I wish you made this back in 2020. But I’ll take it in 2024. Thanks for the money, saving tip.

Thank you! I replaced this back in 2020. I don’t want to buy it at this moment .This works👍🏻

Great video thanks. You don't have to take the yellow clip out though, you just push on it from the back and it releases. It is horseshoe-shaped, just push on the round centre of the horseshoe then gently pull the vacuum tube off. When the two ends of the horseshoe spread apart, the clip releases. I used both silicone and WD40 spray in there and it seems to be a lot quieter. *edit you don't have the recalled part installed. the new part has a black plastic housing and yours is still aluminum. Maybe the dealer didn't actually perform the replacement? The black plastic one still fails though eventually.

Control, Uniformity and Continuous Improvement are keys way to minimize variation and improve the consistency of creating good product. Focusing on just making parts to print will not get you the consistency and uniformity that is needed

This really highlights the value and need to seek out competing and differing ideas while trying to solve problems, and the need to maintain humility while hearing them out. An open mind sees the whole picture, a closed mind only sees the path they're already on.

Having access to better minds/process (the competition) is a blessing. It will not only help you grow to be a better competition but also as an individual.

Impressed with the honesty of Ford to admit when they were not the best. In my experience, companies like this have always been shy about admitting any shortcomings.

Minimizing the variation is the key to good parts being produced for our customers.

The engineers at the customer need to be willing to compromise regarding the capabilities of the supplier regarding the tolerance. It's possible that the supplier's equipment and process is not capable of meeting the engineer's ideal. The two companies need to compromise on what they really need.

Minimizing variation starts with the design. Quoting products in the right material and setting an appropriate tolerance is key to achieving the zero defects goal.

Focusing on specifications vs. Uniformity seems similar to accuracy vs precision.

Brother your about to save me some money thank you

When I worked in the Tooling Machine Shop at Boeing Wichita back in the 1980's, we were required to watch this video in one of our Quality Circle Training meetings. The discoveries made in this study have stayed with me over all these years, and I no longer machine parts to print, but rather to the optimal design target value. As a result, QC Inspectors are no longer viewed as the opposition!

A notable example of how continuous process improvement is not an option, and how meeting only the minimum requirements can very quickly hurt your business, both in reputation and the bottom line.

To be competitive, a company must ensure quality control plus uniformity plus continues improvement to ensure less to no variability. Consistency is key. Good to learn from the experience of others. Thanks Ford for sharing.

Props to Ford for sharing this case study, and showing quality is not just making the parts to print. As said in video "Quality is never ending improvement", and Ford needed to improve on its part-to-part consistency.

Great to have the comments of the other mangers. The reverse engineering was eye-opening.

It woul seem to me that maybe their prints were out of tolerance as well or not tight enough to be able to produce consistent parts. They were so focused on their prints that they seem to foget other processes.

It’s amazing how people strive for accuracy before precision. This highlights the importance of working on precision before accuracy. If a process is repeatable, it’s much easier to make adjustments to improve your output. It also allows more flexibility and adaptability

This highlights how standards and consistency are vital to every operation. This allows flexibility and adaptivity in your production. Its about precision over accuracy

The video clearly demonstrates how breaking the process down and looking at each singular piece in production gives you the perspective to fix the entire part. I love that they ordered the ‘foreign’ parts and reverse engineered them to help them identify their own flaws.

I love that this video shines some light on the flawed perspectives of quality. Focusing on Specifications versus uniformity can blind us to the underlying need to improve what we believe is meeting the standard. To be competitive our processes must adhere to statistical control. This kind of control creates room to make improvement.

It appears that Ford chose to listen to their customers and do copious amounts of research into improvement of their brand. The state of the art facility and their current values as a company were not sustainable. Market research and strategic thinking into ways to be more efficient ultimately kept their stake as an American automobile manufacturer. Building ways to track quality control data, assessing the acceptable tolerance scale for transmission parts, how frequently they are serviced, and their market product into their competition was a required but lucrative change. With the institution of controlled tolerances and their acceptability ultimately made their customers happy, and a better product with sustainable continual improvement. Yee haw!

We spend so much money and time on making a better product, a product that can win against competitors. However, I realized that no matter how good your products are, you will not be able to win against your competitor, if you cannot consistently make the parts and assemble at the highest consistency. Without this, regardless of how good your parts are, the performance will be low and the customer satisfaction level will be low. This video shows the value of the quality and helped me to understand the importance of it.

I love when companies (and individuals) make quality and improvement a priority. Interesting how the desire to rise to the competition led to such detailed and surprising findings that led to a whole overhaul. Seems like a win-win-win for the company, its workers, and the customer.

Gosh, I looked on Amazon here in Canada, and a new one is $140 for a new pump...for all the work to get to it, perhaps putting a new one in is a better option!

Thanks for sharing. This fix is working!

Consistency is key! Even if you have a great quality part or material, if you are not consistent with the creation and fail to search for continuous improvement, your "quality" on the output will be compromised and the customer will notice and your brand will not be perceived positively as you had the expectation for.

This video makes a good point quality is not only making to spec, but rather never ending improvement. Meeting blue print is not good enough.

Measuring success on your own quality standards is not sufficient. Continuous improvement also requires a process to eliminate deviations and keep an eye on your competition.

This video highlights the need for consistency and uniformity. The difference between 27% and 70% is huge and it comes down to how the competitors really strove to have that uniformity with each of their parts.

'Promo sm' 😻

This shows that there was no feedback loop created for the manufacturing team to the engineers and to the executives. The lack of feedback structure cause high variation and quality issues without passing through the inspection points and to the end use customer.

A lot of great points were presented in this video. I really loved the part of "quality is measured by our customers..."which really made me think about how important it is to actively listen to customers and take and type of "return" seriously. Quality doesn't just mean high standards, but consistency in said standards. It's potentially easier to improve an entire system of units with 1 small tweak than it is to investigate every unit individually to identify a root cause. In my job, it makes me think about how customer concessions on orders are not just a result of the human fulfilling said order, but also the process itself overall or even the source of the item in said order too.

Commenting on this video is a requirement for the six sigma course I'm enrolled in. The video highlights the importance of minimizing variation in production to manufacture a high quality product. It's also interesting to note that prior to investigating the competitors product, Ford believed that producing transmissions to spec/print was good enough. Through their investigations they were able to realize the role consistent manufacturing had on a product.

It’s interesting to see how society’s interpretation and mentality of quality has changed. We rely so much on specifications. We often do not take the time to determine how stable a process or product is by conducting studies. These studies can go a long way in allowing us to understand how stable the process and product is by observing the variations in behavior.

My favorite quote in the video was "building parts to print isn't good enough", if I told that to any of the machine operator where I work at they would laugh at me. But it's true and this is a great example of that. Even though the plant in Batavia was running parts to spec they were using 70% of the total tolerance while the competition was only using 27% and were producing much better quality parts.

A very interesting video that really shows that meeting the specifications isn't the only thing that is important in quality. I really enjoyed how the video showed that using less of the specification limit to achieve more consistent products can significantly improve customer satisfied.

An interesting (if dated) video. It would have been good to know what the off-shore company was doing to hit their tolerances so tightly and consistently.

I think this shows how important everyone within an organization is customer focused. Because we can do our jobs right such as making parts to spec but we need to make parts specific to customer expectations . I think this is also a good example of the importance of striving for the correct target in your production. This helps with consistency as well. Be good but also be the best version of that good you can be.

The biggest take away for me on this video was how their competition was able to side-step all the problems that the speakers were having trouble solving. And when you need to have an independent source verify that your quality guy's tools are true, you know that you are doing something right.

well this aged like fine Milk

After having a Batavia ATX I gave up on Ford years ago

Back in high school when I was member of the wrestling club, my coach would say that "practice makes perfect" is not good enough, that you have aspire to "perfect practice makes perfect" to be a champion. I feel this video captures that advice completely. If you do not seek to eliminate all variations from all parts of your process, then your competition will quickly outmaneuver you in quality and, of course, in sales.

This is an incredibly interesting video. There is definitely more to "quality" than meets the eye. It is important to have tolerances for each individual component of a product, but it is also important to view the product holistically when it comes to quality.

Great video... I wonder in a warehouse where we pick and ship parts, how do I determine what the variation should be? There are many factors that come into play. Do I determine all of the causes and begin to eliminate which creates consistency and predictability?

Having tolerance is OK, but there are different ways of getting your tolerances. One way is to build your tolerances based on your part variability, so you don't have any throw-away parts. The other is to have the customer determine what is the appropriate tolerance based on their experience using the part. The big issue, as related in this video to transmissions, is a small tolerance, multiplies by hundreds of components in a transmission, can lead to highly variable transmission performance.

"In some of the plants, I couldn't even find out if we were building to print." Pathetic, but I have seen the same thing.

Very interesting.