Ford Motor: Innovation and improvements to recover from the crisis (Part 2)

Modulation of Ford Motor’s production process has been adopted by digital transformation. Thereby, the computer system will not only assist the operator in all control operations but also notify them of possible errors as well as update the inventory status.

Order processing is also becoming more flexible as Ford’s current production process is divided into separate modules. Each module is responsible for producing its own part, so the manufacturer integrates the right components to create a new design. For example, the Volkswagen Group has collaborated with many famous brands such as Audi, Seat, Skoda to build a modular chassis structure with a horizontal engine called MQB (Modularer QuerBaukasten). This structure has the advantage of being easy to assemble and helps to reduce the weight of the vehicle.

This change not only helped Ford regain trust from customers but also helped expand the company’s network of partners. Synchronous production systems between factories, processes and people have achieved a new level of quality efficiency, reducing waste, improving the efficiency of machines and bringing about many practical economic benefits.

One example of the new production model is the Ford Dearborn factory in Michigan, USA. Here, everything is pre-emulated through the digital twin technology and augmented reality. Aspects of a manufacturing process are carefully considered to optimize performance. “We have created a virtual world that allows us to foresee what’s possible in reality,” said Anne Stevens, vice president of operations in North America.

As Ford opened new dealerships, Ford’s leadership at its Dearborn Michigan headquarters needed to take in a larger amount of information and increased management pressure. To solve this problem, Six Sigma has been put to use everywhere, from production stages to management teams and care / customer surveys. The shift in quality management from TQM to Six Sigma is a trend that can be seen at Ford, especially in a tough economy.

Through Six Sigma and what the Ford Company has demonstrated, Ford has brought value to customers as if caring for relatives in a family. The Company’s quality operating system is critical for identifying and correcting problems in production facilities. The Six Sigma implemented in each factory includes cross-functional teams of engineers, factory managers, and professionals, all professional problem solving manufacturers trained through Six Sigma. .

Thanks to its innovation efforts, Ford Motor has achieved the title of enterprise for 5 consecutive years (2012-2017) with top growth rate in automobile manufacturing by J.D. Power rating. The company also hit a new record on the organization’s service quality scale in 2018.

Productivity and Quality Office