Modelling dimensional variability from the beginning of the Ford Windstar minivan project eliminated hundreds of engineering changes that would have affected nearly every component in the vehicle. Estimated cost savings are between $5 000 000 and $10 000 000. The Ford Windstar is believed to be the first vehicle on which dimensional variability modelling was performed from the beginning of the design process. Ford USA's Manager of Vehicle Engineering Attributes, Tom Sweder explains.
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