Project #09

This project is a passenger vehicle derived from light commercial vehicle cab. Two versions requested: standard with side swing door and High level with side sliding doors. The IP target product level was much higher than competitor and close to and European A class vehicle.

Product description:

This project is a passenger vehicle derived from light commercial vehicle cab. Two versions requested: standard with side swing door and High level with side sliding doors. The IP target product level was much higher than competitor and close to and European A class vehicle.

Objective:

Product development from Style support, Class A surfacing and up to detail design and 3d annotation for:

  • Rear bumper
  • Tail gate
  • Tail gate (canvas version)
  • BIW
  • Under-body
  • Sliding door
  • Side door (swinging version of sliding door)
  • Side door (canvas version)
  • Rear quarter trim lower
  • Rear quarter trim Upper
  • Head liner
  • Pillar trim
  • Tail gate trim
  • Carpet
  • Tool box
  • Glasses
  • Sealing
  • Tail lamps
  • Fuel lid
  • Seating trims
  • Seating integration

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
  • A class Surface (body exterior, interior trim including IP)
  • Homologation verifications (for light vehicle in the target market)
  • Style verification for manufacturability
  • Packaging protection
  • Ergonomic protection
  • Typical section
  • Welding feasibility and Assembly sequence proposal in agreement with assembly team direction
  • Tolerances calculation
  • Supplier and OEM interaction for part manufacturability and performances
  • Supplier management for sliding door system
  • Kinematic verification
  • CAE verification

Inputs:

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

Output:

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

KPI’s:

  • Process duration
  • Phase 1 BIW – March 2008 – January 2009
  • Phase 2 IP – January 2009 – November 2009

MGRD added value and achievement:

  • First sliding door in customer production
  • Complete commonality between side sliding door and side swing door interfaces
  • Reduces parts on IP compared to parent vehicle
  • Reduced manual fixing operation on IP
  • Food tray solution on IP (solution patented by the customer)


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