New series of fact sheets demonstrate Ford’s achievements in quality.
Ford has recently launched an extensive series of fact sheets, aimed at documenting the strides Ford has made in designing, building and delivering quality vehicles. In fact, independent research from the 2009 U.S. Global Quality Research System (GQRS) survey shows that Ford’s quality surpasses Honda and is on par with Toyota.
The fact sheets reveal that Ford continues to be recognized for its quality gains. With 12 Ford Quality fact sheets in all, here are just a few of the highlights:
Designing Quality
Customer insights – A Ford research team identifies, defines and priorities customer needs to deliver customer-driven value in the form of desirable new colors, intricate stitching on seat cushions and other luxurious details that connote quality. Ford also uses “haptics” –the science of measuring how customers sense quality through touch – to determine optimum comfort levels.
Virtual design – Industry-exclusive tools allow Ford to quickly add various vehicle models into an existing facility, as well as evaluate tooling and product interfaces before costly installations are made on the plant floor. The result? Ford’s development time is now eight to 14 months faster than it was as recently as 2004. Other virtual technologies such as two virtual employees, nicknamed “Jack and Jill” provide data to predict and eliminate movements and fatigue concerns for workers, reducing manufacturing issues before prototypes are built.
Building Quality
Error-proof manufacturing – Computerized Direct Current (CDC) electric hand tools, affectionately known as “screwdrivers with brains,” tell operators whether all nuts and bolts are screwed into the vehicle at the right torque in precisely the right way.
Electrical system process checks – Ford’s end-of-line trials and current- based testing are major components of the pre-delivery process and have made Ford’s electrical systems the best among competitors.
Safety and security – Ford builds every vehicle with a focus not just on surviving crashes but avoiding them in the first place, which is why Ford is a consistent safety leader, earning five-star ratings.
Delivering Quality
Seat comfort – In addition to passing Ford’s industry-leading safety tests, Ford is committed to vehicle comfort. Case in point, Ford’s new Multi-Contour Seating with Active Motion™, available in the 2010 Taurus, gives the driver and front seat passenger a subtle massage designed to reduce fatigue. Seven inflatable bladders in each of the seats provide 6-way lumbar support, lumbar massage with a gently rolling pattern and “active motion” of the seat cushion.
Interior quietness – In four years, Ford’s wind noise rating has risen to best in class, according to GQRS. Ford achieved this due to the efforts of a manufacturing/product development team focused on closure systems.
Paint pioneers – Ford is pioneering new technologies, including an environmentally friendly anti-corrosion system that cuts paint shop water use nearly in half and reduces sludge production by 90 percent, as well as a three-part wet application process that reduces CO2 emissions by 15 percent. Ford leads the industry with fewer paint chips and scratches and better long-term durability, according to GQRS.
“We want our customers to be thrilled with the paint on their vehicle from the day they drive it off the lot to the next month, the next year and far beyond. We know they like to make a statement with their vehicles, and an appealing, durable and lasting paint finish helps deliver that.” - Tim Weingartz, Ford Paint Materials Manager
“Understanding what customers will want and need tomorrow – or even next year – isn’t enough. We have to anticipate needs and desires farther out, so we can deliver to our customers in the best ways possible.” - Sheryl Connelly, Ford’s Global Trend Manager
“We know what quality sounds like because customers have told us. They’ve identified the difference between a ‘plasticky’ sound versus one that is solid and secure. We know the metrics of each, and we design to create those sounds customer prefer.” - Mark Vojtisek, Ford Manager of Vehicle integration
Ford brings leadership in Virtual Technology to consortiums.
Ford has been advancing its approach to digital ergonomics work since it began using virtual tools to improve vehicle product development processes and quality since 2000. As a leader in virtual technology, Ford is involved in two major consortiums working to advance the use of virtual ergonomic technology:
The Human Motion Simulation Laboratory at the University of Michigan predicts and evaluates realistic human movements. These models can be used by commercially available human computer aided design (CAD) software to enable ergonomic analysis of products and workplaces.
The University of Michigan, College of Engineering, Center for Ergonomics has created an Affiliates Program for Support of the Human Motion Simulation (HUMOSIM) Laboratory to be operated in accordance with written bylaws and the policies and regulations of the University of Michigan. The concept of this Laboratory was initiated by University of Michigan faculty in close collaboration with a small group of companies who either use human motion simulation, produce technologies that enable its measurement, or develop applications for its use.
The United States Council for Automotive Research (USCAR), an organization composed of DaimlerChrysler, Ford Motor Company and General Motors Corporation, is partnered with the Virtual Soldier Research (VSR) program at the University of Iowa with a $1.5 million contract for manufacturing ergonomics research.
At UI, a team of 35 researchers is advancing state-of-the-art performance in computerized human modeling and simulation. Their work with USCAR will be aimed at helping the U.S. automakers use computer representations of people, called "digital humans," to design safer and more ergonomically acceptable manufacturing plants.
The partnership will address three large projects, identified by USCAR:
A study of the strength and fatigue limits of automotive manufacturing plant workers.
The development and integration of ergonomics tools into "Santos" – VSR's computer representation of a human.
The advancement of the field of predictive mathematics, also referred to as "Predictive Dynamics," to enable Santos to predict such variables as his own walking speed and direction while carrying various loads and while mathematically predicting various postures.
New Tools Helps Ford Flex and Ford F-150 Launch in Quality
The 2009 Ford Flex, Lincoln MKS and Ford F-150 are among the first Ford vehicles to fully utilize a series of virtual manufacturing tools and processes designed to catch possible build concerns by simulating automotive performance.
During the prototype builds, the program teams were able to reduce more than 80 percent of potential manufacturing concerns by running more than 10,000 advanced digital pre-assembly engineering checks on the Flex and the F-150. In addition, engineers were able to reduce design and production tooling issues by 50 percent.
Virtual manufacturing enables Ford to cut production expenditures by reducing the number of prototypes, material waste and cost of tooling. For consumers it translates into more durable vehicles with less repair costs.
Virtual Technology Translates into Real Life Customer Satisfaction
Ford Motor Company’s virtual manufacturing technology allows engineers to take a more holistic view of the product development process as they constantly improve the vehicle’s design and quality. It’s this virtual technology that is one of the key factors behind Ford’s impressive improvement in initial quality levels for the third straight year.
Ford uses customer input to develop engineering design specifications in its digital pre-assembly laboratory. Here, math-based tools are used to check more than 20,000 design elements on a computer screen to ensure they meet the customer-imposed standards.
From there, computer-aided design (CAD) plans are sent to a 3-D visualization center, which Ford calls its “Virtual Build Arena”. This is where the launch team gathers to “build” the vehicle on a virtual assembly line. Using data from the pre-assembly lab, the team observes virtual employees – nicknamed “Jack and Jill” – assemble the vehicle part by part, providing critical ergonomic data as they go.
Jack and Jill personify Ford’s advanced motion capture technology using human modeling software. This ergonomic technology is used to design jobs that are less physically stressful on workers and result in high quality vehicles.
The 2006 Ford Fusion was Ford’s first “digital car.” Building the vehicle first in a virtual factory, using the full suite of digital tools, allowed engineers to spot potential issues earlier on long before a prototype was ever built, eliminating months of product development, saving money and bringing the car to market sooner.
For customers, such advances in virtual engineering have helped the company improve reliability. In 2007 alone, Ford was able to slash $900 million in warranty expenses because of fewer dealer repairs after cars and trucks left the factory.
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While on a job site a Peterbuilt Semi became stuck in the mud. The driver asked me if I could pull him out of the mud because he didnt want to have to call a Semi recovery vehicle. I hooked up to the Semi with a doubled \"snatch strap\" and I put the truck in 4 wheel drive and took off. I pulled the Semi out with literally no resistance.. Job well done Ford!!
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They’ve been around awhile – a snippet of advice here, an old adage there. They’re the guidelines that are supposed to help keep cars running in top condition. Problem is, most of them aren’t based in fact – or they’re just plain outdated.
What's the best selling small car in Europe and the No. 2 best selling car overall in Europe in Feb? Take a guess. http://bit.ly/cWGRI4 ^EA #4 hours ago
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