HOME  |  NEWS  |  BLOGS  |  MESSAGES  |  FEATURES  |  VIDEOS  |  WEBINARS  |  INDUSTRIES  |  FOCUS ON FUNDAMENTALS
  |  REGISTER  |  LOGIN  |  HELP
Comments
View Comments: Newest First|Oldest First|Threaded View
<<  <  Page 2/2
averagejoe72677
User Rank
Gold
Taurus Sho Cost Cutting
averagejoe72677   9/28/2011 9:57:38 AM
NO RATINGS
The pressed on camshaft gear of the SHO Taurus reminds me of a cost savings disaster from GM back in the early 1980's. It seems the GM dscided to pinch pennies by eliminating the oil pan gasket on some engines and substitute silicone sealer in place of the gasket. This didn't work well at all. Tens of thousands of cars were delivered to customers with factory installed oil leaks. GM did save money initially, but soon after this cost cutting measure started it became apparent that this peeny pinching move cost a lot more than it saved in warranty claims, plus some very unhappy customers.

 

3D_Eng
User Rank
Iron
Re: No more dream car
3D_Eng   9/28/2011 9:54:41 AM
NO RATINGS
My company has created a "design manual" for the same purpose.  The intent is to document good design practices that inexperienced engineers can use as a starting point. It includes a "lessons learned" section detailing the things that you shouldn't do because "we did it once and learned our lesson". 

Overall this is a good concept, but the idea that it can replace seasoned engineers and tehcnicians has not proven itself out.  It seems every year we pay the price for our lack of experience with product recalls and reworks that we might have avoided with a more experienced (read expensive) workforce.  I wonder how that cost balance is working out.

John
User Rank
Gold
Re: One Piece camshaft
John   9/28/2011 9:41:31 AM
NO RATINGS
And yet another Ford blunder. lol  Reminds me of the plastic support for the arm rest in my 96 Explorer that Ford replaced with a cast aluminum piece and there dismal handling of Jaguar by making the rear ends of them look like the Taurus and using Taurus window regulators of which has problems.  And you were charged Jag prices not Taurus price.  Don't get me wrong.  I like and still have some of there products, but how do no brainers slip by?  Too much overhead or is it just pushing the envelope to the land of duh.

Jaybird2005
User Rank
Silver
Pressed on parts
Jaybird2005   9/28/2011 9:35:32 AM
NO RATINGS
This is not the only place Detroit is up to something strange. I was working on a Malibu and the torque spec for the heads was x footpounds plus 30 degrees. Is that a spec? Where do I get a torquewrench that measures in footpounds and degrees?

I am willing to bet the Ford precess went something like this:

I need to 'save' x dollars to get my bonus. If we go to a pressed on gear this will save $2 per car for 100,000 cars and..... I can get the bonus. The gear will only fail some of the time in the warranty period so I can still 'save' money.....

Tying bonuses to 'performance' only makes sense, but there has to be a mechinism in place to ensure that the goals are reasonable (you can't cut 50% without cutting quality somewhere) and that there has to be some system to ensure that the 'savings' don't endup costing the company more next year. Everyone has become too short sighted. Everyone wants savings *now*, regardless of the consequences. I just don't understand.

Tim
User Rank
Platinum
Re: No more dream car
Tim   9/27/2011 11:08:28 PM
NO RATINGS
At our company, we have a "Book of Knowledge".  Over the last 20 years, numerous insights on product adjustment and machine and station designs have worked their way into the book.  When a new design is brought up, this book is immediately checked for any major issues that were seen with previous similar models.  It has helped to avoid a lot of failures over the last few years.

jmiller
User Rank
Platinum
Re: No more dream car
jmiller   9/27/2011 9:59:07 PM
NO RATINGS
I think a lot of companies can save and therefore make a lot of money by putting together a little book of things we used to do right, but messed up and are going back to do right again.  At some point I think someone out there has to see warranty costs and realize that if the company doesn't spend that money, the get to keep it.

Perhaps as the internet becomes more and more of an important way that consumers communicate regarding the quality and reliability of products, companies will begin to realize how much a negative perception about the quality of their product will affect their sales.

I wouldn't be surprised if there isn't data out there already that shows the increasing importance of ingternet perception on sales.

TimJones
User Rank
Silver
Re: One Piece camshaft
TimJones   9/27/2011 2:55:17 PM
A one piece camshaft with an integral gear would probably cost a LOT more than a two-piece assembly. But a two-piece assembly with a slot and a key would cost pennies more, and would be much more reliable than an interference fit. Which is why they've been making them that way for over a century.

Ivan Kirkpatrick
User Rank
Platinum
One Piece camshaft
Ivan Kirkpatrick   9/27/2011 2:26:39 PM
I am sure a one piece camshaft with the gear made integral to the shaft would cost more.  But how much more?  How much does this cost Ford in terms of Corporate Brand? 

This goes back a long way at some companies, engineers design and build great products, but the accounting types demand cheap products.  With some products, cheap is okay, but not a car engine that I expect to see run for years and years without issues.

And this is not really something new.  How long has this camshaft gear combination been used and in how many different engine designs?  Isn't this an obvious design issue.  It should get attention even before the products get built or tested.  It should be apparent this is a potential problem.

I know the US Air Force has some rules about locating control system hydraulic lines inside the leading edges of wings.  Why?  Because they know after so many years of flying into birds and hailstorms that the leading edge is subject to damage during flight.  And if that damages the control systems then they have a big problem.  We lost a B1b bomber once because of a bird strike to the engine cowling which damaged the engine or controls.  

Why is there such a dearth of "we used to do that but we learned better so now we don't do that anymore" thinking?  Write it down in some rule book that all engine designs should follow these rules and this is why..... Save the company reputation and the consumer some frustration. 

Beth Stackpole
User Rank
Blogger
No more dream car
Beth Stackpole   9/27/2011 7:53:06 AM
Too bad about this critical design change and subsequent flaw. I know many a person who pined for this car and its powerful SHO engine. Little did they know there was trouble lurking behind the scenes.

<<  <  Page 2/2


Partner Zone
Latest Analysis
The DDV-IP is a two-wheeled self-balancing robot that can deliver cold beverages to thirsty folks on hot summer days. A wireless RF remote enables manual control of the device beyond the act of self-balancing. All of the features of the DDV-IP result in an effective delivery vehicle while providing entertainment to the user.
Eric Doster of iFixit talks about the most surprising aspect of the Microsoft Surface Pro 3 teardown. In a presentation at Medical Design & Manufacturing Midwest, iFixit gave the Surface Pro 3 a score of one (out of a possible 10) for repairability.
Barnacles and mussels stay attached to ship hulls and rocks because of a very sticky protein glue they secrete, holding on for a long time even underwater. Researchers at MIT took mussel glue as inspiration -- and as an ingredient -- for engineering their own sticky waterproof adhesive.
Automation technology advances matched with expanded fracking and the growing urbanization of Asia, South America, and the Middle East, are fueling a boom in the automation industry.
3D printing is becoming a true manufacturing, not just prototyping, process facilitated by new materials.
More:Blogs|News
Design News Webinar Series
10/7/2014 8:00 a.m. California / 11:00 a.m. New York
9/25/2014 11:00 a.m. California / 2:00 p.m. New York
9/10/2014 11:00 a.m. California / 2:00 p.m. New York
7/23/2014 11:00 a.m. California / 2:00 p.m. New York
Quick Poll
The Continuing Education Center offers engineers an entirely new way to get the education they need to formulate next-generation solutions.
Oct 20 - 24, How to Design & Build an Embedded Web Server: An Embedded TCP/IP Tutorial
SEMESTERS: 1  |  2  |  3  |  4  |  5  |  6


Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.
Next Class: 10/28-10/30 11:00 AM
Sponsored by Stratasys
Next Class: 10/28-10/30 2:00 PM
Sponsored by Gates Corporation
Learn More   |   Login   |   Archived Classes
Twitter Feed
Design News Twitter Feed
Like Us on Facebook

Sponsored Content

Technology Marketplace

Copyright © 2014 UBM Canon, A UBM company, All rights reserved. Privacy Policy | Terms of Service