miles per charge hour – so they can more than double the vehicle's range with multiple charging stops during a busy day of driving.

A unique value charging feature, powered by Microsoft, will help owners in the U.S. charge their vehicles at the cheapest utility rates, lowering the cost of ownership.

Focus Electric introduces new features and technologies – including a unique version of the MyFord Touch® driver connect system especially for electric vehicles and a smartphone app called MyFord® Mobile that helps plug-in owners control their vehicles remotely.

The sleek and stylish five-door hatchback is designed to deliver real driving enjoyment as well. The all-electric powertrain and single-speed transmission provide immediate responsiveness and smooth acceleration when the driver steps on the accelerator, up to a top speed of 84 mph.

The Focus Electric is a dynamic driver's car, sharing the steering, handling and braking feel with the agile, sporty, fuel-powered Focus models upon which it's based. At the same time, the absence of a gasoline or diesel engine and outstanding aerodynamics lead to a remarkably quiet, comfortable in-car experience.

A limited number of Focus Electrics will first be available in California and the New York/New Jersey areas. Availability of the Focus Electric will expand in 2012 to the remaining 15 launch markets as production ramps up.

The 19 launch markets also include Atlanta; Austin and Houston, Texas; Boston; Chicago; Denver; Detroit; Los Angeles; San Francisco; San Diego; New York; Orlando, Fla.; Phoenix and Tucson, Ariz.; Portland, Ore.; Raleigh-Durham, N.C.; Richmond, Va.; Seattle; and Washington, D.C.

MAXimum efficiency
The Ford C-MAX Hybrid and C-MAX Energi plug-in hybrid are Ford's first compact multi-activity vehicles (MAVs) in North America and offer high mileage and low emissions as well as a distinctive design and flexible interior.

The C-MAX Hybrid and C-MAX Energi use the company's next-generation powersplit hybrid technology in combination with a lighter, smaller lithium-ion battery system. Both models provide maximum fuel efficiency by pairing the high-voltage lithium-ion battery and electric traction motor with a high-efficiency Atkinson-cycle gasoline engine. This technology enables the gasoline engine to run less than the previous generation.

C-MAX Hybrid is targeted to deliver better fuel economy than the Toyota Prius v. C-MAX Energi is expected to deliver better MPGe in electric mode than the Toyota Prius plug-in hybrid and to achieve more than 500 miles of driving range using the battery and engine.

The C-MAX Hybrid and C-MAX Energi, like the Focus Electric, have been engineered and built to deliver engaging driving dynamics and technologies. In addition, C-MAX Energi and Focus Electric will offer MyFord Touch and MyFord Mobile, designed to make charging and driving the vehicle even more efficient, affordable and easier to live with.

Hybrid transmission leader
When C-MAX Hybrid launches, Ford becomes North America's largest maker of hybrid transmissions.

Ford engineered the transmission and upgraded the controls with a goal of creating the industry's highest-performing and smoothest-operating hybrid transmission. Among the hybrid transmission's innovations:

Electric motors capable of operating at higher electric speeds
A new, super-efficient cooling system that enables higher speeds in electric drive
Optimized gear ratios enabling improvement in fuel economy
More precise controls to deliver higher levels of refinement as the powertrain transitions between engine and electric drive
Reduced weight to help increase fuel economy

This is the first hybrid transmission to be designed and built by Ford. Production is moving from a supplier in Japan to the Van Dyke Transmission Plant in Sterling Heights, Mich., which also will assemble battery packs for Ford's hybrid and electric vehicles.

Building green vehicles cleaner
Ford completely transformed Michigan Assembly Plant in Wayne, Mich., into an environmentally friendly workplace with flexible manufacturing capability.

With the new electrified vehicles and the new Focus ST performance model also coming in 2012, Ford's Michigan Assembly Plant is the first facility in the world capable of building a full array of vehicles – gas-powered, EcoBoost®, electric, hybrid and plug-in hybrid – all on the same production line.

The plant also features one of the largest solar power generation systems in the state as well as several electric vehicle charging stations, allowing the facility to operate on a blend of renewable and conventional electricity.

Renewable energy collected by the solar panels directly feeds the energy-efficient microgrid, helping power the plant. When the plant is inactive, such as holidays, the stored solar energy will provide power during periods of insufficient or inconsistent sunlight. Projected energy cost savings are approximately $160,000 per year.

The plant also has 10 electric vehicle charging stations that recharge the electric switcher trucks that transport parts between adjacent facilities – saving an estimated 86,000 gallons of gas a year.

Plus, 50 percent of the parts arriving for the all-new Focus are packed in cardboard, are carefully collected, sorted and recycled, as is the bubble wrap, the Styrofoam and the water bottles used by employees.

# # #

About Ford Motor Company
Ford Motor Company, a global automotive industry leader based in Dearborn, Mich., manufactures or distributes automobiles across six continents. With about 166,000 employees and about 70 plants worldwide, the company's automotive brands include Ford and Lincoln. The company provides financial services through Ford Motor Credit Company. For more information regarding Ford and its products worldwide, please visit

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    • 1 Second Ago
      • 8 Months Ago
      Awesome! I cannot wait to see these around!
      • 8 Months Ago
      If the EPA AER comes in at 70 miles that will be a big +1 for Ford. I thought it would be between 67 and 71, but I thought Ford might disappoint. 70 isn't bad for a city car. I think Ford is putting more time and money into the C-Max Energi, but the FFE might surprise to the up side. And it probably would have, if Ford had chosen to price it within $2k of the Leaf instead of $4k higher. Given, the Focus Electric is a much better looking car and it has a stronger pack management system, but it has a small boot and a slightly smaller pack. This first generation, the current Volt, Leaf and the coming soon FFE, are each a compromise, in one way or another. But I think in just a few years the negatives will be less noticeable and the positives will be even stronger. It won't hurt that gas prices will probably be 30% to 50% higher and electricity prices will probably only go up 10% to 20%... So electricity will go from being much cheaper than gas to incredibly inexpensive in comparison. Great days, more cars coming on the market with little or no need for foreign oil.
        • 8 Months Ago
        70 miles is pretty short considering it costs $40K. I think the Volt, Leaf, and Mitsubishi-i all present better values. But that said, it is nice to have another EV available to choose from.
      • 8 Months Ago
      ford has made the foucus and festiva its tech show horses if you want to know what they are thinking these two models are where its at
      • 8 Months Ago
      so, you can buy two standard focus's with some change left, or one electric one?
        • 8 Months Ago
        That is right, and it is also apparent that you aren't getting the point. The FFE will use no gasoline at all, so when the price of oil and gas go up in the next few years, they will be cruising around for pennies on the dollar compared to the rest of us with our ICE vehicles. But even that isn't the point right now. The early adopters are paying for the development of an entirely new method of powering our cars. It is going to be more expensive than an ICE hybrid for the next few years, probably, but it will let us transition from relying on foreign oil producers for 50% of our oil, thereby exporting $1,000,000,000 every day. That is a Billion dollars a day we are sending overseas for oil. And these 'expensive' BEV's and EREV's are going to help us reduce that number drastically in the next few years.
      • 8 Months Ago
      Butterflies? Really, Ford, really?
      • 8 Months Ago
      Another car to watch if it gonna sale a lot. To date volt and leaf sales have been quiet. Is it really because they cannot build a lot or because the demand is low or both ?
        • 8 Months Ago
        They are both pretty expensive cars, they are brand new models, and they are filled with new technology. That makes both the Leaf & the Volt pretty small market cars. And then add in the fact that the Leaf has limited range and refueling with electricity is slow. EVs are a tough sell . . . but that said, they are doing pretty well.
      • 8 Months Ago
      More than twice the range, on the same size battery as the Karma. Sounds about right 52MPGe vs 100MPGe. As inaccurate as people may say the EPA numbers are, they are at the very least relative numbers to go by. The Karma is a fantastic car, but it is just not in the ballpark with truly green cars. With Fisker's logic EPA 32/mi range = 50/mi real world (a difference of +36% from EPA), so EPA 70/mi range = 95/mi range (like the 96 number the iPhone app shows). So the FFEV has a real world range of 95/mi on the same size battery as the Fisker. That also means you should be getting 99 real world miles out of the LEAF (which we know gets about that). That said, Fisker was probably right on the money at 50 mile real world. Still not impressive at all, but an accurate real world number no less.
        Marco Polo
        • 8 Months Ago
        @JeremyD Jeremy, I think you are missing the point! The Fisker-Karma is a 'greener' car. The Leaf is a Green car, when both cars are in electric mode, the emissions and fuel consumption are equal. However, buyers of the Fisker like the 'green(er) aspect of the Karma, but are not in the market for a small EV. To most car buyers, fuel consumption is only one of a number of considerations. Marginal fuel consumption differences are not a deciding factor.
          • 8 Months Ago
          @Marco Polo
          @Marco Polo & PR "in electric mode, the emissions and fuel consumption are equal" In this case electricity is fuel. My point was the Karma uses twice the electricity per mile. You cant possibly argue 52MPGe vs 96MPGe 100MPGe etc... all subjected to the same conditions the Karma uses TWICE the electricity for that 32 miles range than does the LEAF. Its like saying the Prius is just as efficient as a car that gets half the MPGs. We dont even have to discuss the range extended efficiency here.
        • 8 Months Ago
        It all comes down to how you use a Karma. On top of that, a Fisker Karma that is driven 30 miles a day all on battey power uses the same amount of gas as a Leaf that is driven 30 miles a day on all battery power. None. Translate that into a typical 2-car car family. If a family (for whatever legitimate reason) decides that they can't replace every car with EV's and still need (for reasons known to them) a vehicle that burns gas, which of these two choices is greener? A) 1 EV, 1 Gasser. B) 1 EV, 1 Karma (or similar PHEV/REEV). If you chose (B) you've figured out exactly why the Fisker is green.
        • 8 Months Ago
        "As inaccurate as people may say the EPA numbers are, they are at the very least relative numbers to go by." And that's why they exist. Not to give a definitive prediction of a specific car, but to help provide a basis of comparison between cars. "Therefore, the EPA ratings are a useful tool for comparing the fuel economies of different vehicles but may not accurately predict the average MPG you will get." As an aside, Edmunds reviews seem to find Fisker better than the EPA: "In our hands the Karma's best range was 45.4 miles. That was done on our "one lap of Orange County" city loop, which includes numerous signals and absolutely zero freeway. The second best range was 43.3 miles, this time on the freeway at 65 mph during the mid-day traffic lull. Leadfoot John O'Dell (ironically our green car editor) got 34.5 and 39.8 out of it at somewhat more impatient freeway speeds. His house also sits atop a significant hill with no small amount of elevation gain along the way. Bottom line, our average range of 40.8 miles is 27% better than EPA's rating. Our best run was 42% better. And I have reason to believe that the Karma was not 100% charged before I made my two mid-40 runs. Fisker, it seems, has a legitimate beef with the EPA and its range rating of just 32 miles." "Admittedly, this was a short test in which fuel economy and range were being examined. People do tend to drive more naturally in our long-term test cars that are in our hands for months on end. In such a scenario the Karma might perform differently than it did here, but we can't see its average performance falling near as low as the EPA ratings it carries. From where we sit, the EPA's rather pessimistic range and gasoline fuel economy ratings for the 2012 Fisker Karma doesn't seem to be an accurate picture of what this series plug-in hybrid can do at the pump or at the plug. We're much more impressed with the 2012 Fisker Karma than we thought we'd be after hearing of EPA's downgrade. In fact the amount of electric range on offer is frankly remarkable for a car of this size and sporting pretense. For now, however, track tests of the sporty side of the Karma's dual personality will have to wait until the next time we get our hands on one."
      • 8 Months Ago
      I still want this car, just need to figure out how to afford it...
      • 8 Months Ago
      I am glad to have another electric vehicle in the market. I just don't particularly care for the battery placement which limits the trunk space.
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