Weld Isues on Cars
I placed the above text in this picture in 2000
18 years later read the next paragraph.
2015: CHRYSLER: IMPORTANT AXLE SAFETY RECALL N26 / NHTSA 13V-239
This notice applies to vehicles (VIN: xxxxxxxxxxxxxxxxx). This notice is sent in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Chrysler has decided that a defect, which relates to motor vehicle safety, exists in some 2012 model year RAM Truck Cab Chassis (4500/5500 series) trucks equipped with four wheel drive.
The problem is the front axle tube welds on the trucks may not have been welded correctly during the manufacturing process. Improperly welded front axle tubes could allow the differential housing to rotate under high torque operating conditions while in four wheel drive. Should the front axle tube welds break, the differential could rotate and cause the front propeller shaft universal joint to break. This can result in a loss of motive power or damage to surrounding components if the propeller shaft continues to spin after separation. This could cause a crash without warning.
Axle weld issues are common in the auto - truck industy and the weld reality is with either robots or manual welds, these are the easiest applications to weld on any vehicle..
look at Auto / Truck Industry, Manufacturing
and Product Recalls and Accountability.
greatest opportunity for dramatic weld productivity / quality improvements, and also for weld cost
reductions, is typically found in large weld shops and
ship yards and especially in just about every global plant that provides robot MIG welds
on car and truck parts.
and Mfg. Management:
As above those robot welds that daily require
extensive weld rework, are an INDICATION OF WHAT?
GLOBAL MANUFACTURING, MANAGEMENT AND ENGINEERS:
ISO, Six Sigma and Lean Manufacturing practices and standards have been successfully
implemented. The company has never had more Black
Belts wrapped around over sized waists while walking the factory
floors, yet from a manufacturing
perspective it did not matter which direction you looked, the evidence of lack
of manufacturing process controls was overwhelming and the weld rework bins are always over flowing.
I wrote the following in 2005: For the first time in this corporation's history, this companies global auto / truck recall costs in 2005 surpassed two billion dollars.
Sounds unreal, take your pick, Chrysler, Ford, GM
and many tier one companies easily meet this criteria.. Now come forward to 2018 and the annual recalls, rejects and rework costs from these and other global auto companies will typically far surpass the companies profits
production plant "B" in the old Detroit facility, the daily robot weld
production efficiency was typically less than 60%, the down time was excessive and the manual weld rework
required was in the 40 to 70% range. THE ENGINEERS AND MANAGEMENT SOLUTION, " PURCHASE MORE ROBOTS" ....
The customers manufacturing & quality ignorance,
provides relief for many of the auto /
If auto / truck customers truly understood
the requirements for weld integrity and the role vehicle designers intend their welds
to play both in the vehicle life and more importantly when a vehicle is in a collision,
we would have more people crawling under that car or truck before they put their
and "welding" steel components for cars and trucks, their is little
evidence from North American, Japanese or European manufacturers of the establishment
"Robot Weld Process Controls" and absolutely no sign
of any multi-plant, international corporations establishing "Global Robot
Weld Best Practices".
I have been in numerous
auto / truck facilities in ten different countries and rarely found a manufacturing
manager that understood the real robot weld production efficiency from his robots
and more importantly how to control weld cost / quality and keep the daily robot
weld rework to less than 2%.
2004. Robot frame welds on the world's best selling trucks:
of the poor welds witnessed for decades in auto / truck plants, along with the
overwhelming evidence of corporate / manufacturing management process control
apathy will one day provide the ammunition lawyers require. It will not take rocket
science to prove that a critical structural component failure of a car / truck
in a crash, was partially a result of MIG welds on the vehicle that lacked weld
integrity. Lawyers will readily find evidence of poor quality welds due to "manufacturing
management / engineering negligence".
Each day thousands die in vehicle collisions, yet how
many may have lived if the vehicle welds
and structure were built in the manner
designer and manufacturing instructions required?
Welds and Recall Terminology.
will rarely see a car or truck recall for "defective welds",
as they would have to replace almost every global vehicle and the costs and liability amifications could be extensive .
Lets face it, an auto
or truck manufacturer will take great care in it's "product failure descriptions to avoid the words "weld failure". For example if a company discloses that the truck or car
frame has a structural defect issue, it's typically an indication
of a major manufacturing process control break down and therefore that break down will typically cover more than a single small defect. Also most high steel parts subject to weld repairs will be carried out at body shops who are not qualified to carry out the repairs so that the repaired product is now in compliance with the orgional design criteria with the mechanical properties specified.
A repeating major weld defect on high volume welded parts would point to the inability
of manufacturing management and engineers to regulate
and optimize a simple, two control, 50 year old manufacturing process, a process
that could I could teach an 11 year old to learn and control in a few hours.
It's only an ASME pipe MIG weld..
teaching Jesse 11 years old,
in a few hours how to MIG weld a pipe.
Robot - Manual weld
failures initiate from "Bad Weld Practices" and
a management's apathy - ignorance on "Weld Process Controls"
When weld issues are discovered on a
vehicle, you are likely to see the weld issue recall notice announce something like
 this recall is due to a "design suspension, axle or body ISSUE"
 this recall is due an "integrity issue in the suspension",
this recall is due to a "component issue near the rear axle",
this recall is due to a "defective, door, latch, lug, bracket, bolt nut etc.".
was a brand new $26,000 LEMON
AUTO / TRUCK CUSTOMERS WILL NOT KNOW THEY HAVE A WELD OR VEHICLE WELD FABRICATION
STRUCTURAL PROBLEM, THAT IS, TILL THEY END UP IN HOSPITAL OR FACE UP IN A COFFIN. Ed Craig. DEC 2005:
|Note: The complete lack of weld fusion and the
weld appearence that
would have told
anyone with a brain in the front office, that this weld
was destined to fail.
From steels to aluminum welds, in the majority of auto / truck plants,
you will find weld quality issues.
This robot truck weld macro indicates it has 200% more weld than it
required, yet the weld joint is greatly weakened by the excess undercut. And another fact
that impacts the costs, the robot required 70 % more time than it should
have to make the welds, Small points lost on this Tier One company management and engineers.
2006. APPROX. 10 BILLION DOLLARS WAS SPENT THIS YEAR IN THE
AUTO / TRUCK
INDUSTRY ON PRODUCT RECALLS
AND WARRANTY ISSUES. JOE, YOU
TELL ME. ARE WE BLOODY WELL MANUFACTURING TO CREATE
MANUFACTURING TO PAY FOR THE COSTS OF REWORK, REJECTS AND RECALLS?
a world where too many managers and engineers have shied away from weld manufacturing equipment and process
ownership, this web site as it has for the last 15 years, remains dedicated to the required manufacturing management and engineer
"Accountability - Responsibility and Ownership"
As many auto part suppliers slowly sink towards chapter 11 or simply dissapear, and the global auto - truck mfg. executives bathe in their own design
/ manufacturing mediocrity, many of the corporate executives in this industry will sit
back in their Ivory Towers, and place the responsibility for their poor mfg quality / productivity performance and the resulting annual profit
quagmire on the trade unions and their wage demands, on the medical costs, on the pension costs, and with the ever changing so called third world labor
costs. How often will you hear these same executives discuss the billions their companies have been loosing annualy for decades, costs on rejects, rework, recalls and warranty issues?
Managers, have you visited the
robot process control management section?
TO KNOW WHAT SOME FORD EXECUTIVES
THINK THEIR CUSTOMERS ARE WORTH?
US Senate , after a "rolling block" passed a watered down version of
a consumer protection bill addressing the issues of tires and auto manufacturers
withholding safety information from the government and the public. Apparently,
a few of the more cretinish senators didn't want to impose criminal penalties
on corporate CEOs who, with intent, withheld public safety information. This is
the result of your auto manufacturer's lobby and money at work -- for them, not
for you. Shouldn't every tire and auto manufacturer be able to make unsafe or
defective products with impunity? Apparently, your government believes so. It
may have been Ford that calculated the value of a human
life to be approximately $200,000 when it decided not to replace or re-engineer
a potentially defective part, because it would have cost the company more money
to do. For more, visit, ttp://www.autobuyology.org/car6.html
this web site is not about the latest car or truck recalls, I would have to hire
a team just to keep up with that demand. The random recall information provided
here barely touches the surface of the real recall issues.
recall data presented here is simply to show the reader the scope of the issues
and to emphasize that global manufacturing management chaos and mediocrity is
today the norm and few auto / truck executives appear accountable for their manufacturing
the total annual recall / warranty costs typically exceed 10 billions, it's logical
to assume that global auto manufacturers
would rather not conduct recalls or pay for unnecessary warranty work, and lets
face it, manufacturing defects do little for a companies reputation and future
sad reality however for the car / truck purchaser, is only a micro amount of a
car's or trucks problems will be identified by the majority of the vehicle manufacturers.
It's ironic in 2005 that Toyota reported more vehicle recall problems than Chrysler,
question that consumers could ask is did Chrysler report all the vehicle problems it was
It's a sad statement that once your warranty is up,
too often you are on your own, even though the vehicle manufacture may have been
aware that the defects you report thirty days after the warranty has expired were
there the day the vehicle left the plant. It's also a reality in 2005 or 2015 that many
of the major global auto manufacturers are experts in defect denial, defect cover
ups and keeping major problems isolated from the public in a cocoon of secret
warranties and technical service bulletins.
2006 OR COULD BE 2016: THE PRICE OF MFG APATHY - MEDIOCRITY:
At this time in the history of vehicle manufacturing recalls
mediocrity and the never ending costly warranty work required, the associated quality costs are pushing many
of the major auto / truck companies and their suppliers towards eventual bankruptcy.
OF THE MANY GREAT VEHICLE COVER UPS.
Mitsubishi recalls over a million of its vehicles self-admittedly
stating they are poorly built vehicles. Mitsubishi
also reportedly acknowledges that it hid consumer safety complaints for the past
Motors and Mitsubishi Fuso Truck and Bus had recalls, that combined to 2,869,366
vehicles, or 38 percent of the tally for the entire country. Last year, Mitsubishi
Motors disclosed that it failed to come clean five years ago and had more hidden
defects. Both companies have seen sales plunge in recent years over the scandal.
Kude said a recent cover-up of auto defects at Mitsubishi Motors Corp.
and its truck making affiliate Mitsubishi Fuso Truck and Bus Corp have had led
motorists to be more vigilant about notifying authorities of possible defects
or safety concerns.
Note from Ed: Many people are in prison today for smoking a joint, and these guys like the greedy bankers and crooked on the take politicians will likely end up with a slap on the wrist or by paying a fine.
News: ORLANDO, Fla. Oct. 12, 2005 AAA and the National Fire Protection
Association will issue a warning tomorrow about car fires. ABC News has learned that last year, 266,000 car fires resulted in 520 deaths,
the organizations say. "It
was a horrible explosion," said one car fire victim Bob Aymar, who, in less than
a minute, suffered third degree burns on his face, hands and arm. He was sprayed
by a gasoline fireball during a violent traffic accident on a Southern California
freeway. "The Bronco behind me was hit and it ruptured
the gas tank," said Aymar, who, after seven surgeries, was finally able to
play the piano again. He is just one of more than 1,300 car fire victims every
year. According to the NFPA, cars catch fire on American highways once every two
minutes. "The risk of a car or vehicle fire is even greater than the risk
of an apartment fire. More people die in vehicle fires than in apartment fires
each year in the United States," said AAA President Robert Darblenet.
CAR - TRUCK FIRES IN USA. 520 DEATHS &
1300 FIRE VICTIMS.
CALL THIS THE "MANAGEMENT MFG. WEAPONS OF MASS DESTRUCTION"
The fires are again simply reflection of design and manufacturing
issues found in so many vehicles....Is anyone going to take responsibility?
these "Management Issues?"
BUILDING THEM FOR 100 YEARS, YOU THINK THAT QUALITY WOULD MEAN MORE THAN A WORD IN A LOGO.
for those that have just purchased that new car or truck and are unfortunate to
end up in a vehicle crash, please remember as the sound of screeching tires and
tearing metal invades your body and your senses;
 the faulty tires may tear
 the seat belt brackets may not hold,
 the steering wheel may
 the seat welds may collapse,
 frame and body welds will
tear apart when they should have held,
 the air bags may get stuck,
 the axles welds may fail and the axles will collapse,
 the wheels
may drop off,
and if you survive the crash, the poorly designed and poorly
built gas tank will start to
leak and premature cremation is a good possibility.
you see the fireman in the following recalls you know why when you buy a new car
or truck your first accessory should be a fire extinguisher.
Manufacturing Management Issues:
recalling 1.2 million trucks and vans recall is in addition to 4.6 million recalled
last year for potential fire hazard.
4 2006: 10:45 AM EDT
YORK (CNNMoney.com) -- Ford Motor Co. is recalling 1.2 million large pick-up trucks,
SUVs and vans because of a problem with the vehicles' cruise control system that
could lead to a fire. This
recall is in addition to a total of 4.6 million Ford vehicles that were recalled
for the same problem last year.
vehicles being recalled are: certain model year 1994 to 2002 F-250 through F-550
Super Duty trucks; 2000-2002 Excursion SUVs; 1994 to 1996 Econoline vans; 1996
to 2002 E-450 vans and 1998 Ford Explorer and Mercury Mountaineer SUVs. Diesel-powered
vehicles are not affected.
rare cases, the company said in a letter to the National Highway Traffic Safety
Administration, brake fluid can leak through the cruise control deactivation switch
causing corrosion in the switch. This can cause the switch to overheat and possibly
burn. The switch shuts off the cruise control when the driver firmly steps on
the brakes. The switch is located under the hood of the vehicle and is attached
to the brake master cylinder on one end and wired to the cruise control on the
other. On most of its
models, Ford designed the switch to be powered -- or "hot"
-- at all times, even when the vehicle is off. Inside the switch, a thin film
barrier separates brake fluid from the switch's electrical components.
January, 2005, Ford recalled approximately 800,000 F-150 pick-ups for the problem.
Later that year, after numerous Ford owners complained that their vehicles caught
fire when their engines were off and the keys weren't in the ignition, CNN launched
an investigation into fires in Ford vehicles that had not been recalled .
September, 2005, Ford recalled certain Bronco, Expedition, Lincoln Blackwood and
Lincoln Navigator SUVs as well well as some Ford Ford F-150 and F-250 pick-ups
for the same problem. A total of 3.8 million vehicles were recalled at that time.
Ford stopped using the switch in 2002.
Ford and Toyota, two of the world's largest auto manufacturers, today recalled
nearly 5 million pickup trucks and sport utility vehicles in separate moves to
respond to concerns of engine fires and problems with the power-steering system. The
recall by Ford Motor Co., the fifth-largest auto industry recall in US history,
involved 3.8 million pickups and SUVs from the 1994-2002 model years, including
the top-selling F-150 pickup.The
National Highway Traffic Safety Administration (NHTSA) and Ford have been investigating
complaints of engine fires linked to the cruise control switch system.
Corp., meanwhile, recalled 978,000 sport utility vehicles and pickup trucks over
complaints that a rod linking the steering wheel and the wheels
could fracture when the steering wheel is
turned while the vehicle is stopped. The affected Toyota vehicles include the
1990-1995 4 Runner SUV, 1989-1995 truck 4WD and 1993-1998 T-100 pickup.
In the Ford case, NHTSA said Wednesday it was reviewing 1,170
allegations of engine fires related
to the vehicles and would continue a probe
launched earlier this year. There have been allegations of three deaths
in cases cited in news reports or lawsuits in Iowa, Georgia and Arkansas.
Ford's recall includes the 1994-2002 F-150, 1997-2002 Ford Expedition, 1998-2002
Lincoln Navigator and 1994-1996 Ford Bronco equipped with factory-installed speed
control. It covers most of the vehicles being evaluated by NHTSA. Ford said its
inquiry found brake fluid could leak through the cruise control's deactivation
switch into the system's electrical components, leading to potential corrosion.
That could lead to a buildup of electrical current that could cause overheating
and a fire.
Cars or trucks, WELD - MECHANICAL OR ELECTRICAL ISSUES,
the end results can be deadly.
recalling over 225,000 cars over fire risks
auto giant Ford is finding itself in more trouble. If falling sales and dropping
market share was not bad enough, it now has a huge PR crisis in its hand. The
company is recalling over 225,000 vehicles over possible fire risks. These vehicles were sold in markets
of US and Canada and include some popular vehicles like Ford Five Hundred sedan
and Freestyle wagon. Most of the vehicles being recalled are from the 2005-model year and include the Crown Victoria, Lincoln Town Car, Mercury Grand
Marquis and Montego sedans. The recall includes 127,493 Ford Five Hundred and
Mercury Montego sedans and Freestyle wagons. These have issues with their straps
that secure the fuel tank to the vehicle body.
recall includes 98,444 Crown Victoria, Lincoln Town Car, and Mercury Grand Marquis
sedans. These recalls are related to the battery cable, which might scrape on
an attaching bolt and could lead to a fire. This is bad time for such a publicity disaster for a company, which
is suffering huge losses in its domestic market. And this latest recalls come
just a few months after they had to recall nearly 4 million vehicles in September
because of the risk of engine fires.
the end of the day Joe, manufacturing defects are not a result of our robots or
people on the shop floors, the defects are a result of inadequate design, poor
engineering, poor manufacturing practices and inadequate quality control.
Vehicle fire data has some experts fuming.
in the Sun, Dec. 11, 2005
safety experts are increasingly concerned that many vehicle fires are going unreported
to government agencies. AAA in October drew attention to the danger of car fires
by reporting that 520 persons died in highway vehicle fires in 2004 more
the number who died in apartment fires.
automobile association said there were more than 266,500 vehicle fires,
resulting in 1,300 injuries and nearly $1 billion in property
Clarence Ditlow, head of the Center for Auto Safety, a Washington-based consumer
advocacy group, said AAAs fire figures were just the tip of the iceberg.
An estimated 500 to 1,000 fatal accidents
involving fires never get reported as fire-related deaths, said Kennerly Digges, president of
the Motor Vehicle Fire Research Institute, an independent nonprofit group based
in Charlottesville, Va, specializing in automobile fire safety research.
In September, Ford recalled cruise control switches on 3.8 million 1994-2002 Ford
pickups and SUVs that can overheat. But critics think the system can be made better
by digging deeper into the causes of vehicle fires. They say the governments
two main databases suffer from serious information gaps and miss many non-crash
experts say the Fatality Analysis Reporting System database can miss incidents
because it was designed only to collect data on fatal accidents on public highways.
To be counted, a car must be in transport in other words: moving.
Cars catching fire in driveways, along the shoulders of roads or in garages weret
always counted. Many problems stem simply from a failure to report fires correctly,
said James Fell, research director at the Pacific Institute for Research and Evaluation.
Fell said as many as half of all states appeared to underreport car fire deaths,
often by simply failing to include death certificates with police reports.
THE REAL FACTS RARELY COME TO THE SURFACE.....If
the police dont list a fire in their report, the death does not get reported
as a "fire-related death Fell said.
the reporting codes used by firefighters to report vehicle fires are the same
ones used for fires in apartment complexes, homes and even skyscrapers. A country
wide coding system specifically for car fires does not exist. Fires that start in cars but spread to houses, where they sometimes cause deaths,
are reported as structural fires.
local case illustrates just how easy it is for a car fire to go unreported.
Tarr said her parents 2001 Buick LeSabre filled with smoke last year as
they were driving near Kansas City. After pulling over, flames shot from the floor between the front and back seats. Tarrs father died of a heart attack
after exiting the vehicle. The
fire department reported the fire but not the cause, and did not list the death
as fire-related. Apparently, in part because the car was not moving, the fire
and death do not appear in the National Transportation Safety Administrations
database. Kevin Stanley, the familys attorney, said the lack of reporting
shows that there should be a priority to find what causes car fires. That
isnt done now.
A note from Ed: If you are unfortunate enough to own one of the thousands
of vehicles that could catch on fire due to the numerous issues that seem to occur
mostly from manufacturing defects with the electrical system, fuel lines or fuel
tanks, when the vehicle starts to burn there is only one logical thing that I
would do. If
my vehicle catches on fire, I will exit promptly, mutter some expletives about
useless, f- - - - - g North American Manufacturing Managers and then let the vehicle
burn to the ground. With the insurance proceeds I would likely buy a Toyota or
auto / truck frame welds.
With some welds I wanted to say, please don't drop those parts.
you tried to create a weld like this with almost
no weld fusion it would
be a difficult task
Quietly Fixing Expedition Weld Faults:
plagued by early quality problems with redesigned vehicles over the last two years,
has been quietly fixing a defect on hundreds of new Expedition sport utility vehicles
that could have led to an embarrassing recall. The problem involved
faulty welding in the rear
suspension area of early production
models of the full-size SUV, which Ford began building in April at its Michigan
Truck assembly plant outside Detroit. Ford held back the first month's production
of 2003 Expedition and the similar Lincoln Navigator for extra quality checks
and caught the problem before any vehicles were shipped to dealers. The work was
being carried out in a hangar of the Willow Run airport near Ann Arbor, Michigan,
which sits alongside a tightly secured parking field where Ford has held many
of its new trucks, clad in white plastic sheeting, since April. Ford wanted to
avoid the negative publicity that would have come with a recall after the recalls
of the new Explorer in 2002 and the Escape in 2000.
Ford GM and Chrysler executive management could ask themselves
a few simple questions.
happened to the more than a billion dollars your organizations
on ISO, LEAN MFG DYNAMIC CONTROL PLANS. SIX SIGMA. TOPS. DOE. FMEA. KAIZEN. KANBAN.
MRP. J.I.T. T.Q.M. SPC. POKE. YOKE. AND LAST BUT NOT LEAST THE BIG JOKE.
While your companies embraced
the many available lean / manufacturing control programs or crutches that seem
to be a requirement by organizations and individuals who lack manufacturing expertise,
where were the;
 professional managers that provided the required leadership.
Managers that stated "the buck stops here". Managers that actually took
ownership of the key manufacturing equipment in their facilities?
managers who had the ability to nurture their engineers and technicians to establish
global, uniform Best Manufacturing and Quality Practices?
professional managers who could instruct their engineers to implement Process
Controls that would guarantee the desired daily quality and productivity?
 professional mangers who knew what was required for an effective training
 designers who took an interest in weld processes used on
their parts and followed through on the components they designed and did not enable
design dimensional deviations or inferior products to replace the products they
 manufacturing engineers that rolled up their sleeves and
built the parts as specified?
the corporate executives who had the leadership and vision to build a safe, stylish,
quality vehicle that required low fuel consumption and was good value for a consumers
these corporate guys pick up their annual bonus, someone should write on the back
of there bonus checks that "responsibility for design, engineering and manufacturing
always starts with the leadership in the corporate office"
more than two decades it looked like the Big
Three were intent on buiding Wall-Mart cars?
Hard to tell which one is which.
Questions for Auto / Truck Executives:
Why do the majority of North American cars you build all look the same and look
like they are in the right place when parked outside a Wall-mart store?
Why have your auto / truck product recall / warranty costs now surpassed the medical
insurance benefits you pay your employee's?
When looking for across the board cost reductions, why do you focus on employee
benefit costs or lower overseas labor costs and never focus on the dramatic cost
savings that could be attained from manufacturing recall or warranty cost reductions?
Why do you continue to award your manufacturing management and supervision with
obscene bonuses at a time when their manufacturing production efficiency is rarely
attained without overtime premiums?
 Why do so many of the managers
and engineers you hire lack the ability or resources to build parts without extensive
rework, parts that actually comply to the engineering design standards provided?
Why do we keep letting your bean counters influence design, engineering and quality?
Why do so many of your plants lack the fundamental ability to establish Global
Best Manufacturing Practices and implement effective shop floor Process Controls?
When did you stop valuing the opinions of your engineers, technicians and customers.
following are typical examples of auto / truck MANUFACTURING MANAGEMENT problems
that typically occur. If you wish to contribute your quality / productivity stories
to this section or any of the data provided you believe is incorrect, contact email@example.com.
2006 or is it 2016?.
While Michigan and Ohio turn into a rust belt,
Ford looks to invest 9.2 Billion dollars in Mexico.
he started Ford Motor company, Henry Ford's philosophy was to pay workers above
the norm, and rely on efficient assembly of the quality, affordable cars he built. The
high pay to the workers would then enable thosee employees to buy their own vehicles
and so began the great American Dream.
2006 as Ford shuts down American plants, Ford Motor company announces approx 9.2
billion dollar investment in Mexican plants.
Whats that American Dream?
when you come home you will find great jobs available at new
like Wallmart and McDonalds.
bad welds at Ford.
to inexperienced Ford manufacturing management and engineer, Ford is recalling 87,515 F-250,
F-350, F-450 and F-550 trucks from the 2008 model year to fix
improper seat welds. The recall is expected to begin on March 24.
National Highway Traffic Safety Administration's recall summary says "some
40 percent split and captain's chair driver seats, equipped with lumbar supports,
may have improper welds at the joint of the seatback pivot bracket and the seatback
frame. In the event of a crash, the seat side pivot bracket may crack or
break, increasing the risk of injury to the seat occupant."
Manufacturing Management Issues:
2004 Ford Ranger:
NHTSA Campaign Number: 04V331000 www.nhtsa.dot.gov
Manufacturer FORD MOTOR CO.
Recall Date: 07/14/2004
Number Of Units Affected: 1395
Description STRUCTURE: FRAME AND MEMBERS:UNDERBODY SHIELDS
ON CERTAIN PICKUP TRUCKS, THE FRAME MAY HAVE A CENTER RAIL SECTION FLANGE THAT WAS NOT FORMED PROPERLY. Consequence.... IN THE EVENT OF A
SIDE IMPACT CRASH, THE FRAME RAIL COULD PUNCTURE THE FUEL TANK, RESULTING IN A
FUEL LEAK THAT IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Manufacturing Management Issues:
A judge in Alameda County, California ordered Ford Motor Company to recall millions
of its vehicles (various models) made between 1983 and 1995 - due to faulty and
potentially hazardous ignition switches (thick, or thin film type) which causes
vehicles to stall out when they heat up during use. Ford denies that the switches
are defective and promises to appeal the decision.
affected vehicles include: 1994-2002 model F-150s, 1997-2002 Expeditions, 1998-2002
Navigators and 1994-1996 Broncos equipped with factory-installed speed control.
Manufacturing Management Issues:
Recalls 220,000 '05 Vehicles.
16, 2005 4:18 pm US / Eastern
(AP) Ford Motor Co. recalled about 220,000 vehicles from the 2005 model year on
Wednesday amid concerns that a battery cable was rubbing against the vehicle frame,
potentially causing fires, and that a fuel tank strap could separate after logging
tens of thousands of miles. The National Highway Traffic Safety Administration
stated that so far it has received four reports of fires.
company's investigation found that the manufacturer of the strap changed to a
weaker grade of steel in December 2004, a grade that could not meet Ford's durability
requirements. Ford declined to disclose the supplier's identity.
Note from Ed. So much for manufacturing management standards
& the millions Ford & its suppliers spent on ISO.
I OWNED A FORD VAN, RATHER THAN PARK IT IN THE GARAGE
LIKELY PARK IT NEAR A FIRE HYDRANT:
Motor Co. issues a pair of safety recalls on certain '03-'04 E-Series full size
vans and is asking dealers to ensure that some of the vehicles not be parked in
enclosed structures due to fears of unattended engine fires. The auto maker is calling back E-Series Econoline work vans and Club Wagon
passenger vans built between April 23, 2002, and April 30, 2004. The recalls
regard two different safety problems, both of which could potentially lead to
vehicle fires, according to two recall notices provided to Ward's.All
affected vehicles were built at Ford's Lorain, OH, assembly operation. About 235,000
Econoline vans built between 2002 and 2003 are being called back to replace defective
parts associated with the vehicle's antilock brake system. A diode in the ABS
could short itself out, leading to overheating even in unattended vehicles. Because
of the risk of unattended vehicle fires, Ford is warning against parking affected
vehicles in enclosed structures, such as garages and parking structures.
is recalling all E-Series vans with gasoline engines built between April 2002
and April 2004, including the affected Econolines, because air-filter paper was
not properly manufactured. The paper is unable to prevent the filter from igniting
when hot particles in the engine air system contact it, therefore leading to potential
IT DOE'S NOT SEEM TO MATTER
MADE BY THE CANADIANS OR THE YANKS.
Ford Windstar and Manufacturing Management:
purchased a brand new Canadian made Ford Windstar in 1999. When we drove it off
the lot we noticed mechanical problems already occurring.
[a] The cruise control was not
hooked up properly, we should of known then we were in for trouble.
[b] We have had a continual ping in the engine that the Ford motor company has
told us we basically have to live with. "We can't seem to find the problem".
[c] When the car was two years old we noticed a leak coming from the
back window. We took it in to Ford and they said not to worry it was just a bad
weld and they fixed it. Little did we know that the moisture had already got into
[d] We now are experiencing severe problems with the electrical
[e] The automatic sliding door works sparingly.
The key faub no longer works for the driver side door.
[g] The lights
and fans sporadically turn on and off, and the worst problem is that there is
a constant drain on our battery because of shorts in the wiring that Ford could
not (would not?) diagnose.
[h] We continually have to charge our battery
nightly so we can make it through the day without getting stranded.
As we gave up on Ford, we took the Windstar to a reputable
car mechanic and within two hours he was able to diagnose the problem and how
we should go about fixing it. The mechanics advice, trade the Windstar in on a
none Ford product. Ford will no longer be getting our business or our friends.
Thanks for a lousy product Ford! Never Again. David Bianchini.
Manufacturing Management Issues:
2004. FORD ENGINEERS MAKE A STARTLING NEW DISCOVERY
"SALT CAUSES CORROSION":
Jul 16 2004.
launches at least its third Taurus and Sable recall in 2004, following a spate
of actions earlier this month. Ford Motor Co. reportedly recalls some 899,060
Taurus and Mercury Sable sedans registered in 22 states that are located in what
is considered cold weather regions, according to the National Highway Traffic
Safety Administration. Reuters says the recall includes '99, '00 and '01 vehicles
with defective springs that potentially could sever due to corrosion, leading
to tire punctures. The use of salt on icy roads is a major cause of corrosion
and Ford dealers are asked to install protective shields over the springs.The
action marks at least the third Taurus / Sable recall this year and Ford's fifth
separate action this month, which include eight different models.
Ford Manufacturing Management Issues:
been going on for decades:
1991. Ford Explorer NHTSA Recall ID Number: 91V026000
Potential Units Affected: 220000 Summary: REAR BUMPER REINFORCEMENT MAY BE SUBJECT
TO FATIGUE CRACKING UNDER EXTENDED TRAILER TOW SERVICE WHEN USING A BUMPER-MOUNTED
TRAILER HITCH BALL.
Manufacturing Management Issues:
2002. The Crown Victoria (Ford Motor, Company) is reported
to be suffering rear gas tank / accident / safety issues. Two bolts may puncture
the gas tank upon rear end collisions.
from Ed: For Gods sake Ford you have been having gas tank
reliabilty issues for at least 50 years, could you put a little focus on building
a simple, strong metal container. A rubber container inside the fuel tank was
an idea presented to Ford in the 1960s. This product was designed to contain the
gas if the gas tank was damaged in a collision, it was rejected, considered too
costly at approx. $5.
Manufacturing Management Issues:
November 27, 2000
By JUSTIN HYDE
THE ASSOCIATED PRESS DETROIT -
For the fifth time in a little over a year, Ford Motor Co. told it's dealers either
to prohibit sales or test-drives of its new Escape sport utility vehicles while
they're checked for safety-related problems. The latest notice
to dealers was sent Nov. 18, affecting 51,022 Escapes and about 24,000 Mazda Tributes,
which share basic parts with the Escape and are built in the same plant in Claycomo,
Mo. Of those, 27,516 Escapes and about 12,500 Tributes have already been sold.
Ford spokesman Mike Vaughn said dealers were told to check for damaged windshield
wiper link ball sockets and replace them if necessary. If the sockets were improperly
built, the wipers
could stop working. Parts to fix the problem "are in the pipeline" to
dealers, Vaughn said. Previous warnings to dealers on the Escape and Tribute,
both of which only went on the market in August, have included warnings about
 steering wheel coming off,
 leaky fuel lines,
incorrect wheel hubs,
 and a problem with the
cruise control that could cause the throttle to stick.
BIG THREE INSIST THAT THEIR WELDED
PARTS ARE ONLY WELDED WITH ROBOTS.
WAIT TILL YOU SEE THE MANUAL WELD
ironic that on the one hand we have the major auto / truck companies providing
a logical mandate which insists that arc welds on cars and trucks will only be
made by robots. Its not dawned on these companies that people who program robots
need process control expertise. For more than two decades the majority of the
companies that use robots will daily allow "unqualified" robot operators,
programmers or maintenance personnel to daily make "unqualified" robot
weld parameter changes to "unqualified" robot welded components. And
then of course they will allow "unqualified" manual welders to make
the "unqualified" manual weld repairs.
Manufacturing Management Issues:
1991 Ford Explorer. NHTSA Recall ID Number: 91V025000
SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY Potential Units Affected: 18000 Summary:
THE HOT PLATE WELD WHICH ATTACHES THE VAPOR VENT VALVE CARRIER TO THE TOP OF THE
PLASTIC FUEL TANK MAY PARTIALLY FRACTURE, ALLOWING VAPOR OF FUEL TO ESCAPE FROM
THE TOP OF THE TANK. Consequence: THE ESCAPED VAPOR OR LEAKED FUEL COULD CAUSE
A FIRE IN THE PRESENCE OF A SOURCE
Hey Yanks, you
don't need to visit Iraq to find those elusive
weapons of mass destruction,
your nearest American new car showroom?
2002 AeroStar Van.
report suggests that the placement of the pressurized fuel line and strategic
fittings near the exhaust system or high heat features may contribute to the potential
for vehicular fires.
and corporate manufacturing management would
do well to remember what Harry
Henry Ford once might have said.