Highly trained production workers conduct an auditory test that confirms the perfect running of the 350PS 2.3-litre EcoBoost engine, in advance of it being fitted to the car. This engine has been specially engineered to ensure the Focus RS can cover 0 to 62mph in 4.7s and achieve a top speed of 165mph.
“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, vice president, 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.
Between them, Ford’s team of engine listeners carries out the test on 2000 engines per day at the Valencia plant.
“The experience of hearing thousands of engines allows us to sense straight away when something is not working perfectly,” explained 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 which indicate a problem.”
Further vehicles that benefit from the scrutiny of the engine listeners in Valencia include the Focus ST, S-MAX and Mondeo.