Overall Attitudes toward the process

[Rkbrumbelow]

When you see a project developed at this kind of speed it’s usually an indicator that the manufacturer set up a skunkworks-esque design program. Disconnect the team from the typical hierarchy of top heavy management which slows down the entire process and adds cost. It’s interesting on a business level to see the cost saving measure being employed by ford throughout the entire process of design and development so they wouldn’t have to cut costs on materials and even fit a hybrid system into the target budget. This might even be an internal test by ford to explore ways to reduce development costs across the board for future projects. Vehicle costs and materials continue to rise in price while incomes are not increasing to arch so manufacturers are going to have to focus on reducing development costs over the next decade to keep their cars affordable.

There is a Ford produced video that goes over some of the internal design flow changes implemented, I will try and find it, but basically they reduced micromanaging and made the design process more open. I don’t want to say casual, as that carries additional implications, but less formal

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[dceggert]

I would just like to clarify the process just a bit because there are way too many misconceptions whipping people into a frenzy. I used to be involved in product launches at Ford some time ago and the process is likely to be following a similar system that was used when I was involved. However, much has changed over the years so this may not match today's process exactly but it likely has not strayed too far.

First, and most importantly, the Maverick is not considered to be in production at this time.

Ford is in is a ramp up to production. Suppliers are producing batches of parts on production tooling at production speeds using production processes. The batches are then inspected and then everything is put on hold waiting for Ford signoff on the part quality level. A good example of this is the recently leaked information of the 120 Hybrid parts made at Sterling Axle followed by a sudden shut down of that line. Those parts are likely for signoff and not any indication of issues as immediately conjectured.

The production ramp up to 'Okay to Sell' requires 2 batch builds at the Assembly Plant (Hermosillo in this case).

The first batch is to try out the tooling that has been installed on the Assembly line including incoming stock, material handling, bar coding, production process development, etc. These units are measured and inspected to make sure the design intent is made for this vehicle. Some of the vehicles that are seen rolling around in spy shots, dealer training events, etc. are likely from this build so this batch may have already happened. One of the outcomes of this process is a 'rebalancing' of the assembly line processes and a streamlining of the operation.

The second batch build is to verify that the vehicle can be built using the production process at production speeds using the supplier certified parts. This batch is then again inspected in detail and the data is used to support the Okay to Sell milestone. When that signoff occurs the Maverick will then go into production. Part orders will be issued with regular weekly deliveries and the line starts when stock levels are sufficient. This signoff MUST OCCUR first. This batch build is likely to not have occurred yet.

The production scheduling that is showing up in everyone's status is assuming Okay to Sell will be met on the program time plan. The earliest scheduled unit should be showing a date following the 9/15 time frame. If there is a build issue found during the batch build that needs to be corrected (and that issue may be minor and not be what YOU would consider to be an issue) before Okay to Sell is declared then there will be a short delay to the signoff. Sometimes a hose needs to be routed differently or a part had a marking or barcode that needs to be fixed.

This process is the same at GM, Toyota, Harley-Davidson, or any other major product manufacturer. People instinctively use this process when building their own furniture, deck, or remodel at home! The 'measure twice and cut once' principle uses this same process but just over simplified.

 

[Rkbrumbelow]

I think this is a great post that is mostly factually accurate and blended with reasonable opinion.

Looking forward to reading more from you.

That’s all I aim for, so thank you.

I try and tell my kids (in my classes/labs) that there are 3 sides to every argument. Yours, mine, & the truth. No one is going to be right 100% of the time.

 

[Platinum2]

That’s all I aim for, so thank you.

I try and tell my kids (in my classes/labs) that there are 3 sides to every argument. Yours, mine, & the truth. No one is going to be right 100% of the time.

Unless it's from the government. Then it's 100% correct 100% of the time for 100% of the people.

 

[Rkbrumbelow]

I would just like to clarify the process just a bit because there are way too many misconceptions whipping people into a frenzy. I used to be involved in product launches at Ford some time ago and the process is likely to be following a similar system that was used when I was involved. However, much has changed over the years so this may not match today's process exactly but it likely has not strayed too far.

First, and most importantly, the Maverick is not considered to be in production at this time.

Ford is in is a ramp up to production. Suppliers are producing batches of parts on production tooling at production speeds using production processes. The batches are then inspected and then everything is put on hold waiting for Ford signoff on the part quality level. A good example of this is the recently leaked information of the 120 Hybrid parts made at Sterling Axle followed by a sudden shut down of that line. Those parts are likely for signoff and not any indication of issues as immediately conjectured.

The production ramp up to 'Okay to Sell' requires 2 batch builds at the Assembly Plant (Hermosillo in this case).

The first batch is to try out the tooling that has been installed on the Assembly line including incoming stock, material handling, bar coding, production process development, etc. These units are measured and inspected to make sure the design intent is made for this vehicle. Some of the vehicles that are seen rolling around in spy shots, dealer training events, etc. are likely from this build so this batch may have already happened. One of the outcomes of this process is a 'rebalancing' of the assembly line processes and a streamlining of the operation.

The second batch build is to verify that the vehicle can be built using the production process at production speeds using the supplier certified parts. This batch is then again inspected in detail and the data is used to support the Okay to Sell milestone. When that signoff occurs the Maverick will then go into production. Part orders will be issued with regular weekly deliveries and the line starts when stock levels are sufficient. This signoff MUST OCCUR first. This batch build is likely to not have occurred yet.

The production scheduling that is showing up in everyone's status is assuming Okay to Sell will be met on the program time plan. The earliest scheduled unit should be showing a date following the 9/15 time frame. If there is a build issue found during the batch build that needs to be corrected (and that issue may be minor and not be what YOU would consider to be an issue) before Okay to Sell is declared then there will be a short delay to the signoff. Sometimes a hose needs to be routed differently or a part had a marking or barcode that needs to be fixed.

This process is the same at GM, Toyota, Harley-Davidson, or any other major product manufacturer. People instinctively use this process when building their own furniture, deck, or remodel at home! The 'measure twice and cut once' principle uses this same process but just over simplified.

Thank you, this is one of the things I was trying to state. Having someone else reiterate the same information in their own words maybe will reach folks I would not have.

 

[NotAnonymous]

Appreciate all of the thoughts here...it's most definitely "a process."

 

[Rkbrumbelow]

As someone who has been closely following and excited about Ford's new products, I will say my frustration has grown after a long, failed attempt to procure a Bronco Sport. The process was botched at the Ford level and this time I decided to get in early on the game regarding the Maverick.
While I understand that Ford is a for-profit company and its main responsibility is to the stockholders, Ford has over-extended itself with so many new-product launches during the pandemic and resultant supply-chain crisis.
Would it have been better to pace the product launches to ensure better customer satisfaction or rush them to market to bolster the stock prices in the near term? Ultimately, it will all depend on maintaining the customer base's interest.
If the product quality and delivery issues weigh heavily on the customer base, then the stock price will eventually reveal that.

My personal understanding is that the rear hard top has been a major issue, in fact I read today that Ford will be replacing every one.

 

[Red Ryder]

I definitely understand the frustration, but I'm not sure exactly how a business can truly plan product rollouts that take multiple years of planning, to anticipate a global pandemic. Given Ford has brought multiple products to market that are seeing significant appeal, they are being about as transparent and accommodating of their customers as I think an average consumer can realistically expect.

They could easily manage their distribution like Hyundai and guide 'reservations' to dealers for random allotments of vehicles to pick and choose from. How would we all be feeling then?

When you develop and introduce any new product, it is a risk. Some of the risks are design and cost issues, supply issues, changing market conditions and so on.
Companies sometimes have to adjust to these conditions dynamically to ensure that their branding and image is not tarnished.
I only question the near simultaneous release of three or four new products knowing that one's resources are limited vs. delaying one or two of them in order to funnel limited resources to maintain a better experience for one's customer.
I did not make a judgement on Ford's success or failure on the strategy that they chose, rather opened for discussion as the OP's title for this thread appeared to solicit "attitudes for the process".

 

[Down]

Not sure why you need to suppress people? Guess it’s the new way . All of this on the board is mostly conjecture anyway. Ford has the definitive say. Everyone has a choice to buy or walk away. We aren’t owed a Maverick nor is Ford entitled to our business. Just let it be! (Guess I’ll be blocked now).

In a comedic twist?
"I want my truck right now!" and "I don't want to see any opinions that differ from mine!" come from the same entitled and easily excitable point of view.

Some folks need to chill out.

 

[oljackfrost]

I would just like to clarify the process just a bit because there are way too many misconceptions whipping people into a frenzy. I used to be involved in product launches at Ford some time ago and the process is likely to be following a similar system that was used when I was involved. However, much has changed over the years so this may not match today's process exactly but it likely has not strayed too far.

First, and most importantly, the Maverick is not considered to be in production at this time.

Ford is in is a ramp up to production. Suppliers are producing batches of parts on production tooling at production speeds using production processes. The batches are then inspected and then everything is put on hold waiting for Ford signoff on the part quality level. A good example of this is the recently leaked information of the 120 Hybrid parts made at Sterling Axle followed by a sudden shut down of that line. Those parts are likely for signoff and not any indication of issues as immediately conjectured.

The production ramp up to 'Okay to Sell' requires 2 batch builds at the Assembly Plant (Hermosillo in this case).

The first batch is to try out the tooling that has been installed on the Assembly line including incoming stock, material handling, bar coding, production process development, etc. These units are measured and inspected to make sure the design intent is made for this vehicle. Some of the vehicles that are seen rolling around in spy shots, dealer training events, etc. are likely from this build so this batch may have already happened. One of the outcomes of this process is a 'rebalancing' of the assembly line processes and a streamlining of the operation.

The second batch build is to verify that the vehicle can be built using the production process at production speeds using the supplier certified parts. This batch is then again inspected in detail and the data is used to support the Okay to Sell milestone. When that signoff occurs the Maverick will then go into production. Part orders will be issued with regular weekly deliveries and the line starts when stock levels are sufficient. This signoff MUST OCCUR first. This batch build is likely to not have occurred yet.

The production scheduling that is showing up in everyone's status is assuming Okay to Sell will be met on the program time plan. The earliest scheduled unit should be showing a date following the 9/15 time frame. If there is a build issue found during the batch build that needs to be corrected (and that issue may be minor and not be what YOU would consider to be an issue) before Okay to Sell is declared then there will be a short delay to the signoff. Sometimes a hose needs to be routed differently or a part had a marking or barcode that needs to be fixed.

This process is the same at GM, Toyota, Harley-Davidson, or any other major product manufacturer. People instinctively use this process when building their own furniture, deck, or remodel at home! The 'measure twice and cut once' principle uses this same process but just over simplified.

Fantastic! Thanks for the insight.

 

[Pogeegitz]

As would be expected, the Facebook groups are a dumpster fire of emotions. This is a fair and balanced thread of discussion with some actual informed opinions rather than, "Ford has it out for me personally and is screwing me over on purpose, I know it!"

 

[SgtLip]

I'm in NO hurry. I made the decision in May to trade both of my vehicles for a single vehicle. I decided we no longer required 2 vehicles. Having said that I caught the Hybrid bug.

I decided that IF I ever wanted another vehicle it would be a truck but not an EV. I can't afford to have the electric service and panel increased in order to install a charging station. Yes I know I can charge it at 110V. Over a course of time.

Along comes the Ford Maverick. So I jumped. No, I did not have any of the history or the struggles or efforts Ford has gone through to bring it into existence. I don't know any of that and don't really care. All I know I learned from the Ford Maverick site. I built my truck and reserved it then ordered it.

Then by pure accident I discovered this forum. I've learned a lot. I don't know anything and can't respond to all of the posts like the OP can. He is a well rounded individual who appears to have done it all.

I'm a retired Contract Manager managing US Government contracts and Oil & Gas contracts. Not a scientist or engineer. But I have life experiences like every one on this forum. I've had BAK Hardroll tonneau covers. I can only share what I like and didn't like. It's MY opinion, not scientific. Just my experience. I know how much cash I was going to spend at local dealer and how much I going to spend at Chapman. For someone to tell me I'm not saving that much, I have no explanation, just facts. Local dealer charging me $36,900, Chapman charging me roughly $33,400. I believe that's $3,500.

I'm not pissed Hybrids aren't being built in record numbers. But when I see and hear they are only making 139 Transmissions, that doesn't give me hope of getting a truck anytime soon.

I DO NOT need this vehicle. I want this vehicle. I will wait. I can cancel. It's my option. But when Ford markets it as a base model a prudent buyer assumes (yes I know what that means) they will push that model. But then to say it will be a 60/40 production, caught a lot of buyers off guard. The ONLY saving grace Ford has is to pump 2.0EB out the door (which none have left yet) to meet what they said, Maverick to be delivered in the Fall of 2022.

But that doesn't make the Hybrid pill any easier to swallow. Again, I personally could care less when it gets here. My car insurance is paid up until the first of the year. If I don't get the truck before then, oh well, I'm saving money. So I'm not upset or anything. And I'm tired on posters telling us we are cry babies. Not the case. Just tired of NO response from dealers, mine or on the forum, and Ford Customer Service. Appears no one at Ford appears to be on the same page. That's my only gripe. In my line of work there is one voice for a company when dealing with a contract. Not everyone gets to speak for the company. Ford appears to have MANY representatives that speak for them.

That's my take. Black ball me if you like, call me a liar if you like, I really don't care. It's MY money and I will direct how and where it gets spent. Thank you for taking the time to read this if you made it this far.

Have a nice day!

 

[Jcj280]

So here's my thing: anybody complaining about production snags and wanting it now A. Should've realized what they were signing up for and B. Seem to not want to acknowledge getting a car made right now is insane. I'm paying $28,000 for my next car that I plan on having a while, and that's a significant investment on my part. When you invest a chunk of money like that, you should do research, and anyone who needs a car right now probably shouldn't have bought a brand new vehicle that isn't even out yet during a global pandemic.

I also think this could be due to people getting bad insight from their dealers. Maybe they were told anything to get to sign and were promised they'd get theirs first. My dealer was straight up and said it was gonna be a few months. They pegged delivery time at "November ish", possibly longer, and if that changed, well it's a crazy time. The crazy boondoggle that's been the Bronco launch should have given us an idea.

 

[rclee]

Dude, we are all in the same boat. I want this truck as bad as you. It will be delivered when it's delivered. I have never been so excited about a new vehicle as this one. This vehicle is a game changer (hybrid) truck. Congrats Ford for building it!

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