Recently, managers and engineers at a major Detroit area automotive company recognized the vital importance of identifying the design and production factors which significantly affect the front end camber angle in vehicles in one of their assembly plants. The goal of identifying these factors was the eventual establishment of a total process control program to maintain the overall quality of the vehicle front end. This paper contains a summary of the numerous on-line and off-line studies undertaken in the assembly plant during a one-year period to gain an understanding of the factors which affect the front end camber angle. It will be shown that commonly used analyses in both on-line and off-line studies can possess limitations which fail to meet the needs of the quality engineer. Understanding the results from these studies is important to understanding the complexity in establishing a quality control program for currently operating assembly processes.