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Designs for Ford


This is a graphic representation of the path that my team took from concept to full production on the CD132 program (Ford Mondeo 2001 - Europe). The beginning conceptual art is what we used to introduce the vehicle team to the IFES concept. The module development and the vehicle buck testing were used to prove the concept out to the vehicle program team. I was able to convince the team to move forward into production with a subset of the overall project we outlined.

The "White Glove Oil Change" was one of the conceptual modules that I developed with Rousch Racing in Detroit and allowed us to maintain the oil reservoir near the fender well inside the engine compartment. In the end, we could do a complete oil change on a DN101 (Ford Taurus - US) in just under 90 seconds without having to go under the vehicle. The concept sketches were done by Mark West.

This the Body-in-White (BIW) image of the front of the CD132 (Ford Mondeo 2001 - Europe). Here, the number one cross member has been removed. To prove out the concept on the vehicle team's platform (the Mondeo), I went to Genk, Belgium and built twelve of them without the front radiator support to see how they would compare to a standard body-in-white during a CMM inspection. For the DOE (Design of Experiments) I had them measure 12 standard BIWs and 12 BIWs modified to the specifications. The results were excellent and the Plant Manager told me he would give a positive recommendation to the project to the vehicle program manager.

The Radiator Support Module shown here in exploded view is an approximation of what we ended up with in the end on the vehicle. The upper portion of the RSM is what ties together the fenders of the BIW after painting. You can see how the module would be assembled off-line and then dropped into place in Final Assembly.

Here is the assembled Radiator Support Module ready to install in the vehicle.

The IFES or Integrated Front End System is a modular assembly built offline from the Finishing Line. Because of the way it is structured, the IFES is actually able to improve crash performance, noise/vehicle handling, assembly time and reduce the final cost of the vehicle.