Ford Motor has started assembling high-voltage battery packs at its Cologne plant, marking a significant step in localising production for its all-electric Explorer and Capri models. The move is expected to improve logistics, quality control, and integration with vehicle assembly, the company said on Thursday.
The Cologne site, which has produced only electric vehicles since last year, now assembles three battery configurations—52 kWh, 77 kWh, and 79 kWh—for the Explorer and newly launched Capri, both based on Volkswagen’s MEB platform. Previously, the battery packs were manufactured by Skoda in the Czech Republic.
Ford has converted a former engine factory at the site to accommodate battery production. The new line features 180 robots performing tasks such as welding and glueing across a two-kilometre automated assembly system. Each battery pack can contain up to 12 modules, comprising around 2,775 parts.
“This investment reflects our commitment to building a vertically integrated EV manufacturing network in Europe,” Ford said. The battery assembly facility is part of a broader $2 billion overhaul aimed at transforming Cologne into a ‘Factory of the Future.’
The upgrade comes amid internal unrest. Workers staged the first strike in the plant’s nearly century-long history in May over job cuts and reduced hours tied to underwhelming EV sales. Despite a €4.4 billion capital injection promise from Ford’s U.S. headquarters in March, a key financial guarantee was simultaneously withdrawn, adding to employee concerns.