Mach-E High Voltage Connector PALOOZA!!!

[@KnowArt]

oh my, this channel is getting better and better. More brutal, more honest, more comparisons. Love it!

[@MunroLive]

Glad you enjoy it!

[@nisheethrastogi]

@@MunroLive absolutely. It takes confidence and skill.

[@no_more_free_nicks]

But Munro is still invited by Ford, so I guess they appreciate it too.

[@patr5902]

@MunroLive You should consider getting an ID6 from China. Do it after the MachE but before the S Plaid. Would be interesting to see the latest updates on the MEB as it is stretched for LWB (ID6, ID8 & Buzz). Show more comparisons with MachE. Then hit us with the Plaid!

[@HillslamsMirror]

I'm not seeing more comparisons. I'm seeing one competitor of Tesla getting torn a new one as visibly as possible. It happens to be the one competitor that is selling high numbers and putting out a quality overall product. ESPECIALLY for a first EV. The first Teslas? Burned to the ground.... Makes you wonder who pays for these.

[@max654000]

To be perfectly honest, we are actually here for the rant. Who doesn’t love seeing Sandy tear them a new one. LMAO

[@no_more_free_nicks]

Rant too, but I'm curious about the engineering too.

[@daniele8257]

Well, for starters i'd say Ford

[@mjcamp01]

I'm here to learn, the rant is just the icing on the knowledge cake

[@georgechoquette5735]

I'd like to see a Japanese car comparison. Unfortunately there are not many pure EV's from Japan.

[@snowmobile74]

Hell yes. Because he's right! Ford has some real innovation when it comes to some things (Ecoboost) but they really miss on a TON of the small stuff. You could have saved the company hundreds of millions of you doubled the number of head bolts on the 6.0 power stroke. They could have saved tens of millions by adding 2 more threads to the early triton engines. Their engineers have been shaving pennies at the expense of dollars.

[@jkimo11]

“I almost swore but I didn’t”. - hilarious …. Luv this guy.

[@stevehockey4]

Haha the next word was definitely Bull$#!*

[@AirmanJH]

Thanks for being first to post everyone's comment. LOL

[@jkimo11]

@@stevehockey4 What I love is that there is no pretense. It’s genuine - what you see is the real Sandy.

[@lapaleves]

the light brown one!

[@gwtill]

The color of the largest connector is the best orange!

[@-JustHuman-]

True.

[@kumarsuraj9450]

yup

[@xcvsdxvsx]

Agree

[@rhamph]

The deep, vibrant orange. Not the ones that look faded. Agreed.

[@Adrian_Stone]

Exactly, an Orange that’s loud & proud of its Voltage.

[@rick67hou]

Munro: Ok kids. Our topic of the day is screws. Engineers in charge of fasteners: we're screwed.

[@PiotrMys]

Seriously, this is so enjoyable - its the same principles as in coding, best code is no code, if you need 2 different routines to do a very similar thing, then you need to rethink the design. I look at this and I am thinking... what THE ACTUAL F....

[@MunroLive]

Glad you enjoyed it!

[@Gaijin101]

Refactoring in Ford seems nonexistent

[@pjb3633]

Preach it, Brother Sandy! As the good Dr. D. said, "Drive out fear!"

[@Jimmy_Jones]

No such thing as repeating a method to perform the same function.

[@mdubz101]

Maverick will prob have same issues then.. :( 2.0 turbo non hybrid ftw 🙌

[@thedmiranda10]

20:12 Cory's post-rant smirk is priceless

[@2nd3rd1st]

In an interview with Cory Sandy one time talked about how he did not like Cory at first but then became impressed with his work, so they both clearly have storied history and an appreciation for each others personalities

[@peterpet77rp]

Finally somebody with clout is speaking up. I'm a body technician and this is a frustrating problem I have working on Fords. To take off a single part why so many different fasteners? It's not rocket science, sometimes I wonder if they are trying to irritate technicians. Thanks very much Sandy and company. Your contributions on this channel will not only make manufacturing better but also will make the technicians life less stressful

[@AnalogueKid2112]

It’s not that they’re trying to make your life difficult, it’s the fact that so much of what you work on was made by suppliers. If the suppliers are tooled up for certain fasteners, they’re going to keep using it. At the end of the day, the suppliers can offer a lower price using their own design rather than Ford’s particular design, including whatever fasteners Bosch/Denso/ZF/Faurecia/etc. have on hand

[@RyanDiederich]

recently did a water pump on 2002 f150, thankfully all 9!!!! fastners had the same size head, however there were 3 different lengths!!!

[@Mellowyellow8888]

@@AnalogueKid2112 but you do realize when you are a large OEM you can dictate the terms to the suppliers and force them to change.. Doesn't matter what industry you are in.. but the big kid on the block always dictate the terms to their suppliers...

[@AnalogueKid2112]

@@Mellowyellow8888 Sure but what value does it provide to Ford? The suppliers probably said we can provide our turnkey module that we’ve already designed or we can redesign it to use identical fasteners which will add 5 months to the design process and $3 per unit. We can see which option Ford chose here. In the long run, Ford is likely to bring a lot of these components in house, which will be a great opportunity to reduce complexity. The Mach E was meant to be an early mover that was good enough for most people. Not an Ultium solution (haha, see what I did there)

[@peterpet77rp]

@@AnalogueKid2112 Suppliers are not the only problem. Removing a bumper for insurance, will have fasteners of different sizes which require several different tools. I will be taking apart a door, which in itself have different fasteners, then suddenly I come upon a bolt that require an 11 mm socket. I've never used an 11 mm socket on anything in my entire 34 years as a body tech. Not that anything is wrong; but why?

[@ericplatzke]

Love a good Sandy rant!

[@MrGonzonator]

Would love to see a Korean car on your show. The new Hyundai and Kia are 2nd gen electric from the ground up, and look real nice outside.. would be awesome to see them inside.

[@635574]

Or a BYD

[@rkan2]

Yeah - I definitely want to see the Ioniq 5! AFAIK it has one of the first 48V systems on a mass production cars - if not the first?

[@martinultimatevw3779]

Korean yes!

[@benjaminheindl1069]

That'd be awesome!!

[@bluetoad2668]

Almost certainly very similar to Tesla, those guys buy Sandy's reports

[@kkal1183]

there is nothing more gratifying than to see someone who's at the top of their craft be so passionate about passing on that knowledge on to make a positive impact.

[@EnerGeezerSquirrel]

"Screws are not your friend." Nine of ten convicts agree.

[@kirkjohnson9353]

Oh, that's a good one Rik. You could be a writer for the upcoming mega movie- The Monroshank Redemption or the sequel We Got Rid of the Screws: The Revenge of Sandy

[@Dave5843-d9m]

There has to be a joke in here about Bolts catching fire.

[@abraxastulammo9940]

@@kirkjohnson9353 Is this a Screwball comedy?

[@suijinnoname6412]

Shouldn't it be 5 out of ten? I'll show myself out now.

[@dr-k1667]

I am so grateful to Sandy for listening to the person who said he should do a KZbin channel. These videos are GOLD! If the videos are this good... what the heck are the reports like and why isn't every who gives a dam not buying them.

[@charles_cody]

Pretty sure that person is Corey here.

[@Pseudoku_RL]

I think it's worth clarifying that Sandy isn't ranting about por design quality. He's ranting about design regression. The facts are in, the study was done, the money was spent, the results are clear. It's embarrassing to ignore all the hard work that was done in the past just to come up with a lazy product now

[@b4804514]

It appears people are just lazy and arrogant

[@WillN2Go1]

Ford paid for what Tesla implemented. I'm a Tesla stockholder with an old old beef against Ford, but com'on Detroit, you won World War Two for cryin' out loud. Get your stuff together!

[@niarkozzy]

This is what you get when you only focused on outsourcing as cheap as possible for decades.

[@franzliszt3195]

Top management at Ford should all be fired. Their bad management is hurting everyone, not just them and their custormers.

[@kkatlvolvo]

@@franzliszt3195 pretty ignorant comment with no facts to back anything you just posted. Their senior leaders are the best in a decade and will continue to improve on future designs. There are always trade offs on any product and for the most part the Mach E has been a well engineered product.

[@ΘάνατοςΧορτοφάγος]

Many different departments doing their own thing it seems.

[@alphaseinor]

Silos, Silos everywhere, but not an email between

[@ronibee]

I had this in the office where I worked. When I moved departments, I found that both were using a small program to make a particular calculation. Both departments had built their own version without checking to see if there was any commonality between the two areas.

[@chrislangstaff]

This is rampant at large corps of all types, lots of middle/upper mgmt types looking to build their own fiefdoms and don't know or care about what their department is doing

[@lsauve]

They are probably different suppliers for many of the components. It looks to me like the Mach-E is a "version zero" product - it just has to work, it doesn't have to look good. Refinement will come later. I don't think reliability will be great for a while with so many hoses and connectors.

[@dr-k1667]

@@chrislangstaff That is exactly what is wrong is most companies and govt and they die... slowly and painfully.

[@danoberste8146]

Show me the orange colors in different lighting conditions. I'm an emergency responder who will be looking for these components in dark, rain, snow, and being illuminated by flood lights and flashing strobes of red, amber and blue. Whichever color is the easiest to distinguish under those conditions. In studio lighting, I like the aesthetic quality of the large connector (#2 from the left) 😁

[@unitrader403]

as emergency responder you should not need to worry about these connections ever actually. All you have to find and cut is the the 12V first responder loop, which will disconnect the High Voltage Battery internally.

[@videcomp]

When I worked for one of the big three in production engineering for wiring harnesses, one of the big issues was the color of the wiring and wiring placards. Plastic and printed colors, especially oranges, change with different artificial and natural lighting. Some oranges went very red in natural light. So we had additional indicators besides color to be sure the worker got it right. I can only imagine the trouble you guys have.

[@w0ttheh3ll]

if you want to distinguish shades of pink/brown (skin), orange, red, etc. in the dark get yourself a flashlight with a "high CRI" LED. for duty light recommendations go to budgetlightforum.com or reddit.com/r/flashlight

[@jamesvandamme7786]

You'd think SAE would have a standard for that. Fluorescent color lights up under LED light, which has a lot of ultraviolet.

[@rodrigobejarano1349]

Just watched this video, and if you compare it with the last one where Sandy was not present, the difference is clear: Sandy is passionate about it and it shows. This channel is the best, not only due to the technical stuff presented, but mainly for the way it is presented and all the real-world (production line) context presented. Great work guys !!

[@marvinjames5141]

You have given this old mechanic a hell of an education. Thank you.

[@soul4saken]

I'm not an engineer, but I find this fascinating.

[@kirkjohnson9353]

Me too. It's a wonderful exercise is analysis, thinking and economy . If you applied all of these principles to a marriage you could be a happy guy.

[@FIGHTTHECABLE]

You find it fastinating

[@Barskor1]

@@FIGHTTHECABLE Thank you for that Punishment FTC :)

[@rogerstarkey5390]

@@FIGHTTHECABLE You locked down that pun!

[@jorgesilva6375]

Greetings from Portugal!! Big fan of your videos, of Mr. Munro and team !! Mr. Munro, please rant as much as you like!! That's one of the reasons I watch you on KZbin. Thank you and good work!! 👍👍

[@Robbie6298]

Looks like Ford built this car using a McMaster Carr catalog.

[@TennisGvy]

They must have been doing some Black Friday deals

[@Robbie6298]

@@TennisGvy The bean counting execs up top must have had a field day. They bought one of each and told the engineers to cobble it all together into a "mustang".

[@grahamstevenson1740]

Exactly. And I think that's largely the problem. It's not been properly production engineered.

[@joeabad5908]

I once worked in a transformer factory and Goldratt's book "The Goal" has changed the way we work.. It's a good read, applying Theory of Constraints principles both at the factory and at home.

[@philipcunio4089]

“If common sense were so common, everybody would have it’ : Mark Twain

[@lonerider5315]

Being aware of common sense doesn’t mean it’s applied.

[@jimave]

Or as I like to say…common sense should be called uncommon sense because not everyone does it.

[@ChunkyMonkaayyy]

Statistically speaking 1/2 the population is stupider than the other half.

[@deeplato5647]

@@ChunkyMonkaayyy That's almost 50% !!!

[@justlisten82]

Norms unnatural, humanity is inhumane, common sense is uncommon so whos really to blame?

[@xiaowang3715]

Thank you for sharing. I’m working as the product manager for these connectors.Your video and opinions are very suggestive to improve our products. Looking forward your updates.😄

[@stevepailet8258]

during the 1970s I was in business school. Deming was my hero. Always amazed me that he had to go to Japan to do his magic. Ford and GM still have not figured it out 50 years later

[@videcomp]

I was with GM 30 years ago and they were adopting Demings across the board, but it was a big ship to turn. At least in my plant we became more like a Japanese plant than a typical American one of the time. Quality went way up and scrape way down. We shrunk our parts and materials inventory from 30+ days to less than 3. I think what we are witnessing to some extent in these tear downs is regression.

[@mgeorge003]

Sandy, it is the scourge of COTS (Common Off the Shelf Parts) causing this situation. Instead of designers doing design, they are more of system integrators purchasing modules and COTS devices from Tier1 and Tier2 suppliers. The specifications for the parts most likely don't include fastener types and focus on operating envelopes, MTBF (for recalls), and weight. And of course I could be wrong about this, however from your videos I see more true design from Tesla than simply integrating COTS parts and modules. The bigger question is 'Does anyone at Ford care?' Thanks for the video!

[@StefanSobkowiak]

Yes. Our goal is to have one screw type on the farm, just varying lengths.

[@mwjoe66]

Sandy's rant was great, grounded in real life examples, and common sense. It helped me learn more about manufacturing.

[@ManKetnas]

damn I like the way Sandy talks, its so understandable for me as a non-native speaker !!

[@1Jbeats]

I didn't even build the damn thing and I feel like Sandy just blew me up. Love seeing his passion and experience come through like this.

[@m3Tesla]

Love your rants Sandy! Don't ever stop

[@Caedin8]

If they re-ran that study on screws in 2020 they'd find 95% of mechanical failures are due to broken plastic interconnects. The industry has replaced screws with plastic interconnects, but because the plastic parts weren't in cars in the 70s like they are now, they didn't show up in the original study. All of my non-standard maintenance automotive issues in my life have been due to plastic clips breaking off, which Sandy is such a fan of. I've never seen a screw or bolt break.

[@scott8919]

I vote second from the left (large). If you're going to go orange, go loud.

[@andyh183]

Every person considering buying a Mach-E really should watch this teardown series. Excellent content.

[@dewiz9596]

Love the rants! Especially because they are so full of common sense!

[@brendan1516]

This reminds me of working on my first car ('88 Mustang). Lots of different sizes, lots of different connectors, basically a new tool for every section of the car. 23 years later, NOTHING HAS CHANGED. lol. Glad I drive a Telsa.

[@scottthomson7953]

Sandy throws alot of rocks, but each one is wrapped in paper describing the problem, a possible solution, and research to back it up.

[@otm646]

As an outsider I could see how you think that. As someone who's dealing with state of the art current automotive fastener development there are some major holes in his understanding. You can tell he's speaking from personal experience that's 20 years dated at times.

[@Barskor1]

@@otm646 To be fastener factious and not really serious Screw you. Now on a serious note explain Sandy's alleged misunderstandings because just saying it is meaningless.

[@otm646]

@@Barskor1 page through the previous videos usually I will leave a comment or two. On this video specifically I believe they have misidentified a torx plus, and they are clearly using the wrong socket for removal based on the counter taper. The torx plus standard was developed by Ford, it has been copied throughout the industry both by Tesla, Nissan and a few others. Low profile Torx plus is something that Tesla is very fond of. I'm not knocking him that hard, you can tell at one point he knew what he was doing. For general advice it's pretty solid. But he's not at a level that you would find in specialized IFI or internal fastener training geared to the design engineer or fastener production guys.

[@Barskor1]

@@otm646 Ah a specialist Obscura so they used the wrong fork at dinner boo hoo.

[@rogerstarkey5390]

@@otm646 "Clearly using the wrong socket for removal...." ? Doesn't that illustrate the problem? 2 screw types, on plain, one shouldered, with the same head type, applied to this whole unit, would seem possible? Single driver/ socket, reduced inventory for the fasteners? (Maybe not 2 types, but my point is that a little thought, maybe some conversation at the design stage could make things much easier)

[@danchatka8613]

Deming and TQM/CQI: America's only hope. Thank you Sandy for keeping this knowledge alive. At some point, people will start listening and benefiting.

[@cartender7501]

I know how this happens. I've been in so many meetings designing this stuff and there's aaaaaalways a reason. I proposed eliminating a component and our internal evaluation said no cost save, so it died. Just like Sandy says, you're not looking at the big picture - less processing, less storage, less incoming receiving, less supplier auditing, less drawings. But yet, there's always a reason....

[@Chainyanker007]

And that reason is lack of common sense.

[@Dave-in-France]

Great great video from a man whose opinion is based on experience. A lifetime in manufacturing and a common sense approach to problem solving. You called it a rant - I call it passion ! Loved it !

[@rasmusvendelboe]

As for someone working in engineering and quality assurance this is so spot on. Thank you!!

[@robertwinterstein6690]

Hello, I just wanted to say thank you! I show your videos to my intro automotive students and it gives them a heads up as to the inner workings of electric vehicles and what is on the horizon for the automotive industry. Thanks again for all of your hard work, this has to be the best channel to learn about EV's!

[@teslaowner9020]

“If you want poor quality add more screws” so Ford adds more

[@JohnPMiller]

At least they're all threaded in the same direction. Oops! I hope I didn't give Ford an idea for their next generation of threaded fasteners.

[@UnipornFrumm]

The dealers will be happy to make money from labour when the cars need repairs

[@no_more_free_nicks]

@@UnipornFrumm That is exactly what I thought about, you make a perfect car, you go broke.

[@antoinepageau8336]

@@JohnPMiller OMG too funny!

[@mitchellbarnow1709]

Does every Ford franchised dealer that is EV trained have to buy all of these specialized tools in order to take these things apart or will they just replace the entire component? I think that I know the answer, replace the entire component, which is how Tesla does it!

[@paulcummings55]

Never thought I would enjoy a talk about screws;-) And yet, how extraordinary that any modern company would have so much trouble with something this simple in their manufacturing design! Much less everything else... Thanks for the talk, guys!

[@patrickradcliffe3837]

8:50 My experiences tell me the reason for the high fastener count is environmental protection. Plastic covers unless well fastened make horrible seals over time. Plastic deformation will occur were the stress is highest which are fastener locations especially when have a through connecter applying torque perpendicular to the fastener from the weight of cabling on the exterior. My guess is Ford is subcontracting out the production of the larger electrical components and each subcontractor is using their perfered fastener unlike Tesla that does pretty much in house.

[@akinpriestley3901]

Wow!! Wow!!! Wow!!!! That was a MASTER CLASS. Thank you for the historical perspective and the call to excellence in the EV sector.

[@b4804514]

What I love about this is that Sandy cares about this stuff. The fact that Ford was told at least 20 years ago and has ignored its own studies would make me swear as well. Keep up the good work. Put it to these guys that make dumb decisions and cost the companies money.

[@waynelevett3632]

Hi Sandy, I have fixed cross threaded aluminum with Devcon A. Oil the bolt and screw it in till it's hard, then remove bolt and dress surface. That's been a big part of my mechanical life with restoring old cars, especially jaguars and Rolls-Royce I specialised in for 30 years. Rolls is all aluminum from sump to block to rocker covers. Including T400 trans and an aluminum differential casing. Yes I've done my time with poor threads and crossed or rusty bolt in aluminum.

[@gasser5001]

I used to be a Ford parts guy... I can confirm our connector assortment was over......... at least 80. And that's a very VERY bearish estimate. It was probably closer to 200. Not, even, lying.

[@kirkjohnson9353]

Imagine if they hired a guy to co ordinate all the fasteners in the vehicle with the goal of having the least number of fasteners and the least number of types - accross all platforms. It's not even rocket science.

[@gasser5001]

@@kirkjohnson9353 it’s also how they don’t make money, lmao. Seriously… 40-60 bucks for the plastic lever that folds a mustang seat forward….

[@kirkjohnson9353]

@@gasser5001 It must have been a nightmare at times to find things.

[@vitavacek3483]

Our customers have a wide variety of colors on the outside and also inside, we are especially proud of the battery pack connector options :)

[@gregfredericks5201]

Hands down one of the best videos about how things should be done. Great job guys. Lets bring back those things that make sense. Too many fasteners = too many problems.

[@MunroLive]

Glad you enjoyed it!

[@ggosbenton]

I am not in automotive or even an engineer.. but I deeply appreciate the quality of this and the lessons Sandy et.al are dishing out.... shocking to me that you are doing this for free! Makes me assume that the stuff people pay you for must be amazing!! Thanks!

[@RayNLA]

This is clearly a case of “we don’t have time to design, so we will Frankenstein”

[@grahamstevenson1740]

Yup. Clearly time ran out for niceties.

[@mechpatt]

To have such passion about screws, tools, and problems, you have definitely been in the trenches and fighting hard. Seems like a funny thing to get worked up about - but this is the face of mechanical engineering! Kudos.

[@shazam6274]

Ford did a magnificent job in reducing the number and type variants of fasteners.... compared to hoses!

[@Chainyanker007]

Before anyone considers getting a Mach-e watch this: kzbin.info/www/bejne/o2LOeaaaaLSWrsU kzbin.info/www/bejne/iKGVnKeAa5ZqasU

[@ferfromla]

I too am a fan of Dr. Deming! I love the "less is more" philosophy and Dr. Deming was always looking to eliminate the number of steps in every process. Hopefully, Ford and the other US manufacturers are tuning in and listening. I also like Sandy's comparative approach. He demonstrates and explains why Tesla's approach to design and assembly are better than the competition. This way of looking at things is healthy as it subscribes to what Dr. Deming always exhorted -- continual improvement. In fact, I think that is also a good life philosophy.

[@gregculverwell]

I thought that the silo mentality was long dead, but it seems it is alive & well @ Ford.

[@bdtang]

Love the honesty and passion that Sandy, Cory and Ben delivers. No sugar coating the bad and giving credit where credit is due. Keep up the great work.

[@mtumasz]

Essential lecture at Munro University of Technology ❤️

[@rpkamins]

You are so inspirational to the aspiring engineer! Thank you so much for doing what you're doing.

[@Clark-Mills]

Sandy Munro has surpassed the idols he worships, and with a much larger and appreciative audience. Thank you so much Cory & Co., you are making a difference.

[@ErkkiKildvee]

I am very thankful for the videos that have been posted on this channel lately. Thank you from the bottom of my heart. I have learned a lot, how to present and give an overview on complicated systems that, in essence, are not so complex if you know how to make them digestible. One spoonful at the time ;)

[@KBeKind]

2nd orange from the left is my favorite (biggest connector)

[@jpcabala]

MY MAN! My Ops Management instructor was so thrilled when I told her I had read multiple Deming books, including Out Of The Crisis. (She was not so thrilled when I opted to go into Transportation instead of manufacturing)

[@jooptablet1727]

Ford engineer: hey boss, which fastener do you want us to use? Ford team manager: yes

[@alanmcintyre9296]

As an older person who has seen first-hand the mechanics of "how big companies do things and are highly resistant to actual improvement," I whole-heartedly approve of Sandy's rants. :)

[@kuldeuec]

As they say, “Orange is the new Black”, “50 shades of Orange”

[@Stefan_Dahn]

And SOME guys get exited from that. 😉

[@FIGHTTHECABLE]

Whip those cables around me

[@522549]

This makes me happt

[@qqnqqpart]

Hey man, just asking cuz you seem to fit the description, you the fella who gave Munro 27k? Edit: Checked out the Facebook link in your About section, never mind my question!

[@rhbob]

Sandy, thank you for your passion!

[@strykerace]

really good episode.

[@MunroLive]

Thanks

[@cascade5682]

19:40 "I almost swore" - lol

[@522549]

This has got to be my favourite video after the octovalve. It just blows my mind that Ford can proudly put out engineering like this.

[@Chainyanker007]

Watch this one on the Mach-e thermal system: kzbin.info/www/bejne/o2LOeaaaaLSWrsU kzbin.info/www/bejne/iKGVnKeAa5ZqasU

[@edvaldoneto1414]

Learning a lot with you guys! Great content!

[@danapeck5382]

"Out of the Crisis", best how-to book ever. I got to see Prof. Deming start a day-long presentation to a roomful of high-level execs, circa 1972, with the statement, "You are the problem." Bet none of them had heard anything that directly critical in years. Room temp dropped noticeably.

[@nelsonmacy1010]

You forgot to mention Innovators Dilemma book which was on the table too.

[@kirkjohnson9353]

I like that Sandy is working out a book club now too.

[@toddsholtis4470]

Excellent analysis, as a past owner of an injection/insert molder plant, we used to insert mold the crush proof collars into the thermoplastic (sometimes with automation if the volume was high). Also, someone is not doing there diligence when coming to matching colors/shades of connectors at the various suppliers of FORD (must use sample chips and hopefully the injection molder owns a spectrophotometer), they should not vary from Reddish-Orange to a light Orange, ridiculous! Lastly, I totally agree 100% that there are way too many different types, number fasteners required and sizes of fasteners used to hold the connector onto the Aluminum components - what a nightmare...

[@RobertWHurst]

I found myself instinctively screaming "why?" at the screen while watching this. This is a strange type of institutional self inflicted sadism

[@stephenward4313]

Understand your concerns. Good rant. When I was working, we were having environmental issues with equipment getting hot or not surviving lightening testing, etc. (was not my area - mine was systems safety/SW integrity [I know - SW integrity - oxymoron but we try]), We brought back in a retired environmental engineer (45-50 yrs service) to help. He told me that he was seeing problems that he solved 20+ years ago. He held sessions with the younger engineers to just discuss how to do it right. My boss (again 40+ yrs in systems) wanted to have people who were retiring write down what they learned over the years. Company would not by into doing that so we might be subject to repeating ourselves.

[@davendrasukha320]

The "Input of high voltage DC supercharging" is my favorite orange so far

[@TheJoeSwanon]

I was going to go with the Coast Guard orange

[@Firestorm637]

Love your unbiased videos. So many cars with each vehicle that has its own specific stuff. Commonality would save the customer and manufacturers as well as improve reliability and complexity. Less complex means less mistakes. Good Points.

[@ccengineer5902]

Looks like Ford outsourced every component. It would explain all the different fasteners.

[@NTNLabs]

Is the product still a Ford? Parts are OEMs and engineering is against the Ford engineering books. Exterior design is Ford I guess. Is it still Ford? Or just "assembled by Ford"...

[@jamesvandamme7786]

@@NTNLabs Henry bought iron ore and sold cars.

[@NTNLabs]

@@jamesvandamme7786 Yep, that's hardcore carmaking. You put iron in one part of the factory and a car comes from the other side...

[@jamesvandamme7786]

@@NTNLabs Nowadays he'd have to buy sand, too. Maybe after this chip shortage they'll consider it. But silicon foundries aren't cheap. SiC is worse.

[@rickfearn3663]

Exceptional analysis. The rants here are applicable to all machinery design, including the machines that make the machines.

[@julianriise5618]

Munro should collaborate with Engineering Schools, I'm not a student but the content is quality

[@h3ku1994]

I think what he's doing in yt earn much more than col

[@kg4lod]

Everything he's saying is already taught in engineering schools... it's not like "use less parts" is a genius idea. Munro's contribution is the tear-down and reveal of how far from first principles modern OEM's have strayed.

[@AnalogueKid2112]

The reason you’re seeing so many different fasteners is because each of those parts were made by different suppliers. So Bosch or whoever is providing a complete PTC heater to the factory in Cuautitlan and all they do at the assembly plant is click stuff together. At the end of the day, the suppliers can offer Ford a lower price by using their existing tooling rather than Ford’s standardized specifications. In the long run, it might make sense for Ford to bring a lot of this stuff in house, but the Mach E was meant to get onto the market as fast as possible which it absolutely did.

[@geoffreyoltmans4356]

There's also not necessarily a reason to condemn all the different fasteners. A lot of these fasteners are not intended to ever be turned by people in final assembly.

[@DereckWonnacott]

I'd like to know what Sandy thinks about lock washers & nordloc washers... Heck a whole video on types lock washers would be neat.

[@chrisheath2637]

Lets geek out on non-locking lock-washers ! Its a thing of mine, too.

[@murphers1095]

This was one of the best videos yet! Fascinating...I truly hope that Ford and all the other OEM's are watching these videos! More like this please!!!

[@sailingsolar2371]

Sandy's message is "Screws will Screw you."

[@aitorbleda8267]

But they allow repair. Plastic fasteners do not last through thermal cycles.

[@petemiller519]

Speaking about using same bolt sizes......I remember when I was a 7 year old boy, the Russians invaded the Czech Republic in 1968. The tanks would have all bolt sizes either one of two bolt sizes with square heads. There would be two wrenches attached to the turret, and with those two wrenches you could take apart pretty well the whole tank. Simplicity to the core. I remember thinking that's pretty smart. Ironically I became an engineer. Cheers from Canada.

[@Stefan_Dahn]

"Connector Palooza"© by Sandy Munro will be THE hot stuff in Las Vegas dice tables in upcoming years! 🤣

[@josephfolender4101]

Hi Sandy. Don't blame you for getting angry at shear stupidity when manufacturers should know better. I also want to mention that I in grad school I was fortunate to have Dr. Deming when I was going for my masters degree. During the semester the would go to Tokyo and give out the Deming prize in quality control. It was a brutal competition. He would show us 8mm films of his visit. I could not distinguish him from the Pope when he visited Japan.

[@davidneuzil9356]

Geeze, Sandy sounds like he is pretty darn frustrated with OEM's continuing disregard for improvement. Hopefully they will listen to him. Heads should roll at OEM's

[@mgmacius]

Thank you Sandy, we are using tons of different “threaded fasteners” at work and we also put flats and springs on everything. Or the locknuts. Well, I kinda believed that this makes sense, after all it was designed by big ass engineering department. Turns out my gut feeling was right - spring washer makes no sense. I was thinking about it for a long time and I couldn’t figure out how the bloody thing is supposed to work, as it’s squished flat by the nut on one side and the silly for washer on the other. Now I hear from the Master himself, that these things are not worth a damn. Wow. Thank you!

[@Heckofadeal]

Great show as always!

[@jimgerrish7077]

Somehow this reminded me of the summer in college I spent, helping a friend rebuild the engine in his 1959 Austin-Healey "bugeye' Sprite. After considerable swearing, we decided that no two bolts in the engine were the same size. I had a mental image of a 'typical' British auto manufacturer of that day: A drafty old garage, where the mechanics assembling the cars would grab an old coffee can full of assorted bolts, nuts and washers and grab whatever same to hand to finish building their masterpiece. If it ran, they'd drive it off to the dealership and sell it.

[@zezizarjaars]

I don't really care about what color of orange is my favorit, as long as it ain't close near red, because that might give some confusion when it comes to electric DC stuff.

[@kirkjohnson9353]

Good point

[@GilmerJohn]

I don't know how much it would cost but adding "stripes" of other primary colors might be useful.

[@techenthusiast4542]

Coral Orange followed by Mahogany Orange followed by Rusty Orange are the best natural orange colors to my eyes. We love your rants Sandy! Otherwise, everyone would be bored with just technical details. LOL!

[@mebran1193]

Never been so excited by screws

[@OnigoroshiZero]

I really love such in-depth videos. It's crazy how many small details can greatly impact the quality or price of the final product.

[@LuisAlfonsoGarciaSegundo]

Are most of those components with connector coming from suppliers that already integrated the connectors to the parts? Or are those connector put in place at assembly?

[@chrisballard9446]

Bingo. Dictating the same screw to suppliers increases the supplier parts count and tooling costs. Sandy even gives the tesla supplier part a pass for being from a supplier.

[@SimonClaringbold]

Great chat Sandy and Cory - so from Sandy's summary we can say it's a win to the Dinks! +1 for the darkest orange color

[@dptubexx]

And another thing… Awesome rant, Sandy!

[@23billd]

Hey Sandy, I thoroughly enjoyed your rant. In the mid-80s I was the Manufacturing Engineering Manager at Hewlett-Packard and I used to give about the same speech. Quality is assured by elegant design. I see that at Tesla, not Ford.