Case Study: Ford Motor Company achieves predictable build quality and reduces assembly variation with SolidWorks

Ford Motor Company - Customer Case Study

Ford Motor Company faced costly quality and assembly issues caused by uncontrolled dimensional variation, where nominal CAD models didn’t reflect real-world manufacturing variance. To address this, Ford used SolidWorks 3D CAD software integrated with Varatech’s SigmundWorks and Sigmund ABA to bring tolerance and assembly-build analysis into the design stage and prevent problems before tooling release.

SolidWorks’ integration with Sigmund allowed Ford to run thousands (typically ≥5,000) of virtual builds and perform Worst Case, Modified RSS and Monte Carlo studies to pinpoint sensitivity and failure drivers. Outcomes included correcting a 5% projected assembly failure by increasing screw-hole diameter from 3.0 mm to 3.8 mm to achieve 100% projected build, hardening a CD mechanism against warped discs, eliminating radio-knob wobble by closing a clearance, and instituting supplier simulation requirements—avoiding scrap, rework, warranty costs and launch delays.

Ford Motor Company

Glenn Reed

Mechanical Technical Expert