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I'd be more concerned about panel fit and finish, Deanh must be having kittens trying to keep customers happy at the moment,

hopefully, there's a speedy end in sight to these rough builds and the normalcy of settled production tolerances arrives soon.

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An occasional misalignment is understandable

 

 

 

 

An occasional misalignment is probably human error. Consistent misalignment indicates a machine that isn't performing as expected.

 

And THAT is probably why Ford hasn't authorized repairs yet. They want to know why it's happening before they do anything to fix it.

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This reminds me of thousands of Taurus sitting on CAP yards that were screwed up (in one way or another) because of needing to make production run numbers. Ahhh Corp. Leadership, an oxymoron...

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This reminds me of thousands of Taurus sitting on CAP yards that were screwed up (in one way or another) because of needing to make production run numbers. Ahhh Corp. Leadership, an oxymoron...

 

Would it be ideal to fix the problem before any more trucks get out the door? Absolutely! Is that what management wants? You darn right it is!

 

However, especially with automation and computers, you don't always know what the problem is, or how to fix it. You may have to shut the entire plant down for 2, 3, 4 or more weeks as you figure out the solution to the problem. That just isn't feasible. You have to have trucks to sell, and if you need to have them fixed at the dealer or after the truck is produced, then that's what you have to do. I'm sure if they knew exactly how to fix it, it would be fixed by now. It's not like these are severe issues like grenading trannies or blown engines. These are minor cosmetic issues that can be resolved after the fact. Granted, it doesn't look good, but you gotta do what you gotta do.

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Would it be ideal to fix the problem before any more trucks get out the door? Absolutely! Is that what management wants? You darn right it is!

 

However, especially with automation and computers, you don't always know what the problem is, or how to fix it. You may have to shut the entire plant down for 2, 3, 4 or more weeks as you figure out the solution to the problem. That just isn't feasible. You have to have trucks to sell, and if you need to have them fixed at the dealer or after the truck is produced, then that's what you have to do. I'm sure if they knew exactly how to fix it, it would be fixed by now. It's not like these are severe issues like grenading trannies or blown engines. These are minor cosmetic issues that can be resolved after the fact. Granted, it doesn't look good, but you gotta do what you gotta do.

 

All these problems should have been caught at pre-production. No excuses!

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All these problems should have been caught at pre-production. No excuses!

 

Should they have? Probably, but at times things get missed. Last time I checked, they weren't running 20k trucks/month down the line in pre-production. It's also quite possible that it was caught during pre-pro, they just don't have a fix yet.

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All these problems should have been caught at pre-production. No excuses!

Yes and no. There's so many moving parts to the assembly process, with every tweak of the process, there's hundreds more that need to be made. So, yes they probably caught it early, determined it's not a safety issue and are still working on a solution that has a minimal disruption to the process as a whole

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are the bumpers mounted to brackets or the frame itself?....I have no idea, and crawling underneath in a dress shirt and tie isn't on the books...

Edited by Deanh

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People who think this is an easy fix clearly do not understand manufacturing processes--especially highly mechanized manufacturing.

 

If the solution were trivial, the implication is that Ford managers are too incompetent to implement a minor change that is causing real-world issues for the company: Issues that have a direct impact on their bonuses.

 

Since this is not occurring universally, Ford needs to determine when it's happening. This is not a trivial matter, given that Ford is building one F150 per minute. I could see this as a reason why Ford does not want these trucks repaired. Ford should know, to the minute, when each one of these trucks rolled off the line. So they can evaluate when these issues are occurring based on data they obtain.

 

In short: Until you've had to debug a system as complex as the assembly of a vehicle with 10,000+ parts, don't declare that the *cause* can be easily determined based by the ease with which you can observe the *effect*.

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Thank you Richard, I wanted to get that detailed, but I can only respond when the line stops right now

 

Now that's multi-tasking right there. If you were at DTP, we'd know why the bumpers were crooked! :hysterical:

 

I'm kidding, BTW...

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you would think a bumper alignment would be relatively simple no? Derek?....

 

If it was a manual process, then yes. An automated process, not so much, especially if it isn't happening on every single vehicle, as RJ mentioned.

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Now that's multi-tasking right there. If you were at DTP, we'd know why the bumpers were crooked! :hysterical:

 

I'm kidding, BTW...

Lol. Makes it easy to multitask when you do the same thing 600 times a day, 4 days a week for 1.5 years

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WATCH THE "FIX BE A SHIM.......

 

Oh, I'm sure that they already know what the fix is going to be--they're not holding up repairs in order to determine the fix. I expect they're holding up the repairs while they investigate the cause.

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are the bumpers mounted to brackets or the frame itself?....I have no idea, and crawling underneath in a dress shirt and tie isn't on the books...

 

The bumpers are mounted on brackets that are welded to the frame.

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meanwhile.............

LOL, love the kittens mate, I'm really feeling for you and your situation at the moment,

beautiful product with glaring mistakes...yikes.

 

It looks like DTP really started hitting the go button last month with over 20,000 builds.

is there any way to identify when the vehicles in question were built?

could they be early builds? or is this a drift in production performance from later builds, going to fast too soon?

Edited by jpd80

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