Lee Meyers, Plant Manager at Ford, joins us for an exclusive interview, offering his insights into this exciting chapter in the company’s history.
Please can you tell us a little bit about your journey at Ford, how you’ve evolved with the company and what your role looks like today?
“I’ve been with Ford for over 30 years now, and it’s been an amazing ride. I started as an apprentice at Dagenham, and over the years, I’ve moved through various leadership roles in production, operations and engineering.
“One thing that’s remained constant is how much this company evolves – and I’ve had to evolve with it. One memorable example is during the COVID-19 pandemic when we pivoted within weeks to build ventilators for the NHS, a project where I was the production lead.
“Now, as Plant Manager at Halewood, my job is to make sure everything runs smoothly as we transition to making EV power units. It’s a mix of big-picture strategy and day-to-day problem-solving. The shift to EVs is one of the most exciting changes I’ve seen at Ford, and being part of this transformation is something I’m really proud of.”
In recent years, the transformation of the Halewood Plant has been a huge effort for you and your team. Where did this decision arise from and what have been some of the major successes and lessons along the way?
“The decision to transform Halewood into an EV power unit facility was all about looking ahead.
“The world is moving towards electric vehicles, and this team knew we had to be part of that shift. Investing £380m into the plant means we’re securing jobs, keeping Halewood at the cutting edge and making sure we’re ready for the future of mobility.
“One of the biggest wins has been our team’s ability to adapt. Switching from building traditional transmissions to EV power units is a huge change, but our workforce has stepped up in every way.
“We’ve provided extensive training, brought in new technology, and completely restructured parts of the plant – and our team has embraced it all.
“That said, it hasn’t been without its challenges. Change on this scale is never easy, and one of the key lessons we’ve learned is how important communication is. Keeping everyone informed, engaged, and confident in the future has been a top priority.
“We’ve also had to rethink our entire supply chain, update our infrastructure, and integrate new processes while keeping things running smoothly.
“The key to making it work? Collaboration. We’ve worked closely with our fantastic teams, suppliers and even the UK government to make this transition a success. And now, we’re proud to say Halewood is a major part of Ford’s electrification journey.”
Where has innovation factored into this journey, and how does Ford embrace it?
“Innovation isn’t just about new products – it’s about how we do things better, smarter and more sustainably. Innovation in isolation can only get you so far. Our innovation teams collaborate throughout Ford to ensure we share our ideas while also replicating successful innovations from elsewhere.
“At Halewood, we’ve embraced cutting-edge technology to make our transition to EV power unit production as seamless as possible.
“One example is using digital twins – virtual models of our production lines that let us test and optimise things before making real-world changes. This has helped us save time, cut costs and improve efficiency.
“Sustainability is also a huge part of our innovation strategy. We’re working on reducing energy use, cutting waste, and incorporating more eco-friendly materials into our processes – we are already using carbon-neutral energy supply at the plant, but we are always looking to do more.
“At the end of the day, it’s all about making sure we’re building a future-ready facility that keeps Ford ahead of the game.”
What implications did this, and will this, have for your supply chain strategy?
“Moving to EV power units has meant a big shake-up in our supply chain.
“The parts and processes for EVs are different from traditional transmissions, so we’ve had to rethink everything from sourcing materials to logistics.
“Another big factor is partnerships. We’re working closely with our suppliers to make sure we’re getting the best technology and materials for our EV power units. And with digital tools giving us better visibility across our supply chain, we can stay ahead of potential issues before they become problems.
“Looking forward, we’ll keep refining our strategy to make sure our supply chain is as strong, efficient and sustainable as possible.”
Looking ahead to the future, what will the coming years hold for the company?
“The future is electric, and Halewood is right at the centre of it.
“In the coming years, we will be scaling up production, improving efficiency, and continuing to innovate to stay ahead of the game.
“With our investment in technology, sustainability, and our people, we’re making sure Ford stays a leader in the EV revolution. It’s an exciting time, and we can’t wait to see what’s next.”
Learn more at ford.co.uk.
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