Ford employs specially trained engine listeners in new Focus RS development

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In the development of the all-new Ford RS, Ford found that for certain tests, nothing beats a set of human ears to help refine the engine’s sound. Highly trained production workers conducted an auditory test to confirm the perfect running of the 350PS 2.3-liter EcoBoost engine, in advance of it being fitted to the completed Ford Focus RS cars.

“This team knows what a perfectly calibrated engine sounds like and they know the tiny sounds to listen for in case there is a problem,” said Gunnar Herrmann, VP quality, Ford of Europe. “Think of it like a doctor who has the most advanced diagnostic technology, but still uses a stethoscope to gather vital clues to a patient’s health.”

Employees at Ford’s manufacturing facility in Valencia, Spain, are taught to identify defects using specially prepared faulty engines that highlight the sound that they need to listen for. After several months of training and coaching, team members are qualified to conduct the intensive one‑minute tests in one of 18 sound-proofed cells at the end of the production line.

Should the engineers hear any rattling or whistling sounds typically associated with issues, such as a blocked lubrication passage or a damaged gear tooth, the engine is removed so that further checks can be carried out, and the problem addressed. In this way the quality of the manufacturing process also can be continuously improved.

Further vehicles that benefit from the scrutiny of the engine listeners in Valencia include the Ford Focus ST, S-Max and Mondeo.

“The experience of hearing thousands of engines allows us to sense straight away when something is not working perfectly,” said Juan Carlos Rosmari, quality technician, Valencia engine plant. “Each different engine type has its own unique sound, and from listening to them in the test cells we get to know their individual characters – and the tell-tale signs that indicate a problem.”

Between them, Ford’s team of engine listeners carries out the test on 2,000 engines per day at the Valencia plant. Preparing engines for testing provides a natural break between the listening sessions, so that the employees can maintain full concentration on the tests over a working day.

April 6, 2016

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John joined UKi Media & Events in 2012 and has worked across a range of B2B titles within the company's automotive, marine and entertainment divisions. Currently editor of Automotive Testing Technology International, Crash Test Technology International and Electric & Hybrid Marine Technology International, John co-ordinates the day-the-day operations of each magazine, from commissioning and writing to editing and signing-off, as well managing web content. Aside from the magazines, John also serves as co-chairman of the annual Electric & Hybrid Marine Awards and can be found sniffing out stories throughout the halls of several of UKI's industry-leading expo events.

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