Ford gets its employee's to place incorrect parts into various vehicles to see how easy they are to locate via the new systems in place.

• “Gremlin Tests”  help realise Ford’s commitment to quality, alongside industry-first digital photo tech that records, checks and traces all vehicle parts at mega-plant in Valencia, Spain
• Vision System takes more than one billion photographs every 14 days – comparable to the number of photographs uploaded to Instagram in Europe

Ford employees are tasked with secretly planting wrong and faulty parts onto the assembly line, including incomplete steering wheels and faulty engine components, as part of a process to ensure all new vehicles built at the plant in Valencia meet Ford’s rigorous quality standards.

Xabier Garciandia’s working day involves literally trying to put a spanner into the works of one of the world’s most advanced auto plants – by making sure wrong parts and faulty components are secretly placed on the assembly line.

Ford’s industry-first Vision System photographs, checks and tracks every single part of each of the 400,000 cars and vans assembled, and 330,000 engines built at the Ford Valencia plant each year.  “Gremlin Tests” are an innovative way of ensuring that each process is working correctly.

“The Vision System is crucial to ensuring every single part of each vehicle is just right,” said Garciandia, technical specialist, Valencia Engine Vision System, Ford of Europe. “The ‘Gremlin Test’ means we can ensure the system is working perfectly.  It is a game with a very serious point; we are making them harder to spot all the time.”

Ford produces more Ford models at the state-of-the-art Ford mega-plant in Valencia than anywhere else in Europe, including Kuga, Kuga Vignale, Mondeo, Mondeo Vignale, Galaxy, S-MAX and Transit Connect and Tourneo Connect.  Ford’s 2.0-litre and 2.3-litre Ecoboost engines are also built at the plant.

The Vision System captures more than a billion photos every 14 days, comparable to the number of photos uploaded to Instagram in Europe. * This also helps to generate a composite image – consisting of 3,150 digital photographs – that highlights any discrepancies to engineers on the spot.

Faulty engine parts, wrong steering wheels, and even incorrect dashboards have been sent down the line, with the “Gremlin Test” now extended to all 34 stages of assembly.

“The way in which we all use digital cameras has totally changed the way we record our daily way of life, and is now transforming the way we build engines and cars,” said Garciandia. “But we also have to test the tests, and we are doing this in a way that is very simple, but which we believe is unique in the auto industry.”

Ford has introduced a range of rigorous and in some instances unusual quality processes at the plant where a new vehicle rolls off the production line every 40sec.

These include:

• Ultra-sensitive microphones used to register engine connectors
• “Engine listeners”ensure each new Ford Focus RS is running flawlessly
• Ostrich feathers that are used to dust models before painting to enhance paint quality
• An industry-first digital camera system that identifies vehicle bodyshell paint defects
• Vehicle audio testing that reflects customer use of audio streamed via Bluetooth
• A virtual rolling road test to evaluate advanced driver technologies