In our earlier post, we explained how automation at the Chennai plant and robots ensured best-in-class vehicles.

But quality doesn’t end with the manufacturing process. We have to ensure that our cars are able to survive tough Indian road conditions before they’re shipped out. For this, Ford’s developed a 3.2-kilometre dedicated vehicle quality testing circuit in our plant.

Testing Time

Name the road type and the testing track has it – straight, twisting, cement, rough roads or village streets! Engineers conduct rigorous quality test drives on Ford cars for up to 40 kilometres.

Our forthcoming Ford Figo will also go through several quality checks and tests to ensure we give consumers nothing but the best. Some of these tests will include:

• Hill climbs to test vehicle power and braking
• Lock-to-lock turning manoeuvres to check the steering system
• Straight line tests to verify wheel and steering alignment

Once we begin Figo production, we will test vehicles at random for quality inconsistencies in manufacturing and get them corrected. “Quality is one of the key pillars our brand stands on and the spirit of commitment to achieve world-class quality is inspiring,” says Ram Ramanathan, general manager, Vehicle Quality, Ford India.

Did You Hear That?
You certainly don’t want to hear squeaks and rattles while driving your car. We’ve adopted a global approach to identify the root causes of such noises and fix them permanently.

Every vehicle goes through the new ‘squeak and rattle track’ after it leaves the assembly line. The uneven and rough surfaces put stresses on the vehicle chassis and body, such as ‘body twists’, where stresses are put to one side of the vehicle (negotiating a curve).

A state-of-the-art hydro-pulse four-post test rig verifies, validates and investigates the squeaks and rattles. Immediately after this, the vehicle goes through further tests at full operating temperature, which include:

• Underbody hot check for leaks in engine oil, transmission oil, engine coolant and air-conditioning refrigerant systems
• Air-conditioning performance
• Grille temperature, which is compared to the ambient temperature
• Correct tyre pressure and battery charge state

Water, Water Everywhere!

Your chances of reaching home in a heavy July downpour are bleak if your vehicle stalls in the water. But if you are in a Ford, you can breathe easy; we put our cars through a water wading test, inspired by the monsoons and the ensuing flooded roads.

Engineers drive the car through a simulated flood (a puddle of water 50 metres across and 450 mm deep) at 10 kmph. Back on dry land, engineers check for leakage and whether the mechanical systems are operating normally. “We engineer our vehicles to endure that level of flooding, and keep testing so that our customers can be assured that their vehicles are manufactured to meet that standard,” Mr Ramanathan says.

What do you think of our new testing track? What tests would you like to see your car go through? Let us know!