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Solar Energy and Advanced AI Help Build All-New Ford Transit Custom at Ford Otosan’s ‘Plant of the Future’

  • Ford Otosan inaugurates revolutionised Yeniköy Assembly Plant that sets a new benchmark for automotive production in Türkiye as part of a record €2 billion investment
  • Production of all-new Transit Custom – Europe’s best-selling one-tonne van – and Tourneo Custom multi-activity vehicle underway; electric versions to follow
  • Official inauguration celebrates plant enhancements that optimise efficiency and are further milestones on Ford Otosan’s journey toward carbon neutrality

KOCAELI, Türkiye, Nov. 4, 2023 – Ford Otosan has celebrated the transformation of its state-of-the-art Yeniköy Assembly Plant, where production of a new generation of Ford Transit Custom vans is underway, boosting productivity for Ford Pro commercial vehicle businesses across Europe.

Advanced solar energy technology, end-to-end management driven by artificial intelligence and noise-reducing assembly lines are among the innovations delivered as part of the €2 billion investment in the Ford Otosan production facilities in Kocaeli including Yeniköy – the largest ever investment in the private sector in Türkiye.

Ford Otosan is a publicly traded joint venture between Ford Motor Company and Koç Holding A.Ş., established more than 60 years ago. The company’s first-of-its-kind multistorey facility produces the all-new Transit Custom 1,2 – Europe’s best-selling one-tonne van 3 – alongside the all-new Tourneo Custom 4,2 multi-activity vehicle offering spacious and flexible accommodation for up to nine occupants.

Next year volume production of the electric E-Transit Custom 5,6 and E-Tourneo Custom will begin, 7,6 supported by sustainability credentials that will contribute to Ford Otosan achieving carbon neutrality across all of its facilities in Türkiye by 2030.

“The state-of-the-art Yeniköy Assembly Plant is already helping Ford Pro enhance quality for customers and as one of the world's most efficient automotive production facilities is setting new standards for producing multi-energy commercial vehicles at scale,” said Hans Schep, general manager, Ford Pro, Europe. “Ford Pro has been Europe’s top-selling commercial vehicle brand for the past eight years. As a leader we want to enhance the ownership experience for our customers with transformative technologies, and by expanding our vehicle offering and streamlining production and engineering.”

The Yeniköy Assembly Plant has been developed to set a new benchmark for automotive manufacturing in Türkiye and leads the electric transformation of the industry in the region.

The revolutionised facility is now one of the most efficient plants in the entire automotive industry. Part of the plant’s annual electricity consumption is provided by built-in innovative applications including the Turkish automotive industry-first use of photovoltaic glass walls. Solar panels on the roof also contribute to reduced reliance on externally sourced electricity, all of which is certified renewable. In addition, Solar Wall technology captures sunlight to heat water for the facility, reducing natural gas usage.

Cutting-edge manufacturing solutions are used across the production process. Real-time data and artificial intelligence combine to create “digital twin” virtual manufacturing simulations, helping to optimise production efficiency and allow nimble responses to demand fluctuations, supply of components or variations in production processes.

The multistorey design of welding and assembly workshops enhances production line efficiency by allowing teams to integrate more closely. Wireless, rechargeable electric tools have also replaced pneumatic equipment in several parts of the production line, for a quieter, more comfortable working environment.

In 2025, the Yeniköy Assembly Plant will expand its capacity to 405,000 units for the production of the new generation one-tonne vehicles.

“As the smart factory of the future, the Yeniköy plant manufactures flexibly, efficiently, and more sustainably; implementing advanced technologies for fully connected and versatile production,” said Güven Özyurt, general manager, Ford Otosan. “The Yeniköy plant represents the future of our business, and it will help us meet the growing demands of our customers who seek cutting-edge design, smart, and zero-emission vehicles now and in the years to come.”

Available to order now, the all-new Transit Custom is reinvented with customer-inspired innovations including a segment-first tilting steering wheel and time-saving Delivery Assist system, while the all-new Tourneo Custom delivers new levels of capability, luxury and design in a versatile multi-activity vehicle with up to nine seats.

Both vehicles offer the broadest-ever choice of variants including new plug-in hybrid models and intelligent all-wheel drive, as well as full integration with the Ford Pro platform of software and services via standard 5G connectivity. 8

The electric E-Transit Custom and E-Tourneo Custom will begin arriving with customers from summer 2024.

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1 Ford Transit Custom EcoBlue diesel homologated CO2 emissions 178-296 g/km WLTP, homologated fuel efficiency 6.8-11.3 l/100 km WLTP. Ford Transit Custom Plug-In Hybrid homologated CO2 emissions 35-45 g/km WLTP, homologated fuel efficiency 1.6-2.0 l/100 km WLTP and pure electric driving range 48-55 km WLTP.

2 The declared WLTP fuel/energy consumptions, CO2 emissions and electric range are determined according to the technical requirements and specifications of the European Regulations (EC) 715/2007 and (EU) 2017/1151 as last amended. The applied standard test procedures enable comparison between different vehicle types and different manufacturers.

3 Austria, Belgium, Britain, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Netherlands, Norway, Poland, Portugal, Spain, Romania, Sweden, Switzerland, Türkiye

4 Ford Tourneo Custom EcoBlue diesel homologated CO2 emissions 192-234 g/km WLTP, homologated fuel efficiency 7.3‑8.9 l/100 km WLTP. Ford Tourneo Custom Plug-In Hybrid homologated CO2 emissions 40-47 g/km WLTP, homologated fuel efficiency 1.7-2.1 l/100 km WLTP and pure electric driving range 46-52 km WLTP.

5 In accordance with the Worldwide Harmonized Light Vehicles Test Procedure (WLTP). A range of up to 337 km can be achieved with a fully charged battery - depending on the existing series and battery configuration.

6 The actual range may vary due to various factors (e.g. weather conditions, driving style, route profile, vehicle condition, age and condition of the lithium-ion battery).

7 In accordance with the Worldwide Harmonized Light Vehicles Test Procedure (WLTP). A range of up to 325 km can be achieved with a fully charged battery - depending on the existing series and battery configuration.

8 FordPass Connect, the FordPass App, and complimentary Connected Service are required for remote features (see FordPass Terms for details). Connected service and features depend on compatible network availability. Evolving technology/cellular networks/vehicle capability may limit functionality and prevent operation of connected features. Connected service excludes Wi-Fi hotspot.

Ford, a global American brand woven into the fabric of Europe for more than 100 years, is committed to freedom of movement that goes hand-in-hand with looking after the planet and each other. The company’s Ford+ plan, with Model e, Ford Pro and the Ford Blue business units is accelerating its European transformation to an all-electric and carbon neutral future by 2035. The company is driving forward with bold, new EVs, each one designed with European drivers in mind and innovating with services to help people connect, communities grow, and businesses thrive. Selling and servicing Ford vehicles in 50 individual European markets, operations also include the Ford Motor Credit Company, Ford Customer Service Division and 14 manufacturing facilities (eight wholly owned and six unconsolidated joint venture facilities) with four centres based in Cologne, Germany; Valencia, Spain and at our joint venture in Craiova, Romania and Kocaeli, Türkiye.  Ford employs approximately 34,000 people at its wholly owned facilities and consolidated joint ventures and approximately 57,000 people including unconsolidated businesses across Europe. More information about the company, its products and Ford Credit is available at corporate.ford.com.

About Ford Otosan

Founded in 1959, Ford Otosan (Ford Otomotiv Sanayi A.Ş.) is a publicly traded company, where Ford Motor Company and Koç Holdings hold equal shares. The company is the second-largest industrial organization in Türkiye, and the most valuable automotive company in Borsa İstanbul. Ford Otosan, operating in 4 main centers with its Kocaeli and Eskişehir Plants and R&D Center in Türkiye as well as Craiova Plant in Romania, employs more than 20,000 people.

Ford Otosan is the largest commercial vehicle manufacturer of Ford in Europe capable of designing, developing, and testing a complete vehicle, including its engine, from scratch to a finished product. (https://fordotosan.com.tr/en)

CO2 Emission