Navigating program objectives through body systems integration

Before DfX methodology gave voice to all equity holders body systems integration could be quite a contentious matter, In the Ford world the BIW and stamping team generally held the biggest hammer in how the vehicle was configured / constructed. But in the late 80s, as the focus was put on product quality and reducing electrical warranty claims the VN58 team (base of the last Econoline) was charged with routing the electrical distribution in a new way. Prior versions of the Econoline would go through the body structure and onto the frame rails to get the circuits to the rear of the vehicle.

Benchmarking had been done to demonstrate the benefits of protecting those circuits by keeping them inside the body shell and I was the designer who did the routing. If you are familiar with the Ford designations the 14401 Main Body harness ran through the Instrument Panel, picked up the ECC on the passenger side and had a big round bulk head connector on the drivers side to connect to the engine harness. It was big and heavy and hard to handle when it went down the left cowl panel and into the step well the packaging did not readily accommodate the 2.5 inch diameter "angry snake". Even though the harness was no more than 70 mm max, it did not want to lay flat it was difficult to shape and fit it to curves without heating up the harness

The old school was way to finish the BIW and then call the electrical distribution (harness) team to layout the routing and the fixing (attaching) strategy. SO when I said I needed a 100mm X 150mm trough the Body Structures engineer (God love em') Jerry Buffelieni said we haven't grown the Christmas tree and this guy wants to string lights on it. So, without the enthusiastic support we may have wanted from the BIW team to reach the program goals of a better harness routing, it fell upon me to lay down the lines which described an all new step well construction with a big fat wide trough in it for my hard to manage harness. Jerry blessed it and the rest was history. Some times the best way to get help from someone is to be very specific and do everything in your power to help them see what you need! The over riding goals of the program team are too important not to step up and take the lead!

DfX is the best tool to help program teams rally around the direction of your leadership team. It gives voice to every equity holder and assures that cooperative collaboration will empower the team to succeed! Ask me more about DfX can help your products and culture...

BTW, the Econoline story still continues the E450 cut away is still being built. Total E-series volume since Pioneer Engineering became a service partner with Ford over 3.5 million units. A great design has longevity and it is REPEATABLE in VOLUME!