Ford uses six sigma to improve powertrain manufacture
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Manufacturing News, Source : TheManufacturer.com
Published : 30 May 2002 8:28
Earlier this week, Ford Motor Company announced plans for a new powertrain diesel engine that will offer up to 10% better fuel economy and 20% lower emissions than current diesel engines.
Ford attributes the improvements to its Six Sigma program and flexible powertrain manufacturing system.
Dave Szczupak, vice president of powertrain operations, said Six Sigma has saved Ford about $375 million in the second year of its implementation. The program involves addressing the top 25 customer concerns for each vehicle while working to eliminate hidden costs. According to Szczupak, internal studies have shown a 3% rise in customer satisfaction with Ford, and a 4% improvement for transmissions, since last year.
The company’s flexible powertrain manufacturing system means engines can be built in configurations from 1.8 to 2.3 liters in up to 100 different derivatives. The new manufacturing system features brightly lit workstations, easily reprogrammed machine tools to minimize production interruptions, and ‘birth certificates’ for each engine documenting every step of production.
The new engine will be built by the International Engine Group of Navistar International at its facilities in Huntsville, Alabama and Indianapolis, Indiana. It will be released in 2003 in the F-Series Super Duty pickup and Excursion sport utility vehicle and will produce 325 horsepower at 3,300 revolutions per minute.
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