Project #03

This project has been a successful development of a C segment vehicle up to working progress new platform.

The vehicle has been redesigned two times with two complete different stile solutions.

Product description:

This project has been a successful development of a C segment vehicle up to working progress new platform. The vehicle has been redesigned two times with two complete different stile solutions.

Objective:

  • Phase 1 – Style feasibility and 3D detailing for:
    • BIW
    • Side doors
  • Phase 2 – Complete new Style emission and related stile feasibility for:
    • Front bumper
    • Rear bumper
    • Front end
    • Side doors
    • Bonnet
    • Tail gate
    • BIW
    • Fender
    • Sealing
    • Glasses
    • Underbody integration
    • Sun roof integration
    • Lighting system integration
    • Side mirror integration
    • Door handles integration

Key activities:

  • Phase 1 and Phase 2:
    • Micro project management
    • Engineering meeting organized in MGRD’s premises
    • Style feasibility
    • Technical surface proposal to Style tem
    • Style verification for manufacturability
    • Resident liaison engineer in Customer’s premises
    • Typical sections
    • Packaging definition
    • Ergonomics verification
    • Homologation verifications
    • Preliminary Assembly sequence proposal
    • Preliminary locator strategy
    • Preliminary welding feasibility
    • GD&T, Gap & Flush
    • Components integration or preliminary component 3D base on existing part.
    • Supplier interaction for part manufacturability and performances

Inputs:

  • CAS surfaces
  • A-class surfaces
  • Project macro Time plan
  • Body interfaces
  • Carry over target par

Output:

  • CAS surfaces feasibility studies
  • BOM, FMEA
  • 3D data and 2D drawings of parts and assemblies
  • Clash and clearance Analysis (DMU)
  • Modification management
  • Meeting calendar organization

KPI’s:

Process duration

  • Phase 1 – December 2003 – July 2004
  • Phase 2 – May 2005 – July 2005

MGRD added value and achievement:

  • Quick and prompt support to customer requirements gives the style more option to be optimized in less time.
  • Unigraphics solid modelling method, proposed by MGRD, has successfully and quickly respond to huge modification request producing up to date model for the CAE and Cost analysis.
  • Best body side panel ever done (declared by customer tooling department director after the first polyester milling) thanks to peculiar MGRD attention in managing all the sheet metal panels’ edges.


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