Ford’s Bridgend engine plant’s new SI6 engine is the latest product to benefit from what the automaker claims are the “groundbreaking techniques” of the plant’s prototype centre.

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Technicians in the prototype centre defined how the new short in-line six-cylinder (SI6) petrol engines would be built on the same line as the V8. They highlighted better assembly processes aimed at improved overall efficiency.


In a claimed industry first, the prototype centre built a replica SI6 engine and sent the model down the line to ensure it easily passed all assembly points without fouling or sticking. Lessons learned were incorporated on the production line and in the build instructions to operators.


Bridgend has been assembling the initial run of SI6 engines at a rate of 20 a week for Volvo. They were assembled by a two-man team in two shifts, prior to volume production beginning this week.


Launch manager Jaime Ortiz Canavate said: “This is a highly motivated team. Everyone is enthusiastic and brought a lot of ideas to the project to make the new engine easier to build and to maintain during service.

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“Many gasket and sealing concepts were created by the team and tooling was developed with the assistance of the prototype centre team.”


Plant manager Bob Murphy sees tremendous potential for the prototype centre: “Concepts can be tried out in the centre and taken to the assembly line for verification or we can bring something off a line and test it in the centre without interrupting the assembly operation.”


Suppliers can also visit the centre to discuss projects and products, which can be tested without affecting production.