Project #04

This project has been the engineering of a SUV with sort rear overhang derived from rear long overhang vehicle. The BIW solution and tailgate concept have completed redefined to improve the door sag performance respect to the existing product. Moreover the interior and exterior rear trim had, as a target, the integration of many utility features for the final customer.

Product description:

This project has been the engineering of a SUV with sort rear overhang derived from rear long overhang vehicle. The BIW solution and tailgate concept have completed redefined to improve the door sag performance respect to the existing product. Moreover the interior and exterior rear trim had, as a target, the integration of many utility features for the final customer.

Objective:

Product development from Style support up to detail design and 3d annotation for:

  • Rear Bumber
  • Rear Bumber brackets
  • Tail gate
  • BIW
  • Under-body
  • Spare wheel bracket on tail gate
  • Spare wheel cover
  • Rear quarter trim lower
  • Rear quarter trim Upper
  • Head liner
  • Pillar trim
  • Carpet
  • Tool box
  • Glasses
  • Sealing
  • Polycarbonate rear quarter glass
  • Tail lamps
  • Parcel shell
  • Ski racks
  • Tail gate
  • Fuel lid
  • Centre console

Key activities:

Product development from Style support up to detail design of Upper and under body, Closures, Interior and Exterior trim.

  • Project management
  • Style feasibility
  • Homologation verifications
  • Stile surfacing up to A class
  • Detail design
  • Style verification for manufacturability
  • Packaging definition
  • Ergonomics definition
  • Typical sections
  • Welding feasibility and Assembly sequence proposal in agreement with assembly team direction
  • Tolerances calculation
  • Supplier and OEM interaction for part manufacturability and performances
  • CAE verification
  • Back-up study to create a unique polycarbonate system for rear quarte glass/rear quarter trim upper/tail lamp
  • Back-up solution for Retractable rear step
  • Jack storing box integrated into the scuff plate

Inputs:

  • CAS surfaces/ sketches
  • Program macro Time plan
  • Underbody and parent vehicle parts
  • Manufacturing Process constrains

Output:

  • CAS surfaces feasibility studies
  • BOM, FMEA
  • 3D data and annotation of parts and assemblies
  • Clash and clearance Analysis (DMU)
  • Modification management

KPI’s:

  • Weight
  • Tail gate sag
  • Target Performance without the application of High strength steel (HSS)
  • Phase 1 BIW – February 2009 – December 2008
  • Phase 2 Trim – February 2009 – March 2010

MGRD added value and achievement:

  • Door sag target achieved. Solution have become for the customer a reference for old product improvement and future product application
  • Rear quarter glass with integration of rear lamp and rear quarter interior panel
  • MGRD Retractable rear step study (solution patented by the customer)
  • MGRD Jack storing box integrated into the scuff plate (solution patented by the customer)
  • MGRD tail gate tightening solution (solution patented by the customer)
  • MGRD third row seat integration on a base interior trim version
  • MGRD solution to use the same spare wheel cover for different alloy and stamped rims.


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