This is the second part of an earlier blog post.

After visiting the Ford India Engine Plant, the bloggers were showcased the company’s efforts to reduce the cost of owning Ford cars through its selection of child parts. These child parts reduce the cost of repairing or replacing spare parts by eliminating the need to replace large sections of the car. This is done by simplifying major assemblies into component-level parts. For example, a starter motor, which was previously replaced as a complete unit, has now been classified into several component-level parts such as the arm assembly, housing assembly, bushing, drive assembly and solenoid assembly. Similar child parts are also developed for engine components and transmission systems, to name a few.

“Ford has taken an awesome initiative to reduce costs at both the manufacturing as well as maintenance level. Owners of the Figo will experience very reasonable prices of spares. Add to that, the company has ensured that you don’t need to change the complete part should anything go wrong with a part being made of sub-parts and thus making it cheap to replace,” Faisal of Motorbeam wrote on his blog.

The last stop for the bloggers was the delivery yard, where the cars are stored when they are ready for delivery hundreds of Ford Figos stood waiting to be delivered to dealers. For the car-loving bloggers, it was a fascinating experience to watch the journey of a Ford car from bare metal to the finished product. It gave them all a glimpse into cutting-edge car manufacturing technology. Ford India is a 6-Sigma company, and every process and step is planned to perfection.

Earlier, we posted about the Ford facility tour and Driving Skills for Life session, which we organized recently for select auto bloggers. Here is a sneak peek into the Ford manufacturing facility. The video starts with a visit at the Blanking facility where sheets of steel are cut into ‘blanks’ or shapes of the car’s body , according to specifications. It then moves on to the Stamping unit , where the blanks are moulded into specific car body components such as doors, hood, roof etc. Then, it is moved to the Body Shop where 66 robots spot weld the ‘stamped’ sections of the cars, followed by the Paint Shop where the cars are painted in the vibrant colours. Finally, the tour moves on to the Trim Chassis and Finish (TCF) where the engines, doors and seats as well as other electrical parts are fitted in the cars before they finally roll out for stringent quality tests. We also have a sneak peek of the delivery yard where your favourite Figos are parked after production, ready for final checks before they are dispatched to the dealers. The video ends with a snippet of Driving Skills for Life training, about safe and economical driving, conducted through classroom and practical sessions.

More people die in road accidents in India than anywhere else in the world, according to the Global Status Report on Road Safety by the World Health Organization. Each of us can reduce the likelihood of an accident by driving safely and cultivating good driving habits.

Ford conducts the Driving Skills for Life programme that helps new and old drivers stay safe behind the wheel. Here are a few of our best tips:

Tip 1: Use seat belts all the time

-A seat belt can significantly reduce the chance of a serious injury or death
-Fasten your seat belt before you turn on the engine
-Insist that all your passengers use their seat belts

Tip 2: Adjust rear view and side mirrors

-Before you turn on the engine, adjust your rear and side view mirrors to the appropriate angles to maximise your field of vision
-Your views from the back window and along the sides of the vehicle should be clear and unobstructed

Tip 3: Drive relaxed by anticipating traffic situations

-Avoid constant accelerating-braking sequences
-Change lanes early when approaching obstacles – always use left/ right turn signals
-Smoothly equalise speed differences
-Allow other vehicles to proceed before you – be courteous to other drivers

Tip 4: Avoid distractions while driving

-Driving demands your full attention and distractions can increase the risk of a crash
-Distractions include adjusting the radio, talking on mobile phones or with other passengers, sending text messages… which can take your attention away from the road, and increase driving risk

Tip 5: Maintain a safe three-second distance between vehicles

-Keep a safe distance between your vehicle and the one in front of you, to prevent crashing into it if it stops abruptly
-Use the three-second rule – as safe distances change with different speeds
-Pick a stationary point on the road; when the car in front of you passes it, you should be able to count to 3 before you pass the same object
-If the weather is bad and visibility is low – i.e. if there is heavy rain or fog – increase he time interval to 6 seconds

Tip 6: Use your gears effectively

-You should shift to the next highest gear when engine speeds reach 2,000-2,500 rpm
-Maintain uniform driving at engine speed of 2,000 rpm and below.

Target Gear      Speed

1st Gear                Start up
2nd Gear              After 1 car length
3rd Gear               at 30 km/h
4th Gear               at 40 km/h
5th Gear               at 50 km/h
6th Gear               possible above 50 km/h

Tip 7: Use the vehicle’s momentum and built-up energy

Take the foot off the accelerator pedal early and roll with the traffic when:

-Approaching a red light
-Before changing direction
-In stop-and-go traffic
-At a “give-way” or “yield” traffic sign
-Approaching a “Stop” traffic sign

Tip 8: Switch off the engine selectively

If you expect to stop your vehicle and remain idle for more than 20 seconds, you can save fuel by switching off the engine. An engine idling for three minutes is equivalent to driving one kilometre at 50 km per hour. Typical situations include:

-While loading and unloading
-At traffic lights
-In traffic jams
-At closed gates (railway crossing).

Note: Switching the engine on off frequently does not damage the starter switch or decrease its life

Tip 9: Ensure adequate tyre pressure

-Check your tyres regularly and adjust it to appropriate pressure (see car manual). It saves fuel and increases safety!
-Correct tyre pressure can improve fuel economy by up to 1%-3%
-Tyre pressure that is 0.3 BAR below the optimum can increase the rolling resistance by up to 10%
-A tyre can lose up to half of its air pressure without appearing flat

Tip 10: Remove weight and unused racks

-An additional weight of 20 kg can increase fuel consumption by approximately 1%
-Remove unnecessary weight from the trunk (boot)
-Take off racks (roof and rear) when they’re not being used
-Use lower speeds while transporting goods with roof or rear racks for better fuel economy and safety

We would like to hear how you practise safe driving. Please leave a comment with your own driving tips.