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sorry guys, got a question. I thought Ford was hell bent on a batch and hold for QC purposes. Our first F-150s have been ripe with misaligned body panels ( and sadly some have bordered on inexcusable ) I though process's had been put in place to alleviate potential issues such as these. We have several with blatantly misaligned front bumpers that cannot be adjusted without the ok from Ford. Seems they are aware, but have yet to green light the fix...are there line problems?....sort of explains why they are so slow in coming if Ford is aware of the issues?....

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What's the manufacture date for these vehicles?

 

It's only the run-up to the OKTB that all builds are closely inspected.

 

After that batch/hold mandates 'shakedowns' of representative samples from a 'batch'. The batch is 'held' while the sample group is tested. When they pass muster, the batch is released. So not every vehicle will be closely inspected for misaligned panels.

 

However, there is also supposed to be laser monitoring of panel alignment during assembly, but Ford has reportedly ignored those readings on occasion (during the Focus launch).

Edited by RichardJensen

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Rich, my own personal units were factory orders, both of which took from August 2014 to get here.....one was passable, then I noticed on the other the front bumper is tilted skywards rear to front and gaps on one side larger than the other. We had one truck as a dealer trade that was so bad ( body panels and doors ) we literally sent it back...this is something I thought had been adressed since the Focus , then Fusion Hood days....I have also noted a few Mustang hoods that I personally wouldn't accept.....FRUSTRATING, but our body shop will embrace the additional work once greenlighted.

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However, there is also supposed to be laser monitoring of panel alignment during assembly, but Ford has reportedly ignored those readings on occasion (during the Focus launch).

And they're doing it again. I can see the laser station from my work station and I only just started seeing them working within the last 2-3 weeks.

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then someone needs a good kick up the ass....releasing these units is unacceptable, and reflects badly on the delivering dealers...after all, we ARE the fall guys if anything isn't kosher..

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Did DTP employ the laser stations for panel alignment prior to the 2015 switchover? Curious as my 2013 F150 has a misaligned front bumper.

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then someone needs a good kick up the ass....releasing these units is unacceptable, and reflects badly on the delivering dealers...after all, we ARE the fall guys if anything isn't kosher..

I have a feeling they're taking the stance of just pushing units out the door and letting the dealers fix the problems. I have no evidence to back that claim up, it's just a gut feeling I have.

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only problem I have with that is there is NO greenlight to re-align the bumpers yet, we have been told to leave them alone until further contact.....

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I have a feeling they're taking the stance of just pushing units out the door and letting the dealers fix the problems. I have no evidence to back that claim up, it's just a gut feeling I have.

Incredible. Ford spent a ton trying to launch the aluminum F150 clean and it comes out like this?!

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F250....unfortunately Im somewhat of the same frame of mind...someone somewhere cut corners or ignored responsibility...Based on past experience, Focus, Fusion hoods etc, the issue will finally be addressed and rectified...but in the meantime, all I can do is raise my hands in anguish and sigh "REALLY FORD"???????

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Did DTP employ the laser stations for panel alignment prior to the 2015 switchover? Curious as my 2013 F150 has a misaligned front bumper.

Yes. At the time, we were the first Ford plant to get them. They were used in the body shop before the unit went to paint. Not sure they had another station in the final assembly building, so they wouldn't have helped with bumper alignment.

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Yes. At the time, we were the first Ford plant to get them. They were used in the body shop before the unit went to paint. Not sure they had another station in the final assembly building, so they wouldn't have helped with bumper alignment.

If they do, it's at the beginning of final inspection (CAL). That's where the one at MAP is that I was alluding to earlier.

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@fuzzy...part of me is starting to doubt there IS in fact a FINAL INSPECTION, or that THAT is performed by Lasik guinea pigs.....

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I got to take a gander at a White XLT 4X4 3.5 Ecoboost in the showroom at my local dealership. Did not notice any problems with the exterior, but did find the glove box would not close on the left side without slamming it shut (Opens a little slow for my taste also). Pointed it out to the salesman. Next time I was in there, they had it fixed. They had a 2.7 supercrew 4X2 XLT outside and I got to drive it. Wow, very impressive, it was a Hot Rod. :rockon: I did not take the time to inspect body panels on this one either, but the glove box was fine!! :camera:

Edited by danglin

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@fuzzy...part of me is starting to doubt there IS in fact a FINAL INSPECTION, or that THAT is performed by Lasik guinea pigs.....

There is a final inspection, but I get the impression that they tend to let a little more stuff go in the name of getting units out the door faster during a launch. This isn't stuff you generally hear about 6 months into production, and I don't think Ford is the only company that does this either.

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then someone needs a good kick up the ass....releasing these units is unacceptable, and reflects badly on the delivering dealers...after all, we ARE the fall guys if anything isn't kosher..

How bad are these Deanh? Do you have pictures? I realize the bumper is fixed mounted to the frame and the cab assembly is dropped later with insulating mounts but your first post referred to body panels so misaligned you sent the DX truck back. Looks like Dearborn hasn't progressed much since they built my Mustang.

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F250, if we sent a dealer trade truck BACK they had to be pretty bad. That truck I didn't see personally, the bumpers I have, all tilted the same way. Bodyshop contacted Ford, apparently they are aware of the issue but have stated hands off until further notice. Its not groundbreakingly bad, but if I was the buyer Id sure as hell want it fixed because it IS noticeable, some worse than others...and some door panels are 1/8 of an inch out...

Edited by Deanh

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DTP is Ford's no expense spared best of everything home plant and they can't get the bumpers and doors hung straight!

"It's a big risk. So far this year, one out of every three vehicles Ford sold in the U.S. was an F-Series pickup. Morgan Stanley estimates F-Series trucks account for 90 percent of Ford's global automotive profit...The aluminum-sided F-150 could set a new industry standard — or cost the company its pickup truck crown."

 

And they're apparently shipping sloppy work just to meet a launch quota!

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fact is they will get it right in a few months, Im just getting a little tired of initial quality not being up to par, and either making excuses or scheduling re-alignment appointments for the buyers of the first few batches......

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Could be worse. Back in the early 50's, Ford of Canada had to ship every Ford/Meteor/Mercury/Monarch convertible sold in Canada to a particular Toronto Ford dealer, which would take the convertible roof apart, re-assemble, re-install and align windows and lifts, all the details. Then the cars were shipped to the selling dealers. By '56 or so, assembly plant quality no longer required the re-do. :)

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Could be worse. Back in the early 50's, Ford of Canada had to ship every Ford/Meteor/Mercury/Monarch convertible sold in Canada to a particular Toronto Ford dealer, which would take the convertible roof apart, re-assemble, re-install and align windows and lifts, all the details. Then the cars were shipped to the selling dealers. By '56 or so, assembly plant quality no longer required the re-do. :)

 

Through the years certain Ford plants had a reputation for consistent outstanding quality and some others were known for shipping poorly built vehicles. This seemed to be a serious problem in the late 1950's.

I think you'll find this story interesting:

http://hamptonroads.com/node/67561

 

The assembly quality of these vehicles was so bad thousands were shipped to a separate Ford assembly plant that did not originally build them to have all the quality issues corrected. "In 1957, dealers angered by the poor workmanship "demanded a quality car," Jimmy Holt says. "Our guys made sure they got it."

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I was at my Ford / Lincoln dealership yesterday for a State inspection and they were delivering a 2015 F150 Super Crew King Ranch.....WOW!! That was one beautiful looking truck!!

Edited by twintornados

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I was at my Ford / Lincoln dealership yesterday for a State inspection and they were delivering a 2015 F150 Super Crew King Ranch.....WOW!! That was one beautiful looking truck!!

 

Pictures don't do 'em justice! There was a bright red Lariat at the dealer when I drove through the other day. I've never seen a better looking truck...absolutely beautiful! And it's like a vault inside when you close the doors. Of course, 2 vehicles down was a sexy black Mustang. Both are tremendous styling hits in my book!

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