Project #08

This project has been a complex study to reach the knee protection requirement for the USA market with existing IP and without the implementation of a knee bag. A special attention was required to minimize the affect on the carryover parts.

Product description:

This project has been a complex study to reach the knee protection requirement for the USA market with existing IP and without the implementation of a knee bag. A special attention was required to minimize the affect on the carryover parts.

Objective:

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

  • Cross car bim
  • IP
  • IP shell
  • IP structure
  • IP glow box
  • IP lid
  • IP shroud interface
  • IP packaging

Key activities:

  • Project management
  • Homologation verifications
  • Benchmark
  • Stile surfacing
  • Detail design
  • Style verification for manufacturability
  • Packaging 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
  • Physical test activity monitoring

Inputs:

  • Existing IP
  • Program macro Time plan
  • Manufacturing Process constrains
  • Knee protection parameter targets

Output:

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

KPI’s:

  • Crash energy control
  • Knee displacement target
  • Investment cost target
  • Process duration – October 2009 – April 2010

MGRD added value and achievement:

  • Knee protection target achievement
  • Mold insert proposal to IP component supplier in order to create two part version: base and knee protection
  • Shape and welding process suggestion for glows box lid parts base on MGRD experience and Benchmark able to properly absorb crash energy.


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