Ford opened order books for the new 2023 F-Series Super Duty trucks last October, piling up 150,000 pre-orders in five weeks. Ford is committed to getting this launch right so that it doesn’t hand back Super Duty profits for warranty costs and recalls.
The company implemented Zero Defect processes at the Louisville Assembly Plant and Ohio Assembly Plant that build the truck. The entirety of the Zero Defect enhancements are said to take three hours per vehicle. A contingent of 350 quality inspectors check every truck off the line, including driving every unit 25 miles to look for potential issues that escaped scrutiny.