This paper describes the new flexible manufacturing system that was installed at Ford's Chicago assembly plant (CAP) as part of the $800 M investment in renovation and retooling initiative. The flexible manufacturing system allows CAP to produce three distinct models on one vehicle platform: the Ford 500, the Mercury Montego sedans and the Ford Freestyle SUV. With its flexible body shop and final assembly area, the plant can employ the new flexible tooling to quickly change over and build up to eight different models on two vehicle platforms. The flexible manufacturing system also enables CAP to respond quickly to changes in customer demand and do so efficiently.