Ford Boosting Fusion Output By More than 30 Percent to Meet Demand
Ford hired 1,400 new employees at the Flat Rock Assembly plant and building the vehicle at this plant will expand Fusion availability by 30 percent, up to 350,000 units annually, according to the automaker.

Joe Hinrichs, Ford President of the Americas, celebrates with team members during the Fusion Job One celebration event at Flat Rock Assembly Plant. Photo courtesy Ford.

Joe Hinrichs, Ford President of the Americas, celebrates with team members during the Fusion Job One celebration event at Flat Rock Assembly Plant. Photo courtesy Ford.
Ford’s Flat Rock Assembly plant is now building the Ford Fusion, the first time the vehicle has been built in the U.S., the automaker stated. Ford hired 1,400 new employees at the Flat Rock Assembly plant and building the vehicle at this plant will expand Fusion availability by 30 percent, up to 350,000 units annually, according to the automaker.
Ford said Fusion sales are up 13 percent in the U.S. this year, and that through July, the automaker sold more than 181,000 Fusions, which is 21,000 more units than the automaker sold during the same period last year.
The automaker has invested $555 million in the Flat Rock Assembly plant, including the addition of a fully flexible body shop, which allows multiple models to be produced on the same assembly line. Ford also upgraded the plant’s paint shop with its three-wet paint process. The automaker said this process is more environmentally friendly and takes less time than conventional paint processes without compromising paint quality or durability.
Ford plans to introduce “dirt detection” technology at the plant as well, in order to ensure optimal paint surface quality. The automaker also uses laser brazing to weld the roof of the Fusion to the body and create a high-quality and aesthetically pleasing seam.
More Operations

Top 50 Executive Fleets
It is that time of year again! Time for the 2026 list of the Top 50 Executive Fleets, presented by Automotive Fleet and Volvo as part of its annual Fleet 500. Download now to see this year's list of companies!
Read More →
Gary Van Orden Retires After Nearly Four Decades in Commercial Fleet
From answering customer calls at Ford Motor Company to leading fleet sales across multiple OEMs and a fleet management company, Gary Van Orden's career reflects nearly four decades of leadership in commercial fleet.
Read More →
How Stellantis Plans to Get Ahead of Fleet Downtime
Vehicle acquisition may grab the headlines, but fleet uptime increasingly determines operating success. Darren Bradshaw of Mopar North America gives the details.
Read More →
Hyundai Releases 2027 Commercial Program Incentives
The 2027 Model Year "Fleet Street Incentives" are available to commercial and government fleets.
Read More →
It's All Downhill from Here! Fleet Industry Raises $22,000 for Skilled Trades Scholarships
Work Truck’s Lauren Fletcher and Automotive Fleet’s Chris Brown turned a friendly racing rivalry into $22,000 for automotive technology and skilled trades scholarships.
Read More →The Top 300 Commercial Fleets
The Top 300 Commercial Fleets: See the List
Read More →
Your Local Dealer Knows More Than You Think
Your local dealer can provide an information advantage that extends well beyond courtesy deliveries.
Read More →
Fleet Meets: Austin Schutte
Here are some industry insights, personal touches, and words of advice from the CEO and Founder of Anew Solutions.
Read More →Soap Box Derby Challenge: What’s Powering Team Brown
The car is coming together, the students are solving real build problems, and the fleet industry is helping push Team Brown toward the starting line.
Read More →
