Honda Rethinks EV Assembly Process

MARYSVILLE, OH—Honda Motor Co. has unveiled how it will mass-produce electric vehicles alongside hybrid and traditional internal combustion engine (ICE) models at its flexible factory here. The automaker is investing more than $1 billion to retool its assembly plant, in addition to nearby facilities in Anna and East Liberty. The company claims that it has “reimagined manufacturing to create a work environment that is more human-friendly and environmentally responsible, while achieving the highest levels of quality, efficiency and value for customers.”

"The Honda EV Hub provides [us] with the flexibility to produce ICE, hybrid-electric and EV models on the same production lines so we can quickly respond to shifting customer needs and market conditions," says Bob Schwyn, senior vice president of Honda Development and Manufacturing of America LLC. "Beyond adding the capability to produce EVs, we completely reimagined our approach to manufacturing, transforming the production environment with more human-friendly processes and sustainable manufacturing practices."

The Honda EV Hub will begin EV production in late 2025 with the all-new Acura RSX EV followed by models based on the Honda 0 SUV and Honda 0 Saloon prototypes the company debuted last month at CES 2025 in Las Vegas.

The Marysville Auto Plant (MAP) consolidated its two production lines, removing much of Line 2 to create the capability to produce EVs on the same line with ICE and hybrid vehicles. Major changes in the 43-year-old facility include:

*Reconfigured welding operations. Retooling one of MAP’s two weld lines involved installing new robots and technology to enable welding EV bodies on the same line with ICE models, while enhancing quality. “This included changes to secure the EV battery case in the vehicle floor, which required welding side sills to the floor comp just for EV models,” explains Schwyn. “MAP also is adding constant DC chopping (CDC) welding for the first time at Honda globally. This technology, added to existing weld robots, will expand the use of lightweight and high-strength materials to enhance collision safety performance and improve electrical efficiency by reducing the body frame weight.”

*EV Battery Pack assembly. Honda engineers renovated an area of the plant to create space of battery pack assembly. This process will combine battery modules produced at L-H Battery Co. (a joint-venture with LG Energy Solution in Jeffersonville, OH) with battery cases megacast at the Anna Engine Plant to create battery packs for midsize and large vehicles that will be used for EV production at both MAP and the East Liberty plant. The battery pack assembly will have the longest automated guided vehicle line at Honda.

*EV Battery Pack installation. A new dedicated area on the production line was established for installation of battery packs into EVs. ICE and hybrid vehicles will pass through this new area without stopping, allowing for multi-platform flexibility.

*Hybrid-electric battery assembly. ”Highlighting the ability to produce multiple vehicle types on one line, a new hybrid battery assembly area was established, moved closer to the installation area on the vehicle assembly line and expanded to meet the record customer demand for hybrid-electric models,” says Schwyn.