Ford Focus recalls. An opportunity to discuss preventive and corrective actions

I just learned that Ford Motor is recalling 572 795 Ford Focus. That's a big recall, and I see a discussion about preventive and corrective actions coming up.

Apparently, two things prompted this (Please forgive me if I'm misinformed):

1. Salt water corrosion may occur inside a seal at the rear wheels. It could cause the rear wheels to wobble.

2. Something has caused cables to melt and in some cases caused engine fires.

Now: Seen from the ISO 9000 perspective the first clauses that come to mind are 8.5.2 & 8.5.3, but there is more to it. Let's hear your comments and opinions...

Elsmar Forum Sponsor
Design, process?

Good point Laura. My take would be to ask if the problem(s) are related to a design flaw, or to a manufacturing flaw. If design didn't take into account salt water, we would be driven in one direction. If rather, the problem is material that did not meet spec, then perhaps purchasing or inspeciton might be a better place to look.

My understanding is that a certain amount of validation occurs through the end user. Perhaps we need better validation instructions.
DFMEA availability

Nudge, nudge, wink, wink indeed. We are primarily not an automotive supplier (~8% of our business) but we have QS-9000. In the last three years we have done 6 full APQPs for new parts. Despite, any number of pleas we have never been able to to obtain a customer DFMEA. If you appreciate the intent of APQP you know that the process is severely compromised by this. Classic case of, "Do what I say, not as I do". Wasn't the Ford Focus the automobile of the year according to a major automotive magazine...NNWW;)

Randy Stewart

Ya gotta wonder

I have to be careful on this one - Ford is our parent company!!! I know how I feel dealing with Ford and I can't imagine what it would be like as an outside supplier to them. We have a job running now that requires us to buy parts from another production stamping plant, we re-strike it and add an assembly to make a RH drive vehicle. When we went for engineering buy-off they laughed at us. We had to do a study to show we actually made the part better in order to get the buyoff. When we asked the stamping plant about the tools they stated that the job had been running for 5 years and they weren't going to touch the dies!!!! I know the Focus hasn't been around that long but I do believe it is a good look at the mentality. Suppliers can show the need for changes, but if it isn't in the budget forget it. APQP, etc. only works if you do it honestly and not just for paperwork requirements. IMO Ford messed up by making the "STA" an entry level position to get your career started. These people have too many programs, too little experience, too many OEM directed changes to track which directly links to too many deadlines to make. It is a wasted resource. Now with Toyota boasting about going from clay freeze to 1st part delivery in 12 months, watch out. That means less product development time and what will be cut????? DFMEA's and APQP of course!


Disclaimer: I am an automotive consumer and not a supplier or producer, so I am not familiar with QS9xxx exept to the extent that it overlaps other standards I am familiar with. I am also a reasonably satisfied owner of a 2000 Focus.

Question - what kind of defect (whatever the cause) would allow salt water corrosion but not fresh water corrosion? Last August, well before this recall was announced, I had to have a rear wheel bearing replaced due to corrosion and "loss of lubricant". (The grease got hot, melted and flowed out.) Yet the car has not been anywhere near salt water, and I live far enough south that we don't even salt the roads in the winter. (This year, winter happened on February 3 & 4. :cool: )

Comment - I guess I am going to have to talk to my dealer to see if my car is included in the recall. It would be nice to get the bill for the bearing adjusted, and I am curious about the hot cable problem.

Irrelevant but True story about engine fires - long ago and far away, my wife was driving our first car (also a Ford product). She observed that the pale blue paint on the hood was turning brown, and she was starting to look through a definite heat haze in the air. Most odd, as it was the middle of winter (Maryland then, not Georgia!) Anyway, she decided to look into this phenomenon and pulled off the road at the next convenient place. She stopped, got out of the car, and then observed that a major panic attack appeared to be in progress. Everybody in sight was yelling and screaming, and most were running away - FAST! That was when she noticed that (a) she had pulled into a service station, (b) there was now a LOT of smoke coming from the engine area, and (c) she had parked next to the gasoline pumps! Fortunately, the fire station was only two blocks away. Root cause analysis showed that the problem started when the car had received routine service a couple of weeks earlier. The mechanic changed the fuel filter, which threaded into the carburetor body. He got it cross-threaded and rather than redo it again, he just got on it with the proverbial bigger wrench. That resulted in a cracked carburetor body and eventually gasoline leaking onto the exhaust manifold.

(Does everybody remember what a carburetor was? As in a Motorcraft 4-barrel on a 302 engine with dual exhaust!)

Any water of course...

Good question about the salt water, Graeme. I'll have to assume that any kind of water could enter, but of course the road salt used on the winter roads here would make the matter so much worse.

P.s. I just heard that only the U.S. manufactured cars are affected by the recall....



Super Moderator
Trusted Information Resource
Graeme said:

Disclaimer: I am an automotive consumer and not a supplier or producer,
(also a Ford product).
Graeme, you must be a REAL loyal customer.:biglaugh:

Maybe brand loyalty isn't what it's cracked up to be? I've driven 2 Fords in my life, both were recalled, both were constant trouble. I think that maybe that is where I learned my lesson on cause and effect.

Sorry to all the loyal Ford buyers, but this one just couldn't be ignored by the sarcastic, evil twin.:eek:


SteelMaiden said:

Graeme, you must be a REAL loyal customer.:biglaugh:
Not ALL that loyal, actually ... From the time I started driving, my automobiles have been: Morris Minor, Triumph Herald, Triumph Spitfire, great big green tracked vehicles that had USMC painted on them & big guns on top, Mercury Montego, Saab 99, Dodge Tradesman (van), Pontiac Bonneville (the small one), Oldsmobile Ciera (with the imitation diesel engine), Nissan pickup truck, Dodge Lancer (my mid-life crisis hot RED car), Mercury Sable, Mercury Villager and then the Ford Focus. And in truth the Montego, Bonneville, Nissan and Villager were/are in my wife's name so they are hers/ours instead of mine/ours.

Graeme :bigwave:
Thread starter Similar threads Forum Replies Date
Marc NHTSA - Ford Focus and Dodge Durango (Daimler-Chrysler) to be recalled World News 1
D Ford CSR Cpk/Ppk Requirements Statistical Analysis Tools, Techniques and SPC 8
Vader22 FORD CSR Gap Analysis Checklist IATF 16949 - Automotive Quality Systems Standard 4
T Ford Q1 MSA - Virtual Site Visit Hardware Manufacturing and Related Processes 14
Dan Pare Ford CSR Update (FMEA's) - January 2022 FMEA and Control Plans 24
T Ford CSR for Internal Auditors 2021 Internal Auditing 4
Techilady Ford Special Characteristics Communication and Agreement Form (SCCAF) provides production requirements? FMEA and Control Plans 4
B Struggling with using the 5.6 version Ford Capacity Analysis Report APQP and PPAP 5
O Informational Ford Motor Company Customer Specific Requirements for IATF 16949:2016 - 08 Jan 2021 Customer and Company Specific Requirements 0
O IATF 16949 News Ford Motors Customer Specific Requirements Update - Nov 2020 IATF 16949 - Automotive Quality Systems Standard 5
C Ford's MMOG/le Template wanted Manufacturing and Related Processes 0
H FORD's project milestone acronyms Customer and Company Specific Requirements 4
R Ford Q1 Manufacturing Site assessment result Customer and Company Specific Requirements 3
Ron Rompen Ford Method - Position Capability with MMC Modifier Capability, Accuracy and Stability - Processes, Machines, etc. 14
M Ford Q1 Revocation Recovery Process Customer and Company Specific Requirements 5
A Is normal for FORD EU ask for the PSW every year APQP and PPAP 5
C A couple CSR (Customer Specific Requirements) questions... Esp. Ford & Toyota Customer and Company Specific Requirements 5
V What document to use to document Welding PV testing - Supplier to Ford APQP and PPAP 1
E Ford Phased PPAP and T2 timing APQP and PPAP 1
S Where to get Ford document FAP 03-111 FMEA and Control Plans 12
Q Ford's Q1 Score Prediction Customer and Company Specific Requirements 2
V Ford Dimensional Tag Characteristics requirements APQP and PPAP 2
R Ford Motor Company new CSR document - May 2014 Customer and Company Specific Requirements 1
K Q1-Ford - Does anyone have any Q1 templates? Document Control Systems, Procedures, Forms and Templates 2
Ron Rompen Ford Paint Audit Checklist Customer and Company Specific Requirements 4
S ASTM-D4000 & FORD "ZW" Call-Outs Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
S Dimensional Issues because of the last years FORD Recall Manufacturing and Related Processes 2
J JMP Gauge R&R with FORD MSA Data Quality Tools, Improvement and Analysis 2
A Statistical Software Calibration using Ford's "Sample Calibration File" Statistical Analysis Tools, Techniques and SPC 8
V Where I can find an AAR form on Ford Covisint? APQP and PPAP 1
Marc Ford is introducing an Aluminum F-150 Pick 'em Up Truck World News 1
V Webasto Ford Exceptions Form APQP and PPAP 1
Marc Ford - Self-parking technology called Fully Assisted Parking Aid World News 1
M Advise on R Chart with Ppk of 17.85 for Ford Capability, Accuracy and Stability - Processes, Machines, etc. 37
V What Ford Phase PPAP Level should DV testing be submitted? APQP and PPAP 1
Stijloor Ford - June 2013 Customer Specific Requirements (CSR) Customer and Company Specific Requirements 1
T What innovations led to Ford's production line? Coffee Break and Water Cooler Discussions 5
Ajit Basrur On Henry Ford's 150th Birthday, His Greatest Insight Has Been Tragically Forgotten Coffee Break and Water Cooler Discussions 11
D How long must we provide service parts to Ford? IATF 16949 - Automotive Quality Systems Standard 7
S Ford Motor Engineering Change Level definition Customer and Company Specific Requirements 6
C Will Ford accept AS9100 certification in place of ISO9001 ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 16
R Ford SQDCME manual Manufacturing and Related Processes 1
D What is the Ford Troubled Supplier group? Manufacturing and Related Processes 7
V Ford SREA (Supplier Request for Engineering Approval) 2007 revision Document Control Systems, Procedures, Forms and Templates 2
C New Ford CQI 15 Rollout Requirement and reference to ESBC24-5005-AB IATF 16949 - Automotive Quality Systems Standard 3
D What is a Ford Single Scale? Customer and Company Specific Requirements 2
J Ford changing their acronym for Significant Characteristics from HIC to CTQ Customer and Company Specific Requirements 2
K How to fill out an SREA (Supplier Request for Engineering Approval) form at Ford? APQP and PPAP 3
G Ford - Type 1 Gage Study MSA (Measurement Systems Analysis) acceptable? Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 7
xfngrs What does the Ford Europe acronym ISRD stand for? APQP and PPAP 6

Similar threads

Top Bottom