- Ford's aggressive testing includes driving, shaking, baking and freezing the vehicle to simulate all environmental scenarios.
- Ford's sophisticated, proprietary technology brings top results.
DEARBORN, Mich., Aug. 6, 2008 - It's more than magic that gives the 2009 Flex the smooth, quiet ride that's earning accolades from customers and media alike. A unique mix of innovative Ford technology, blended with the teamwork and pure tenacity of the behind-the-scenes Squeak and Rattle Prevention team that allows Ford customers enjoy the sound of silence.
"Squeak and rattle is taken very seriously here at Ford," said Julie Roehner, Vehicle Functional Group leader. "We're not just building the car for the 70-degree drive down the highway. We're building the car for the customers in Arizona to the customers in Alaska. The expectation of our team is whether you're driving down a smooth highway, a dirt road, or a pothole-filled street, we are squeak and rattle free. Whether it's a squeak, a moan, a hiss, a whistle, a tick, a buzz, a rattle, a squeal, a pop - it's unintended and unexpected by the customer, and it needs to be taken care of."
The Flex, like ever other Ford vehicle, was subjected to rigorous testing for squeaks and rattles at every build phase.
Inspection starts early, at the virtual design phase, looking at not only the materials used but at potential risk factors. "We review with the program team not only the design content, but also new risks that might not have been experienced in the past - including new content or new technology," said Vy Tran, Unibody Platforms Squeak and Rattle Prevention Supervisor, who oversaw the launch of the Flex along with John Haren, lead Squeak and Rattle Prevention Engineer.
In Flex, for example, the new refrigerated console raised a potential red flag for Haren, who immediately instituted new testing and sorting criteria to determine what was necessary to keep the component squeak-and-rattle-free. That type of focus continues as the team reviews every inch of the vehicle.
"One of the things we look at early on is material compatibility," said Haren. "We have the corporate engineering expertise that helps guide our focus of attention at what joints might be needing attention."
As the build progresses, inspections continue. The vehicle is subjected to rough-road testing on a multitude of specially designed surfaces such as cobblestone and Vienna brick. There, it's taken through bumps and curves that rival a Cedar Point coaster and shaken like a dry martini in a James Bond movie.
That's just the beginning. Select vehicles, depending on the issues that are identified, may be again shaken, often on the plant hydraulic shaker, then again inside a transportable climate-controlled trailer - the unique facility that uses proprietary technology developed and patented by Ford to simulate a complete environmental cycle.
This environmental testing vigorously shakes the vehicle at each wheel with loads derived from track testing. The climate-control testing puts the vehicle through its paces in extreme conditions that range from 20 degrees below zero to 140 degrees Fahrenheit.
Because the trailer is transportable, it can be relocated to the assembly plant for major launches, as it was taken to the Oakville, Ont. Assembly Complex where the Flex is built.
Testing goes on, vehicle after vehicle, day after day.
Testing Ford's complete vehicle range means Tran, Haren and their extended support team are working in temperatures that range from bone-chilling cold to sweltering heat, in search of that elusive unexpected noise sources.
"The cold is tough," Haren admits. "You can only stay in there for about 20 minutes at a time. But the heat, I think, might actually be worse."
In return for the team's hard work and success, they'll often hear, well, nothing.
"The goal is to build a world-class vehicle," said Tran. "Our job is to deliver the best-performing squeak and rattle vehicle possible. We aim for the No. 1 spot. Our job is like that of the unsung hero - if they don't mention you, it's good."
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About Ford Motor Company
Ford Motor Company, a global automotive industry leader based in Dearborn, Mich., manufactures or distributes automobiles in 200 markets across six continents. With about 229,000 employees and about 90 plants worldwide, the company's core and affiliated automotive brands include Ford, Lincoln, Mercury, Volvo and Mazda. The company provides financial services through Ford Motor Credit Company. For more information regarding Ford's products, please visit www.ford.com.