Marand helps Ford make the FG Falcon launch


The Challenge :

When Ford required Body-shop upgrades for the "FG" Orion Falcon Sedan & Ute variants, they turned to Marand to provide turn-key solutions for the assembly of the "top-hat" structures.  This involved new flexible Body-sides and Framing robotic assembly facilities and upgrades to the existing Ballooning, Roofing & Shotgun stations.  Marand was responsible for simultaneous engineering, design, manufacture, installation, commissioning, launch and support through to mass production.  Ford standards required ABB robots and Allen Bradley PLCs.

The Solution provided :

Verified through simulation, the new flexible Body-sides facility comprised a total of 40 robots, 36 weld-guns, 30 grippers, 10 tool-changers, 5 buffer conveyors, 6 custom robot tracks & 18 combination assembly fixtures were required to achieve the cycle time of 110 seconds and an overall uptime of 98%.  The tooling was designed and manufactured to Ford Europe standards and the facility delivered in-line with the objectives defined by the Ford Production System.

The flexible Framing facility comprised 10 robots and formed part of the existing Framing Line, and involved an innovative combination of tooling frames mounted to 4 large payload robots with tool-changers that protected for quick change-over between models.  The facility was successfully integrated into the existing line after extensive civil and structural works completed during scheduled shutdowns and weekends.

The Outcome :

The entire Orion project was manufactured locally in Moorabbin and formed one of Marand’s most significant projects completed to date.  All equipment was successfully installed, integrated and commissioned by the local team, often within very short timeframes, without disruption to Ford’s existing production activities.  Through the combined efforts of Ford’s manufacturing team and Marand to thoroughly test and tryout facilities through pre-production run-at-rates, the facilities were successfully launched into mass production and almost immediately achieved the cycle time, MTBF & MTTR metrics.

The Customer :


Ford motor company is one of Australia’s leading local automotive manufacturers employing more than 3000 employees locally with production operations in Campbellfield and Geelong; they locally produce the world class Ford Falcon and Ford Territory range of vehicles.

More info: