Awaiting inspectionUnsellable Lincoln MKZs were jammed together at Ford's Flat Rock, Mich., plant in March. Ford assembled the imperfect cars in Hermosillo, Mexico, then shipped them to Michigan for rework and final inspection.
Assembly line 101Susan Spaulding, an employee at Ford's Flat Rock, Mich., assembly plant, demonstrates the fine points of handling a wiring harness. Ford gave workers extra training before the launch of the 2014 Fusion after being stung by several vehicle launches gone awry.
Double-checking CherokeesIn October, a car hauler loaded with 2014 Jeep Cherokees rumbled the 15 miles from Chrysler Group's Toledo, Ohio, assembly complex to a testing center. The detour was needed to install software to smooth out the way the Cherokee's engine, nine-speed transmission and disconnecting drivetrain interact.Credit: Larry P. Vellequette