Ford Team Project Builds Relationships, Improves Quality

Case Study

- September 2011

Abstract: With Ford Fiesta’s launch fast approaching, the organization wrestled with quality concerns over the vehicle’s floor carpets. Using quality tools, Ford’s body engineering team took on the project, uncovering complicated two- and three-way interactions in the carpet manufacturing process. Once these interactions were understood, the supplier modified its process to produce carpets that met Ford’s and the supplier’s specifications. The two-week project was completed just prior to the start of mass production of the Fiesta. Ford entered this project in ASQ’s International Team Excellence Award competition, where it earned finalist honors.

Keywords: Case study; Design of experiments (DOE); Supplier quality; Supplier relationships; Six Sigma; Define - measure - analyze - improve - control (DMAIC); Critical to quality; Teamwork

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