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BlueOvalNews.com |
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How a Ford Modular engine is built |
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The 6.8 liter single overhead cam Triton V-10 gasoline engine is the largest engine in Ford's modular engine line up. The V-10 develops 265 horsepower at 4250 rpm and 410 foot-pounds of torque at 2750 rpm. The V-10 is controlled and monitored by Ford's new generation electronic engine control module, EEC-V. Like the modular V-8 engines, the V-10 is equipped with distributor-less ignition and platinum-tipped spark plugs, which can perform at 160,000 km tune up intervals with routine filter and fluid changes under normal driving conditions. Windsor Engine Plant has a zero defect policy. To achieve zero defects, the plant uses world class machinery operated by highly trained employees and has adopted extensive in process testing to identify and resolve defects in the manufacturing process. In a traditional engine plant, engines are "hot tested" at the end of the assembly process to verify quality and identify defects. At Windsor, hot testing is only part of the testing process, with additional in process (or "cold") testing taking place at nine key stages in the assembly process. Cold testing means that each engine is checked against a model template or "signature" to ensure that it is within the tolerances required at the stage of assembly it has reached. For example, testing can identify if the timing chain is even one tooth advanced or retarded, so that immediate corrective action can be taken. This level of analysis can trace defects that would not be picked up by conventional means and might not arise in vehicle use until the engine has been run to high mileage levels. As each engine goes though the complete testing process a detailed computer profile is made, which is filed at the plant. These records can be used throughout the lifetime of the engine to help Ford dealers identify and correct any problems that a customer might experience. "By implementing in-process tests and testing for more features during the manufacturing process, we are confident of producing higher quality products, and this is proven evident from the results we are seeing in real world usage by our customers," said Mike Bastian, Engineering Team Leader, Engineering and Assembly. Sophisticated testing is only of value is the highest level of quality is being built into the product in the first instance. At Windsor, employees have undergone extensive training to optimize on the job skills and develop teamworking. COPYRIGHT 1999 WARNER PUBLICATIONS. ALL RIGHTS RESERVED BlueOvalNews.com |
INTERCHANGEABILITY - Modular engines share the same basic design in blocks, aluminum heads and other key components. Advantages associated with Ford's modular engine series are: increased power, durability, fuel efficiency, and reduced noise, vibration and harshness.
MACHINING, grinding and polishing equipment is installed to produce a tubular camshaft as well as cast iron and forged, heat treated steel crankshafts, depending on the engine's application.
ONE LINE: Three cast iron cylinder blocks are machined on a single line. Aluminum cylinder heads are produced on two lines, one fixed and one flexible, to produce the 1,300,000 cylinder heads required for an annual output of 650,000 engines. Two connecting rod lines are in place to meet the demand of two types of powdered metal connecting rods.
SENSORS with technologically advanced signature analysis capabilities are placed throughout the assembly line to detect virtually any type of manufacturing defect at point of assembly, to ensure defect free engines are delivered to vehicle assembly plants.
A CYLINDER head sub assembly area supplies this main MODULAR ENGINE LINE, which is flexible to accommodate a batch of one throughout the three displacements, with pre-assembled cylinder head and camshaft components.
AUTOMATED application of the cylinder heads to the cylinder block is standard procedure for all modular V-8 and V-10 engines.
AERIAL VIEW of the Windsor Engine Plant. The plant is located at 1000 Henry Ford Centre Drive, Windsor, Ontario - Canada. Total plant size is 1,202,650 square feet situated on 38.75 acres. The plant has the capacity to produce 650,000 engines a year and supplies 4.6, 5.4 and 6.8 modular engines for Expedition, Econoline, F-Series and Navigator. The assembly line length is 3,147 feet long!
Ford Windsor Engine Plant - Zero defects is Job #1. BlueOvalNews.com |
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