Vehicle Design and Integration

Vehicle Design and Integration — Overview Style Freeze -28 -26 -24 -22 -20

Toyota

-24

-1 -18

-1 - 16 -14 -12

-20

Total Product Planning

-10

-8

-6

-4

-2

0

-12

2

4

6

8

10

Chief Engineer Product Concept Development

Product Design

-16

14 16

18

20

22

24 24

26 26

28

18 Sales Preparation

Product Developm Development ent & Engineering

Packaging/layout

Develop Needs

12 12

0

TrialProduction

Design Revision for Mass Productions

+ 12

Product Design

- 8 Mule mfg and evaluation 0

Hyundai

-22

-12

0

Concept Development

Product Planning

– 17

Design

-6

Develop Draft Design

-5 - 14

- 11 T-car Design

-17

Product Preparation

Prototyping

Develop Design Master Detailed Plan Drawing

+21 Manage Engineering Changes

+1

Pre-evaluation of T-car

-12

Product Strategy and Planning

24

+6

-8

T-car Mfg.

15

0

Package Layout

- 14

TML (As Defined in NPI)

6

-6

Concept Evaluation

0

Concept Development

10

Product Design and Development

16 Design Validation and Productionisation

22

Pre-production

27

Ramp-up

Packaging BIW, Closures, Trim Design Vehicle Integration

Source: Source:

A.T. Kearney Kearney research, research, analysis analysis and and interview interviewss

A.T. Kearney 82/6865 4

Product design needs identification — Toyota definition

Start Time/Finish Time (From SF)

New: Minor: Carry Over:

-20 / +12 -12 / +8 -7 / +4

Inputs for Work Stream

Source of Inputs

• • • •

Product plans • Product Product concept management Key dimensions dept. Available • CE and staff parts/component • Power train • Status of office/Vehicle Advanced Technology component office development

Outputs From Work Stream

• Direction of platform/component/parts design; e.g. vehicle architecture, component families, carryover / modification plan

Source:

Scope of Work /Activities Build consensus on basic architecture and development needs • Define basic architecture/structure per system/components • Finalize carry-over/modification plan • Finalize items to which new technology will be applied Present at CE concept review

Departments Involved

R

20

CE and Staff

R

10

Manufacturing Engineering

S

Need basis

A.T. Kearney research, analysis and interviews

Key Best Practices

• Set based approach • Aggressive reuse of existing parts/components • Ohbeya activity

Facilities and Tools

•

• Suppliers with long term relationship and mutual trust like Denso, Aishin, Araco etc. (the Keiretsu) participate unofficially

• Styling design • CE concept development

FTEs

Product engineers at VDCs

Supplier Integration

Parallel Work Streams in VDP

Role

Key Decisions

• Platform / component / parts carry over strategy • New technology deployment plan

Role//Nature of Involvement

• Provide inputs and hold discussions on latest technologies

Review and Decision Making Forum

• ECE & CE • EVP of Engineering • VDP Centre Head • VP of Vehicle Planning • VP of Production (Some of the above are Toyota Board members)

A.T. Kearney 82/6865 8

Packaging/Layout — Toyota definition




-16/ 0 -9/0 -6/ 0

Source of Inputs

• Direction of • CE and staff platform/compo • Styling design nent/parts design • Styling options • Product plans • Product positioning

Scope of Work /Activities Conduct design • Review key requirements for packaging/layout • Develop rough dimensions and layout based on the category and concept of the vehicle • Develop packaging/layout plan in accordance with styling design options • Finalize packaging/layout Present at design check gate review


R

20

Product/evaluation engineers at VDCs

A

Need basis

CE and Staff

A

Need basis


S

Need basis

Source:


• • • •

Styling design Product design Design in activity by key suppliers Manufacturing process design


Key Best Practices

• Set based approach • Front loading • Simultaneous engineering • Close work with styling design studio


• CATIA V5 • Engineering standards Role//Nature of Involvement



FTEs

Styling design dept

• -

• Frozen detailed dimensions and package layout

Role

• -

Key Decisions

• Detailed dimensions and layout freeze


• ECE & CE • EVP of Engineering • VDP Centre Head • VP of Vehicle Planning • VP of Production (Some of the above are Toyota Board members)

A.T. Kearney 82/6865 11

Product Design — Toyota definition



-12/ 0 -7/0 -4/ 0


Source of Inputs

• Product Design • CE and staff Needs • Styling design • Direction of platform/compo nent/parts design • Available parts/component • Key dimensions • Styling options • Product plans • Product positioning • Target cost Outputs From Work Stream

• Drawings and 3D models of components and parts • Bill of material for prototyping

Source:

Scope of Work /Activities Conduct design • Develop layout plan in accordance with styling design options • Develop drawings/3D models based on R&D standards and packaging/layout plan • Give approval for design-in parts • Develop physical pre-proto subsystems and evaluate for new subsystems by using mules • Develop bill of material Present at design check gate review


R

100

Styling design dept

R

20

CE and Staff

A

Need basis


S

Need basis


Key Best Practices

• • • •

Set based approach Front loading Simultaneous engineering Strong involvement of manufacturing engineering function


• CATIA V5, Pro/Engineer, In-house CAD/CAM/CAE system: existing parts • Engineering standards • Prototype developing plant

• Key design-in suppliers

• Styling design • Design in activity by key suppliers • Manufacturing process design

FTEs




Role

Key Decisions

• Detailed dimensions and layout freeze • Approval of parts drawings and bill of material


• Design and evaluate parts • Request for approval


• ECE & CE • EVP of Engineering • VDP Centre Head • VP of Vehicle Planning • VP of Production (Some of the above are Toyota Board members) A.T. Kearney 82/6865 12

Vehicle Design and Integration — Product design modification for mass production



0/ +12 0/+10 0/ +8


• Drawings and 3D models of components and parts • Bill of material for prototyping • Prototyping and vehicle evaluation results

Source of Inputs


Role

Modify design based on prototyping • Result of pre-production • Result of pre-production vehicle tests Present design check gate review Release product drawing for Pre production and mass production


R

110

Prototyping

A

Need basis

CE and Staff

A

Need basis


S

Need basis

• Drawings release for pre-production and mass production

FTEs


• CE and staff • Prototyping engineers • Product / evaluation engineers at VDCs


Source:

Scope of Work /Activities

Key Best Practices

• Documentation of lessons and learns • Extensive use of digital assembly and virtual testing • Strong involvement of manufacturing engineering function

• CATIA V5, Pro/Engineer, In-house CAD/CAM/CAE system: existing parts • Engineering standards • Prototype developing plant Supplier Integration

• Key design-in suppliers


• Development and evaluation of pre-prototypes • Die design and development • Manufacturing process design • Suppler selection for mass production


Key Decisions

• Detailed dimensions and layout freeze • Approval of parts drawings


• Design and evaluate parts • Request for approval Review and Decision Making Forum

• ECE & CE • EVP of Engineering • VDP Centre Head • VP of Vehicle Planning • VP of Production (Some of the above are Toyota Board members) A.T. Kearney 82/6865 19

Facilities and tools

Facilities and Tools IT Tools

Description

• CAD/CAM/CAE

• CATIA V5 — Used for parts made from sheet metal like body design to develop “surface” model • Pro/Engineer — Used for power train and engine design to develop “solid” model • In-house CAD/CAM/CAE system — Mainly used for modification of existing parts developed by using the in-house system

• Test and Communication

• V-Comm — A space consists of three 200 inches screen and CAE tools (Delmia) in order to observe and evaluate digital mock-ups- visual appearance, interference, various ergonomic situation in manufacturing, etc. — Basically led by manufacturing engineering depts. — 20 locations in Toyota and key suppliers (mainly body makers) • Virtual Real Simulator • VCS (Visual Communication Service) — Communicate result of each digital mock-up evaluation to all related engineers by email enclosed URL address where snap shot of digital mock-up shown with some comment on design problems

Design Standard

• Component/Parts layout standard — A standard defined parts and component layout/anatomy • Engineering check list — A design guideline and checklist, continuously updated by the responsible engineer • Requirements provided by Manufacturing Engineering — Requirements to be obeyed in product design stage, considering manufacturability and constraints of existing production equipments

Prototype Manufacturing Factory (In-house)

• Huge machining line and flexible assembly line to develop pre-prototype vehicle beside Toyota R&D center

Source:


A.T. Kearney 82/6865 22

Vehicle design — Sequential validation process versus functional build

Definitions 

Sequential Build — Process of validating the specs of components, sub-assemblies and the vehicle in a bottom-up, serial and hierarchical manner



Functional Build — Integrated process of validating the components, sub-assemblies and the vehicle at a single point in time Sequential Build Process (Hyundai way)

Functional Build (Toyota way)

• Fundamental assumption that quality of each higher assembly is dependant on quality of incoming lower level components • Bottom up approach to validation — Components — Sub assemblies — Finished body • Components need to pass stringent dimensional norms before validating sub assemblies; sub assemblies need to be developed to specs before reaching the finished body validation stage • The approach often leads to high lead time, high cost and excessive rework — Components are checked for specs before they are tried in subassemblies / final assemblies — Dies need to be reworked if components do not meet specs • The original part dimensions are required to be treated as absolute requirements though in reality changes take place • Relatively narrow focus of design engineers – trying to perfect the components through re-work and iterations

• Quality and fit of final assembly is paramount over that of individual parts • Process takes into account the fact that components dimensions change while handling, welding and assembly; therefore need to hold component level re-work till after assembly stage • Integrated process of validating components, sub-assemblies and finished body i.e. Functional Build • Components and sub-assemblies with dimensional deviations may not be corrected immediately • Decisions are taken at “screw-body” stage when all components and sub assemblies are screwed/riveted together to create a “screw-body” • Focus is on “what is important to customer”; do not commit resources to correct dimensions that are un-important to customer • Treat original part dimensions as targets rather than given or absolute requirements • Shifting of designers’ view from components to entire body • Final specs for components within an assembly are determined concurrently along with approval of assembly • Requires active downstream involvement of designers in the validation process

Toyota pioneered the functional build approach; NA OEMs are beginning to adopt this approach, although slowly Source:


A.T. Kearney 82/6865 33

Package layout — Hyundai definition

Scope of Work/Activities


• New • Facelift


• Product initiation report • 1st/2nd product plan

• -17 / 0 • -8 / 0

Source of Inputs

• Product Planning


1 st product

• Review plan • Develop basic layout — Engine — Transmission — Chassis — Electricals • Set weight target • Prepare styling requirement and provide inputs to Styling • Specify and refine package layout • Conduct layout presentation meeting • Release skin layout and freeze layout • Identify interferences and propose potential solution


• • • • • • • • •

Product planning (R&D and marketing) Sales planning Quality targeting Styling design Draft design and T-car evaluation Product profitability review Material cost estimation Production preparation Supplier selection for long lead time parts


Role

FTEs

• Product Dev. Team 1, 2, 3

• R

• ~12

• Project Manager

• A

• Need basis

• Product Planning

• S

• Need basis

• Engineering Design

• S

• Need basis


Key Best Practices

• Close and frequent coordination among related functions/ work streams • Continuous realtime benchmarking • Quick adoption of best practices and global benchmarks

• CAD Supplier Integration/ Involvement of Suppliers

• N/A

• Skin layout • Finalised package layout

Source:


Role/nature of Involvement

• N/A Key Decisions

• Confirmation of final package layout


• Layout presentation meeting • Project Manager • Head of Product Dev. Center • Head of R&D

A.T. Kearney 82/6865 38

Develop design draft and plan — Hyundai definition



-14 / -6 (draft) -5 / 0 (plan) -6 / -3 (draft) -2 / 0 (plan)


Source of Inputs

• Past claim/issue data • Principles in applying new technology • Parts commonization plan • Approved design draft • 1st/2nd// 3 rd product plan

• Product planning • Product Dev. Center (I) • Parts Development (in Purchasing BU) • Eng. Design Center

Scope of Work/Activities Develop Design Draft • Define basic structure of key vehicle systems • Incorporate learnings from past field claims/issues in design • Develop approaches to realize product and performance targets • Define items to which new technology will be applied • Arrange design draft presentation meeting Develop Design Plan • Specify design concept draft — Define target dimensions — Clarify design target for key vehicle systems — Reflect new technologies — Solve past issues in the new design • Arrange design plan presentation meeting


Role

FTEs

• Eng. Design Center

R

~90

• Project Manager

A

Need basis

• Product Engineering

S

Need basis

• Powertrain R&D

S

Need basis



• • • • • • • •

Product planning (R&D and marketing) Styling design Sales planning Quality targeting Product profitability review Material cost estimation Production preparation Supplier selection for long lead time parts


Key Best Practices

• Close and frequent coordination among related functions/ work streams • Quick adoption of best practices and global benchmarks

• CAD/CAM/CAE

Supplier Integration/ Involvement of Suppliers

• Key suppliers (most are Level III integration suppliers)

• Design draft • Design plan

Source:


Key Decisions

• Design draft approval • Design plan approval


• Propose new tech. and products Review and Decision Making Forum

• Design draft presentation meeting • Design plan presentation meeting • Head of R&D

A.T. Kearney 82/6865 39

Master/detail drawing — Hyundai definition




+1 / +6 +1 / +5


Role

FTEs

Key Best Practices

• Close and frequent coordination among related functions/ work streams • Quick adoption of best practice and global benchmark

• Validate Lay Out (powertrain, body, chassis, trim, electrics) — Check part-to-part fitness — Check mass production feasibility • Develop parts/assembly drawings which meet regulation, reliability, and proto design standards Inputs for Work Source of • Conduct design review meetings Stream Inputs — Master drawing presentation meeting • List of Black Box • Product (Master drawing step) items planning — Product drawing final review meeting • Proto design • Product Dev. (Detail drawing step) standard Center • Release product drawing • Existing model • Parts — Provide dimension spec. of MIP, black BOM drawing Development box item, detail-controlled items • List/data of • Eng. Design Center commonization parts • Parts numbering system • Existing model Parts Catalogue • Joint cost review • Design draft • Design plan • Package layout Parallel Work • PEI Streams in VDP


R

~100

• Vehicle Electronic Center

R

~20

• Powertrain R&D

S

Need basis

• Production Engineering

S

Need basis

• • • Product drawings which include dimension spec. of MIP, black box • • item, detail-controlled items) • • •

• Approval of product • Drawing


Source:

Product planning (R&D and marketing) Sales planning Quality targeting Product profitability review Material cost estimation Production preparation Supplier selection for long lead time parts



• CAD • FMEA (Failure Mode Effect Analysis) Supplier Integration/ Involvement of Suppliers

• Suppliers for black box items and detail controlled parts

Key Decisions


• Propose new tech. and products • Supplier design-in activities


• Master drawing • presentation meeting • Product drawing final review meeting • Head of R&D

A.T. Kearney 82/6865 40

Inputs from parallel workstreams linked with vehicle design -20 -19 Key Milestones

-18

-17

-16 -15

-14 -13

-12 -11

-10

-9

1st

-8

-7

2nd

-6

-5

-4

Product Initiation

Styling Evaluation

Styling Evaluation

Model Approval

▼

▼

▼

▼

Layout Presentation Meeting

Product Planning (R&D)

Design Draft Presentation Meeting

-3

-2

-1

0

1

2

3

4

5

6

Model Start Freeze Die Design ▼

Design Plan Presentation Meeting

▼

Master Drawing Presentation Meeting

Product Drawing Final Review

Product Planning & PEI 1st

2nd

Product Plan

3rd Product Plan

Product Plan

Product Development

Package Layout Skin Layout

Layout Freeze

Concept Sketch Rendering & Tape Drawing

Styling Design

External/Internal Modeling

CAD data for model ready for mass production

Design Draft Design Plan

Eng. Design

Master/Detail Drawing

T-Car Design

Prototyping

T-Car Mfg. T-Car Mfg. (2) T-Car Test Results

Test

Source:

T-Car Test/Evaluation A.T. Kearney research, analysis and interviews

A.T. Kearney 82/6865 41

Inputs/outputs of vehicle design workstream

• Past claim/issue data • Principles in applying new tech. • Parts commonization plan • 1st/2nd product plan

• Approved design draft • Skin layout • 3rd product plan

• Approved design plan • CAD data for model ready for mass production • T-car test results

Input

Input

Input

Develop Design Draft

Develop Design Plan

Master/Detail Drawing

Output

Output

Output

Design Draft

• Basic structure for key systems — Body/Chassis/Trim/Electricals/Po wertrain • How to reflect/solve past claim/issues in design • Design approach to achieve targets Specify — Performance And — Durability Refine — New Tech. — Automation — Cost — Weight • FMEA* plan by system — Body/Chassis/Trim/Electricals/Po wertrain * Failure Mode Effect Analysis Source: A.T. Kearney research, analysis and interviews

Design Plan

• Specified structure for key systems — Body/Chassis/Trim/Electricals/ Powertrain • How to reflect/solve past claim/issues in design • Design approach to achieve targets — Performance — Durability — New Tech. — Automation — Cost — Weight • FMEA* plan by system — Body/Chassis/Trim/Electricals/ Powertrain

• Product Drawing — Mainly, dimension spec. of MIP, black box, detail-controlled items (Test spec. is usually finalized during Pilot 1 period)

A.T. Kearney 82/6865 42

T-car design, manufacturing, and evaluation — Hyundai definition


• New

-14 / -12 (Design) -11 / -9 (Mfg.) -8 / +1 (Test)


Source of Inputs

• Product plan • Product — Key specs planning — Powertrain (R&D focused) selection/ installation plan — Platform sharing plan — Configuratio n plan for body, chassis, powertrain, etc.


• Design T-car (Eng. Design Center incharge) — Review 1st/2nd product plan for input — Design T-car layout • Manufacture T-car (Prototyping Office incharge) — Manufacture T-car body, chassis, trim (Existing models are used) — Install powertrain for 1st T-car — Release 1st T-car • Test/Evaluate T-car (Test Center in-charge) — Conduct powertrain mountability test and basic test in 1 st T-car — Install powertrain for 2nd T-car to 1 st Tcar and release 2 nd T-car — Conduct vehicle power performance test, emission test, gear ratio test in 2 nd T-car — Input test results to VDP


Role

FTEs

Key Best Practices


R

Not available

• Prototyping Office

R

Not available

• Test Center

R

Not available

• Install powertrain for 2nd T-Car to 1st TCar, and modify these vehicles suitable for 2nd T-Car test (thus avoid manufacturing additional vehicles for 2nd T-Car test) • Reflect T-car test results in early stage of VDP

Not available • Project Manager

A

Need basis


• CAD • Proto Assembly Line (In-house) Supplier Integration/ Involvement of Suppliers

• Suppliers for assembly work


• Outsource T-Car assembly work in inhouse Proto Assembly line


• T-Car test results • Engineering changes input


• • • • • • • • • Source:

Product planning (R&D and marketing) Sales planning Quality targeting Styling design Development of design draft and plan Product profitability review Material cost estimation Production preparation Supplier selection for long lead time parts


Key Decisions


• T-car release/test schedule • Project manager mgt. • Functional managers • Reflection of T-car test (product planning, eng. results to eng. design design, prototyping, test, powertrain R&D)

A.T. Kearney 82/6865 43

HMC is executing sequential validation process, using FMEA activities

FMEA* Interpretation Level

Validation Approach

Vehicle System Level FMEA

Impact to Vehicle

Sub-system Level FMEA

Impact to System

System

Sub-system

Bottom-up

Characteristics

• Fundamental assumption that quality of each higher assembly is dependant on quality of incoming lower level components • To interpret a failure that took place, failures are analyzed in the reverse order, or from small to big parts like “component failure impact to sub-system functions impact to system functions” • Components need to pass stringent dimensional norms before validating sub assemblies; sub assemblies need to be developed to specs before reaching the finished body validation stage →

Assembly

Assembly Level FMEA

Impact to Sub-system /Assembly

Component Level FMEA

Impact to Assembly/ Sub-assembly

Sub-assembly

Component Note:

Source:

→

*Failure Mode Effect Analysis


A.T. Kearney 82/6865 46

Facilities and tools used in the work stream


Description

• CAD (Catia V5) • FMEA (Failure Mode Effect Analysis)

• A means to estimate and interpret potential failures, its impact to customer and the root cause of the failure in the product under development. • This is conducted during design stage to secure product quality in the earlier phase of product development and to ensure quality products are delivered to customers. • Objective of FMEA is — To identify potential failure modes and assess its impact — To identify key characteristics that should be checked with extra care — To prioritize potential mfg/design failures — Help eliminating/preventing product and process issues

• In-house Proto Assembly Line

• Assembly line to manufacture proto-car is also used for manufacturing T-car • The assembly line is located within Namyang R&D Center

Source:


A.T. Kearney 82/6865 49

Key Best Practices







Participation by all relevant functions in the design presentation/review meeting has been introduced as a formal process in Vehicle Development Process to emphasize cross-functional consensus With recent focus on quality activities in the NPD process, quality-related activities are given high priorities • FMEA activities • Planning/Reflection activities to solve Initial Quality Study (IQS) / past claim issues Cost reduction by avoiding additional T-Car manufacturing • 2nd T-car is not manufactured separately, instead, 1st T-car is modified for 2nd test

Note: Source:

Initial Quality Study: Regular survey conducted by J.D. Power to identify customers’ claims on a vehicle quality 3 months after their purchasing. A.T. Kearney research, analysis and interviews A.T. Kearney 82/6865 50

Parallel Workstreams -22 Phases

-20

-18

-16

-14

-12

-10

-8

Concept Development

-6

-4

-2

0

Product Planning

2

4

6

8

Design

10

12

14

16

18

Prototyping

20

22

24

Product Preparation

Develop Concept

Product Planning and Development of PEI

Product Planning (Marketing Side)

Concept Sketch

Rendering & Tape Drawing

External/Internal Modeling

Package Layout

Develop Draft Design

T- ca r D esi gn

T- car M fg.

Develop Design Plan

Master Detailed Drawing

Manage engineering changes

1st Prototyping

P re -e va lu at io n o f T- ca r

2nd Prototyping

1st Test / Evaluation

Select Suppliers for Long Lead Parts

2nd Test / Evaluation

Select Suppliers for Other Parts

Develop Prototype Parts

D ev elop Pi lo t P ar ts

In it ial Sa mp le In spe ct io n

Development Schedule Management

Prepare Die and Jig

Production Prep .Draft /Plan

Modification

Secure Process Capability

P1

P2

Final Test/Eval.

VDP Phases Core workstream

Cost Estimation & Target Cost Review

Ensure Quality

Parallel work streams Material Cost Estimation

Source:


A.T. Kearney 82/6865 51

Vehicle Design and Integration

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