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Instrument Panel Scrap Reduction Team, Ford Motor Company, Dearborn, MI, USA

This is the story of the transition from petroleum-based foam to environmentally friendly castor oil foam for the 2013 Ford Escape's instrument panel. Suffering from a 30 percent scrap rate, the team-from Ford, Faurecia (instrument panel suppler), and BASF (foam supplier)-used the physics of foam formation and sensitivity-based designed experiments to scientifically determine root cause and develop improvement actions. Actions resulted in a sustained scrap rate of 0.1%.

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