Ford ditches century-old assembly line for parallel-branch production system at Louisville

Ford's $2 billion Louisville overhaul replaces its moving assembly line with a "universal production system" from a team led by ex-Tesla executive Alan Clarke. A three-branched assembly tree builds front, rear, and battery-plus-interior modules in parallel, converging for final mating. Ford targets a net 15% assembly-time reduction. Prototype builds of the Fathom EV truck begin Q1 2027.