The Fumes to Fuel program at Ford Rouge Complex strives to make process of adding color onto cars more environmentally friendly
Take the Ford Rouge Factory Tour, and a number of sustainable, environmentally conscious manufacturing practices and processes jump out at you right away. You’ll see the Dearborn Truck Plant’s massive living roof and purposeful use of natural light. You can even walk the surrounding outdoor sanctuary where birds nest, flowers bloom and honeybees flourish.
“What really impresses me is Ford’s continued commitment to tackle big issues and figure out new processes and ways of doing things that not only make it better for the product but also address air and water issues,” said Cynthia Jones, general manager of the Ford Rouge Factory Tour. “Ford is pushing the paint industry to make paints better, and it is also pushing to make its own processes better.”
Solvents in the paint used to coat vehicles wind up in the exhaust system, and what’s left is “nasty stuff,” according to David Crompton, a senior environmental engineer at Ford Motor Company. “A lot of countries will not permit the discharge of it into the atmosphere,” he added, “so our early work focused on developing ways of abating those solvents.”
The Fumes to Fuel process, which has been refined over several years, pushes solventladen exhaust air through a carbon bed. The carbon removes the solvents from the exhaust, leaving behind clean exhaust that can be safely discharged into the atmosphere. The carbon is then swept with nitrogen, heating it up and removing the solvents. The carbon returns to the absorption stage, and the solvent-laden nitrogen is condensed into a liquid form.
The entire process ends up being more environmentally friendly than producing waterbased coatings, because less energy is required and the potentially harmful solvents are abated.
“Some of our competitors chose waterbased coatings,” Crompton said. “We believe that solvent-born technology provides the best overall environmental performance because the technology requires less energy consumption, which translates into lower CO2 emissions. It also allows lower facility and operating costs, so there’s a smaller overall footprint.”
Another added benefit, the solvent-born coatings give Ford vehicles a best-in-class finish in terms of durability and chip and scratch resistance.
Did You Know? The Ford Rouge Factory Tour’s Manufacturing Innovation Theater received a 2016 Thea Award for outstanding achievement for a brand experience. The Thea awards program honors creative excellence in theme parks, museums and other attractions, and is considered one of the attraction industry’s greatest honors.
This story originally ran in the June-December 2016 edition of The Henry Ford Magazine.
Bruce McLaren and Chris Amon won the 1966 24 Hours of Le Mans in the #2 Ford GT40 Mark II. THF252433
Fifty years ago this month, Ford Motor Company earned one of its most memorable racing victories: a stunning 1-2-3 finish at the 24 Hours of Le Mans endurance race. No win in that famed French contest comes easily, and Ford’s arrived only after two years of struggle and disappointment. But that story is among the most interesting in motorsport.
There was Ford’s failed bid to buy Ferrari in 1963, which left Chairman and CEO Henry Ford II determined to beat the Italian automaker on the race track. There was British designer Eric Broadley, whose sleek Lola GT Mark VI car inspired the design of Ford’s Le Mans car, the GT40. There was Carroll Shelby, the larger-than-life designer and team manager who turned around Ford’s struggling program. And there were drivers like Ken Miles, who gave everything – including his life – to the effort.
It all culminated with New Zealander drivers Bruce McLaren and Chris Amon standing on the podium with Henry Ford II on June 19, 1966, having proved that Ford Motor Company could build race cars as good as – better than – any in the world. As if to prove that the win wasn’t a fluke, Ford came back to do it again in 1967, this time with American drivers – Dan Gurney and A.J. Fort – in an American-designed and built car – the Mark IV.
In recognition of the 50th anniversary of Ford’s first Le Mans victory (and, not incidentally, on the eve of Ford’s return to that race), we’ve produced a short film on the 1967-winning Ford Mark IV and the bumpy road that led to it. It’s a story that’s always worth retelling, but especially in a milestone year like this.
Matt Anderson is Curator of Transportation at The Henry Ford.
This month, AAA of Michigan commemorates 100 years of serving motorists in the Great Lakes State. It’s an impressive milestone. The first automobile clubs were founded in 1899, not long after the automobile itself debuted on American streets. These original groups were social and political organizations that arranged auto tours, lobbied for car-friendly legislation, and encouraged road and highway improvements throughout the United States. Their work did much to change the car from a plaything for the wealthy into an everyday necessity.
In time, these clubs evolved into non-profit service organizations that, under the national umbrella of the American Automobile Association (established in 1902), printed road maps, created hotel guides, sponsored driver safety programs, offered automobile insurance, and provided roadside assistance to their members. Until the mid-1950s, AAA even sanctioned automobile races, including the Indianapolis 500.
As of 2016, AAA is comprised of 69 member clubs across the country. AAA of Michigan is located right here in Dearborn, not far from The Henry Ford’s campus. In honor of the anniversary, enjoy a few of the AAA of Michigan-related pieces in our collection.
Matt Anderson is Curator of Transportation at The Henry Ford.
John was motivated the same way many photographers with a deep appreciation for history are: he wanted to capture things that had become overlooked, structures that were endangered, vulnerable, and on the brink of destruction. But rather than choosing a neighborhood, or town or region he chose what could be found along the edges of all the old roads, the pre-interstate routes stretched throughout the United States—like a local historian of endless highways. His finest images look like stills from a perfect road movie, and they capture an element of the nation’s essence and identity—mom and pop businesses, motels, diners, crazy signage and attractions, clamoring for the attention of motorists, played out against distance and motion.
Restored architectural gem stands out in its industrial space You don’t usually associate large manufacturing factories with architectural beauty. Sightseers at the Ford Rouge Complex’s glass plant, however, might be inclined to think otherwise.
This plant looks different. No concrete, only rivets and steel. From inside, the high roof and floor-to-ceiling windows create an unusually airy, spacious atmosphere. Natural light can’t help but stream in, creating a softness and easy glow.
Designed by famed American industrial architect Albert Kahn, the Ford Rouge’s glass plant was built in 1923 as an automotive glass-production facility. “It was about achieving volume,” Don Pijor, launch manager at the Dearborn Truck Plant and site expert for the glass plant, said of the building’s original design. “This space was built with steel columns riveted together, which gives it much more usable real estate.”
In the late ‘90s, the 40,000-square-foot building was taken out of the complex’s production equation, its sweeping windows covered with aluminum and its new primary purpose as a warehouse.
When the restoration process began in the mid-2000s, the original intent was to transition the building into office space. Pijor later helped persuade Ford Motor Company leadership to put the plant to better use as a prove-out and employee training building for the Ford F-150, the truck built at the Rouge’s Dearborn Truck Plant.
Careful decisions were made at every corner during the restoration. The building’s window glass, for example, had come from Europe, so the restoration team reached out overseas to the original manufacturer for the glass to replace the windows. Entry doors to a fire station that was part of the building’s layout were also replaced to replicate those of the original specs.
“It’s beautiful,” Cynthia Jones, The Henry Ford’s Ford Rouge Factory Tour manager, said of the glass plant today. “There’s lots of natural light, and even though the fire station doors are in an area the public doesn’t see, restoring them showed respect for the continuing history of the site.”
Today, the glass plant is a house for innovation, used for prototyping by Ford engineers and designers. As a result of its newfound purpose, the building’s glass at the lower levels is frosted so outsiders can’t see the confidential work being done inside.
Said Jones of balancing the building’s historical integrity with its modern uses, “When you’re making choices about restoring buildings, you look at product — what is it we’re making at this place and what does it need? You’re also employee-driven because if they can’t do their job well here, changes have to be made. Third, how does it affect the area around it? I think this site has that balance.”
Though the effectiveness of the plant’s current functions are at the forefront of any decision-making about its form, preserving its history is meaningful for the people who work there as well as for posterity. Added Pijor, “To sit in this space and watch flaming ore cars go by, it’s as if it has been like this for 100 years.”
National Historic Landmark The Ford Rouge Complex was designated a National Historic Landmark in 1978.
The rare designation (with just 2,500 historic landmarks nationwide) usually restricts future changes to a site. The Ford Rouge Complex, however, is recognized as remaining in continual operation, which means the designation can be maintained even as the site continues to evolve.
“It’s important for the public to be aware” of the designation, said Jones. The designation is marked at the complex’s entry with a plaque and a statue of Henry Ford.
Summer 2015 marked 100 years since Ford started acquiring the property which the Rouge now inhabits. “We’re carving out space within this giant industrial complex to recognize its history and the history of the hundreds of thousands of people that have been employed here,” said Jones.
We're very pleased to announce that we are launching a new partnership between The Henry Ford and the Google Cultural Institute, available to anyone with Internet access here. The Google Cultural Institute platform features over 1,000 cultural heritage institutions worldwide, and more than 6 million total artifacts, “putting the world’s cultural treasures at the fingertips of Internet users and … building tools that allow the cultural sector to share more of its diverse heritage online” (in Google’s own words).
How did a shirt pocket lead to a feat of engineering?
The origins of Hewlett Packard’s HP-35 Scientific Calculator began with a challenge. In 1971, William Hewlett dared his engineers to prove their engineering prowess by miniaturizing the company’s 9100A Desktop Calculator—a forty-pound machine—into a device small enough to fit into a shirt pocket. The calculator’s target size of approximately 6x3 inches was supposedly arrived at by measuring one of Hewlett’s own shirt pockets.
The twelve or so experimental HP-35s that began as "company hacks" soon proved useful beyond the prototype stage. They were popular among the staff who built and tested them, and were presented for marketing studies. Despite a high manufacturing cost driving a retail cost of $395 (equivalent to $2200 in 2015), and research that warned of a limited market, Hewlett-Packard decided to proceed with production. The company’s 1972 sales goal of selling 10,000 calculators was quickly exceeded: they sold 100,000. Its rapid success made the slide rule obsolete practically overnight, as engineers, scientists, and mathematicians abandoned their analog calculating devices in favor of embracing the digital future.
The HP-35 (named for its 35 keys) was the world’s first handheld scientific calculator. This advanced machine, with its full suite of features, was capable of processing more complex mathematical functions than any other calculator on the market at the time. It was also the company’s first product to use both integrated circuits and an LED display, which eased communication between the screen and keys. The HP-35 inspired others too—it caught the attention of a young Hewlett Packard engineer named Steve Wozniak. During the day, he worked at designing follow-up models of the calculator; in the evening, he developed his own electronic projects at home. All the while, he was percolating ideas towards the beginnings of the Apple 1 computer.
The Henry Ford Archive of American Innovation™ opens the door to knowledge for lifelong learners by immersing them in stories of the greatest inventions and breakthroughs throughout history. Join us on our quest to spark innovation around the globe by giving a gift to The Henry Ford today.
How did a weaving loom lead to one of the greatest technology innovations of the 21st century?
The Jacquard Loom was a significant breakthrough in the history of textile production, an essential manufacturing tool of the Industrial Revolution. Joseph Marie Jacquard, a silk weaver from Lyon, France, first demonstrated his improved drawloom at an industrial exposition in Paris in 1801. By 1803, a spark of genius inspired him to make another improvement to this loom—the “Jacquard attachment.”
This mechanism, mounted above the loom, uses a continuous chain of punch cards to control the lifting of individual threads. Each card on the loom corresponds to a hook, which can be raised or stopped depending on whether the hole is punched out or solid. The cards are mounted on a rotating cylinder and pressed against pins, which detect the presence of holes. The loom’s hooks are raised or lowered by a harness, which guides the thread to form a pattern in the fabric.
The reviewers thought it had no chance of becoming a hit. Even writer-director George Lucas wasn’t sure about it. Sure, he’d had a hit with “American Graffiti”—a film deeply rooted in nostalgia and American popular culture. But this was different. Maybe a little too wacky for the general public, he thought.
But moviegoers thought differently. They turned out in record numbers to see “Star Wars” over the summer of 1977. Lines stretched for miles outside movie theaters. Tickets sold out as soon as their box offices opened. This first “Star Wars” movie (later subtitled “Episode IV - A New Hope”) went on to not only win six Oscars but to become one of the most popular and highest-grossing films of all time.
It’s an old museum-related joke: You don’t feel old until you see your toys exhibited as historic artifacts. Okay, so I felt a bit aged the first time I saw that Star Wars lunchbox in Your Place in Time, but I never questioned its right to be there. For us Gen X types, few things are so much of our time as Star Wars.
While I was around when all three of the original films were in theaters, most of my viewings came via videotapes recorded from HBO airings. (Heh, a Star Wars viewing still doesn’t feel quite right to me unless it starts with this.) Not until Return of the Jedi arrived in 1983 was I old enough to see one of the movies on the big screen. I still remember being thrilled by the sarlacc pit battle and the speeder bike chase, being saddened at Yoda’s death, and being generally grossed out by Jabba the Hutt. Disgusting or not, it was satisfying to finally see that vile gangster after hearing his name dropped ominously in the first two movies. All in all, it was a magical experience, and the reason that I don’t personally rate Jedi as a lesser work than its predecessors.