Bob Himes, chief engineer of the Advanced Vehicle Engineering staff, helped in incorporating ergonomics and vehicle pack-aging as a vehicle attribute in systems engineering implementatio
Trang 1Tai ngay!!! Ban co the xoa dong chu nay!!!
Trang 2Automotive Product
Development
Trang 3Automotive Product
Development
A Systems Engineering Implementation
by Vivek D Bhise
Trang 4Taylor & Francis Group
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Names: Bhise, Vivek D (Vivek Dattatray), 1944- author.
Title: Automotive product development : a systems engineering implementation
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Identiiers: LCCN 2016037644| ISBN 9781498706810 (hardback : alk paper) |
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Trang 5Preface xxi
Acknowledgments xxiii
Author xxv
SECTION I Automotive Product Development Process Chapter 1 Introduction: Automotive Product Development 3
Introduction 3
Complex Product, Many Inputs, Many Designers and Engineers 3
Basic Deinitions of Process, System, and Systems Engineering 3
Process 3
System 4
Systems Engineering (SE) 4
Systems Approach 5
Multidisciplinary Approach 6
Customer Focused 6
Basic Characteristics of SE 6
Product Development 8
Processes and Phases in Product Development 9
Automotive Product as a System 11
Automotive Product Development Process 11
What is Automotive Product Development? 11
Flow Diagram of Automotive Product Development 14
Timing Chart of Automotive Product Development 14
Understanding Customer Needs 17
Program Scope, Timings, and Challenges 17
Scope of Vehicle Development Programs 17
Program Timings 18
Important Considerations in Managing Vehicle Programs 19
Some Frequently Asked Questions during Vehicle Development 21
Decision Making during Product Development 21
Disciplines Involved in Automotive Product Development 22
Selecting the Program Leader 22
Role of Early Vehicle Concept Development 24
Formation of Team Structure and Teams 24
Treating Suppliers as Partners 26
Other Internal and External Factors Affecting Vehicle Programs 26
Internal Factors 26
External Factors 27
Trang 6Importance, Advantages, and Disadvantages of Systems
Engineering 27
Importance of Systems Engineering 27
Advantages and Disadvantages of the Systems Engineering Process 28
Concluding Remarks 28
References 28
Chapter 2 Steps and Iterations Involved in Automotive Product Development 31
Introduction 31
Systems Engineering Process and Models 32
The Process Begins with Understanding Customer and Business Needs and Government Requirements 32
Systems Engineering Process 33
Systems Engineering “ V” Model 35
Left Side of the “ V” : Design and Engineering 37
Right Side of the “ V” : Veriication, Manufacturing, and Assembly 38
Right Side of the Diagram: Operation and Disposal 38
Systems Engineering Model with Five Types of Loop 39
Management of the Systems Engineering Process 39
Deining and Locating Gateways in Vehicle Program Timings 41
Managing by Vehicle Attributes 42
Vehicle Attributes and Attribute Requirements 42
What Is an Attribute? 42
Attribute Requirements 46
Attribute Management 46
Importance of Attributes 47
Vehicle-Level Target Setting 47
Target Setting and Measures 47
Some Examples of Attribute-level Measures 48
Decomposition of a Vehicle into Manageable Lower-Level Entities 49
Managing a Complex Product 49
Decomposition Tree 50
Relationship between Vehicle Attributes and Vehicle Systems 50
Interfaces between Vehicle Systems 52
Setting and Analyzing Requirements 54
What Is a Requirement? 54
Why “ Specify” Requirements? 54
How Are Requirements Developed? 55
Characteristics of a Good Requirement 55
Evaluations, Veriication, and Validation Tests 56
Concluding Remarks 57
References 57
Trang 7Chapter 3 Customer Needs, Business Needs, and Government Requirements 59
Introduction 59
Inputs to the Automotive Development Process 60
Customer Needs 60
List of Customer Needs 61
Mid-Size Sports Utility Vehicle (SUV) 61
Heavy-Duty Pickup Truck 62
Primary Vehicle Controls 62
Business Needs 63
Government Requirements 63
Obtaining Customer Inputs 64
Observation Methods 64
Communication Methods 65
Experimentation Methods 65
Additional Methods 66
Determining Business Needs: Product Portfolio, Model Changes, and Proitability 66
Government Requirements for Safety, Emissions, and Fuel Economy 67
Government Safety Requirements 67
EPA’ s Greenhouse Gas (GHG) Emissions and NHTSA’ s Corporate Average Fuel Economy (CAFE) Standards 67
Rationale behind Footprint-Based Standard 68
Implementation Readiness of New Technologies 70
Vehicle Features: “ Wow,” “ Must Have,” and “ Nice to Have” Features 71
Global Customers and Suppliers 71
Comparison of Vehicles Based on Customer Needs 72
Concluding Remarks 72
References 72
Chapter 4 Role of Benchmarking and Target Setting 75
Introduction 75
Benchmarking 75
An Example: Mid-Size Cross-over SUV 77
Photo-Benchmarking 78
Breakthrough 79
Differences between Benchmarking and Breakthrough 80
Benchmarking Competitors’ Vehicles: An Example 80
Examples of System, Subsystem, and Component-Level Benchmarking 87
Concluding Remarks 90
References .90
Trang 8Chapter 5 Business Plan Development and Getting Management Approval 93
Introduction 93
Business Plan 93
What Is a Business Plan? 93
Contents of the Business Plan 93
Process of Preparing a Business Plan 96
Risks in Product Programs 97
Make versus Buy Decisions 99
Concluding Remarks 99
References 100
Chapter 6 New Technologies, Vehicle Features, and Technology Development Plan 101
Introduction 101
Implementing New Technologies 101
Major Reasons for Changes Affecting Future Vehicle Designs 102
Creating a Technology Plan 102
Risks in Technology Implementation 103
New Technologies 103
Design Trends in Powertrain Development 103
Smaller, Lighter, and More Fuel-Eficient Gasoline Engines 103
Higher-Eficiency Transmissions 109
Driver Aids and Safety Technologies 109
Driver Information Interface Technologies 112
Connected Vehicles or Vehicle-to-X (V2X) Technologies 114
Self-Driving Vehicles 116
Lightweighting Technologies 116
Aerodynamic Drag Reduction 118
Technology Plan 118
Concluding Remarks 118
References 119
Chapter 7 Relation of Vehicle Attributes to Vehicle Systems 121
Introduction 121
Overview of Tasks and Relationships between Customer Needs and Systems Design 121
Allocation of Attribute Requirements to Vehicle Systems 124
Development of Overall Vehicle Speciications 124
Deining Attribute Requirements for the Proposed Vehicle 125
Reinement of Vehicle Attribute Requirements 127
Speciication of Vehicle Functions from Vehicle Attribute Requirements and Allocation of Functions to Vehicle Systems 128
Cascading Vehicle Attribute Requirements to Vehicle Systems 129
System Design Speciications 131
Trang 9Concluding Remarks 131
References 132
Chapter 8 Understanding Interfaces between Vehicle Systems 133
Introduction 133
Interfaces 133
What I s an Interface? 133
Types of Interface 134
Interface Requirements 136
Visualizing Interfaces 137
Representing an Interface 137
Interface Diagram 138
Interface Matrix 138
Examples of Interface Diagram and Interface Matrix 141
Vehicle Systems Interface Diagram and Interface Matrix 141
Vehicle Brake System Interfaces 141
Important Interfaces 146
Design Trade-Offs 146
Other Observations 147
Design Iterations to Eliminate or Improve Interfaces 147
Sharing of Common Entities Across Vehicle Lines 148
Concluding Remarks 148
References 148
Chapter 9 Cascading Vehicle Attribute Requirements to Vehicle Systems 151
Introduction 151
What I s a Requirements Cascade? 151
Cascading Attribute Requirements to Lower Levels 153
Example: Subattributes of Vehicle Attributes 153
Cascading Attribute Requirements to Develop Systems Design Requirements 155
Considerations Related to Cascading Attribute Requirements for Vehicle Systems 155
Examples of Attribute Cascading 156
The Brake System and Its Subsystem Requirements 156
Concluding Remarks 165
References 165
Chapter 10 Development of Vehicle Concepts 167
Introduction 167
Why Create a Vehicle Concept? 167
Process of Developing Vehicle Concepts 172
Other Issues Related to Vehicle Concept Creation 173
Trang 10Product Variations and Differentiation 173
Deinition of a Vehicle Platform 173
Number of Vehicle Concepts and Variations 174
Designing Vehicle Exterior and Interior as a System 174
Evaluation of Vehicle Concepts 177
Use of a Pugh Diagram for Concept Selection and Improvements 177
Planning for Models, Packages, and Optional Features 177
Concluding Remarks 178
References 178
Chapter 11 Selecting a Vehicle Concept 179
Introduction 179
Market Research Clinics 179
What Is Market Research? 179
New Concept Vehicle 180
Speciic Evaluation Issues 180
Evaluation Issues for Exterior Clinics 180
Issues for Interior Clinics 181
Pros and Cons of Market Research 181
Market Research Methods Used in Product Development 182
Methods to Obtain Data 182
Personal Interview 182
Focus Group Sessions 183
Mail, Web-based, and Telephone Surveys 183
Market Research Clinics 184
Some Examples of Vehicle Characteristics Evaluated in Market Research Clinics 184
Commonly Evaluated Vehicle Characteristics Covered in Market Research Clinics 185
Exterior Evaluation Characteristics 185
Interior Evaluation Characteristics 186
Exterior Buck Preparation and Evaluation Setup 187
Interior Buck Preparation for Package Surveys 188
Precautions for Clinics to Avoid Biases 189
Sources of Errors 190
Types of Survey Questions and Data Analyses 191
Types of Market Research Clinics 194
Static versus Dynamic Clinics 194
Concluding Remarks 195
References 195
Chapter 12 Managing Vehicle Development Programs 197
Introduction 197
Program Manager 197
Program versus Project Management 199
Trang 11Program Management Functions 199
Development of Detailed Project Plan 200
Project Management 200
Steps in Project Planning 201
Tools Used in Project Planning 202
Gantt Chart 202
Critical Path Method 202
Program (or Project) Evaluation and Review Technique 203
Work Breakdown Structure 205
Project Management Software 205
Other Tools 205
Systems Engineering Management Plan (SEMP) 206
Contents of SEMP 206
Checklist for Critical Information 210
Role of Systems Engineers 210
Value of Systems Engineering Management Plan 211
Example of a Systems Engineering Management Plan 211
Complexity in Program Management 219
Timings in Project Management 220
Cost Management 221
Challenges in Project Management 221
Concluding Remarks 221
References 222
Chapter 13 Computer-Aided Technologies 223
Introduction 223
Computer-Aided Technologies 223
Claims: Advantages and Disadvantages of Computer-Aided Technologies 224
Computer-Aided Design, Engineering, and Manufacturing 226
Computer-Aided Engineering (CAE) Methods and Visualizations 226
Product Visualization Tools 226
Design Tools Used in Specialized Engineering Activities 227
Concept Design 227
CAE versus Physical Tests and Prototype Builds 228
Design Review Meetings 228
Veriication Tests 228
Validation Tests 229
Advantages of CAD 229
Concluding Remarks 230
References 230
Chapter 14 Vehicle Validation 231
Introduction 231
Trang 12Scope of Validation Testing 231
When Is Validation Performed? 231
Whole-Vehicle Tests 232
Methods Used for Evaluation 233
Customer Ratings 233
Expert Reviews 238
Company Employees and Management Personnel 238
Laboratory and Controlled Field Tests 238
Some Examples of Validation Tests and Test Details 239
Vehicle Performance 239
Comfort 240
Noise, Vibration, and Harshness 241
Crash Safety 242
Styling and Appearance 243
Packaging and Ergonomics 243
Electrical and Electronics 245
Concluding Remarks 245
References .246
Chapter 15 Creating a Brochure and a Website for the Vehicle 247
Introduction 247
Why Create a Vehicle Brochure? 247
Vehicle Website versus Brochure 248
Contents of the Brochure 249
Vehicle Models, Packages, and Their Features 249
Types of Model and Optional Packages of Features 249
Vehicle Models 249
Standard Features 250
Optional Features 250
Vehicle Packages 250
Exterior and Interior Colors and Materials 251
Picture Galleries 251
Vehicle Price 251
Examples of Brochure Contents 251
Vehicle Dimensions: Exterior and Interior 252
Powertrain and Fuel Economy 252
Key Vehicle Attributes 253
Safety Features 253
Special Feature Categories 253
“Wow” Features 255
“Must Have” Features 255
“Nice to Have” Features 255
Concluding Remarks 255
Reference 255
Trang 13SECTION II Tools Used in the
Automotive Design Process
Chapter 16 Tool Box for Automotive Product Development 259
Introduction 259
Tools Used During Vehicle Development Phases 260
Spreadsheets 260
Design Standards and Guidelines 260
Product Planning Tools 261
Benchmarking 261
Pugh Diagram 261
Quality Function Deployment (QFD) 261
Failure Modes and Effects Analysis 262
CAD and Packaging Tools 262
Engineering Analysis Tools 263
Quality Tools 263
Human Factors and Ergonomics Tools 263
Safety Engineering Tools 264
Measurement Tools 264
Program/Project Management Tools 264
Financial Analysis Tools 265
Market Research Tools 265
Concluding Remarks 265
References 265
Chapter 17 Decision-Making Tools 267
Introduction 267
An Automaker’s Decision-Making Problem: An Example 268
Decision Making in Product Design 269
Key Decisions in Product Life Cycle 269
Trade-Offs during Design Stages 270
What Is Involved In Decision Making? 272
Alternatives, Outcomes, Payoffs, and Risks 272
Maximum Expected Value Principle 273
Other Principles in Selecting Alternatives 274
Data Gathering for Decision Making 277
Importance of Timely Decisions 278
Robustness Evaluation through Sensitivity Analysis 278
Multi-attribute Decision Models 278
Pugh Diagram 278
Weighted Pugh Analysis 280
Weighted Total Score for Concept Selection 281
Analytical Hierarchy Method 282
Trang 14AHP Application for Multi-attribute Decision Making 286
Example: Multiattribute Weighting 286
Informational Needs in Decision Making 289
Risks in Product Development and Product Uses 290
Deinition of Risk and Types of Risks in Product Development 291
Types of Risks during Product Use 292
Risk Analysis 292
Risk Matrix 293
Risk Priority Number 293
Problems in Risk Measurements 294
Importance of Early Decisions During Product Development 295
Concluding Comments 295
References 296
Chapter 18 Product Planning Tools 297
Introduction 297
Benchmarking and Breakthrough 298
Benchmarking 298
Breakthrough 299
Pugh Diagram 299
An Example of Pugh Diagram Application 300
Timing Charts and Gateways 302
Quality Function Deployment 303
An Example of the QFD Chart 307
Cascading QFDs 311
Advantages and Disadvantages of QFD 311
Failure Modes and Effects Analysis 313
An Example of an FMEA 314
Failure Modes and Effects and Criticality Analysis 318
Other Product Development Tools 318
Business Plan 318
Program Status Chart 320
Standards 320
CAD Tools 322
Prototyping and Simulation 323
Physical Mock-Ups 323
Technology Assessment Tools 323
Concluding Remarks 324
References 324
Chapter 19 Financial Analysis in Automotive Programs 325
Introduction 325
Types of Costs and Revenues in Vehicle Programs 325
Nonrecurring and Recurring Costs 326
Trang 15Costs and Revenues In Product Life Cycle 326
Fixed versus Variable Costs 328
Make versus Buy Decisions 329
Parts and Platform Sharing 330
Quality Costs 330
Manufacturing Costs 331
Safety Costs 331
Product Termination Costs 332
Total Life−Cycle Costs 332
Effect of Time on Costs 333
Program Financial Plan 333
Example: Automotive Product Program Cash Flow 333
Challenges in Estimating Costs and Revenues 347
Product Pricing Approaches 347
Traditional Costs−Plus Approach 347
Market Price−Minus Proit Approach 349
Other Cost Management Software Applications 349
Trade−offs and Risks 351
Concluding Remarks 354
References 354
Chapter 20 Vehicle Package Engineering Tools 355
Introduction 355
Vehicle Packaging Background 355
What Is Vehicle Packaging? 355
What Is Packaged in a Vehicle? 356
Vehicle Packaging Organizations 356
Specialization within Vehicle Package Engineering 356
Vehicle Packaging Personnel 357
Package Engineering and Ergonomics 358
Principles Used in Vehicle Packaging 360
Vehicle Packaging Procedure 360
Vehicle Package Engineering Tasks and Process 360
Standard Practices Used in Vehicle Packaging 363
Mechanical Packaging 363
Occupant Packaging 367
CAD Models and Package Bucks 370
Interior Package Reference Points and Seat Track– Related Dimensions 371
Interior Dimensions 374
Driver Package Development Steps and Calculations 379
Entry and Exit Considerations 389
Problems during Entry and Exit 389
Vehicle Features and Dimensions Related to Entry and Exit 392
Door Handles 392
Trang 16Lateral Section at the SgRP and Foot Movement Areas 392
Body Opening Clearances from SgRP Locations 393
Driver Field of View 394
Visibility of and over the Hood 394
Command Seating Position 395
Short Driver Problems 395
Tall Driver Problems 396
Sun Visor Design Issues 396
Wiper and Defroster Requirements 396
Obscurations Caused by A-Pillars 398
Mirror Field of View Requirements 398
Mirror Locations 398
Inside Mirror Location 398
Outside Mirror Locations 398
Procedure for Determining Driver’ s Field of View through Mirrors 400
Methods to Measure Fields of View 400
Polar Plots 401
Other Packaging Issues and Vehicle Dimensions 402
Concluding Remarks 402
References .402
Chapter 21 Vehicle Evaluation Methods 405
Introduction 405
Overview of Product Evaluation Methods 405
Types of Data Collection and Measurement Methods 406
Methods of Data Collection and Analysis 407
Observational Methods 407
Communication Methods 408
Experimental Methods 409
Evaluations during vehicle development 409
Physical Tests with Measurement Instruments 409
Market Research Methods 410
Mail Surveys 411
Internet Surveys 411
Personal Interviews 411
Focus Group Sessions 411
Ergonomic Evaluations 412
Databases on Human Characteristics and Capabilities 413
Anthropometric and Biomechanical Human Models 414
Human Factors Checklists and Score Cards 414
Task Analysis 417
Human Performance Evaluation Models 418
Laboratory, Simulator, and Field Studies 419
Human Performance Measurement Methods 419
Trang 17Objective Measures and Data Analysis Methods 420
Subjective Methods and Data Analysis 420
Rating on a Scale 421
Paired Comparison–Based Methods 421
Thurstone’s Method of Paired Comparisons 423
Step 1: Select an Attribute for Evaluation of the Products 423
Step 2: Prepare the Products for Evaluation 423
Step 3: Obtain Responses of Each Subject on All Pairs 423
Step 4: Summarize Responses of All Subjects in Terms of Proportion of Product in the Column Better Than the Product in the Row 424
Step 5: Adjusting p ij Values 425
Step 6: Computation of Z-values and Scale Values for the Products 425
Analytical Hierarchy Method 427
Some Applications of Evaluation Techniques in Automotive Design 427
Checklists 427
Observational Studies 428
Vehicle User Interviews 428
Ratings on Interval Scales 428
Studies Using Programmable Vehicle Bucks 428
Driving Simulator Studies 429
Field Studies and Drive Tests 429
System and Component Veriication and Vehicle Validation Methods 429
Concluding Remarks 429
References 430
SECTION III Applications of Tools: Examples and Illustrations Chapter 22 Evaluation Studies 435
Introduction 435
Benchmarking of Low-Cost Vehicles 435
Photo-Benchmarking 436
Quality Function Deployment 436
CAD Evaluations 440
Superimposed Drawings 440
Composite Views of Left Side and Right Sides of Different Vehicles 441
Sequential Views of Assembly 441
Dynamic Action Simulations/Videos 445
Trang 18Observational Studies in Designing a Center Console 446
Models for Ergonomic Evaluations 446
Legibility Prediction Model 447
Windshield Veiling Glare Prediction Model 449
Simulator, Laboratory, and Field Studies 450
Driving Simulators 451
Laboratory and Field Tests 452
Package Evaluation Surveys 452
Concept Selection Market Research 455
Concluding Remarks 455
References 459
Chapter 23 Developing a Passenger Car: A Case Study 461
Introduction 461
Customer Characteristics, Needs, Market Segment, Benchmarking, and Vehicle Speciication 461
Customer Characteristics 462
Customer Needs 463
Market Segment 463
Benchmarking 463
Description of the Target Vehicle 468
Changes in the Target Vehicle 469
Assessment of Target Vehicle 469
Customer Needs Pugh Diagram 469
Vehicle Attributes Pugh Diagram 469
Vehicle Systems Pugh Diagram 469
Program Timings, Sales, and Financial Projections 474
Program Timings 474
Projected Sales 474
Financial Projections 475
Concluding Remarks 475
Reference 477
Chapter 24 Developing a Pickup Truck: A Case Study 479
Introduction 479
Customer Characteristics and Needs, Market Segment, Benchmarking, and Vehicle Speciication 479
Customer Characteristics 479
Customer Needs 481
Market Segment 483
Benchmarking and Vehicle Speciication 483
Description of Target Vehicle 483
Changes in the Target Vehicle 490
Assessment of the Target Vehicle 490
Trang 19Customer Needs Pugh Diagram 490
Vehicle Attributes Pugh Diagram 490
Vehicle Systems Pugh Diagram 492
Program Timings, Sales, and Financial Projections 492
Program Timings 492
Projected Sales 493
Financial Projections 494
Concluding Remarks 494
Reference 495
Chapter 25 Developing a Sports Utility Vehicle: A Case Study 497
Introduction 497
Customer Characteristics and Needs and Market Segment 497
Customer Characteristics 497
Customer Needs 498
Market Segment 499
Description of the Target Vehicle 500
Benchmarking Data 500
Technology Plan 500
Assessment of the Proposed Vehicle 500
Program Timings, Sales, and Financial Projections 523
Program Timings 523
Projected Sales 523
Financial Projections 523
Concluding Remarks 523
Reference 524
Appendix I 525
Appendix II 529
Appendix III 533
Appendix IV 535
Appendix V 537
Index 539
Trang 20Preface
The development of a new automotive product requires an understanding of the gration of knowledge from a number of disciplines In this book, I have provided material that was generated and used in teaching the automotive product develop-ment process to graduate students in Automotive Engineering over many years at the University of Michigan-Dearborn
inte-The material provides the basic background, principles, techniques, and steps that
I found to be useful in understanding the complex and coordinated activities that need
to be undertaken to ensure successful development of the “right vehicle” that ers will enjoy driving Proper implementation of the process should make the prod-uct development team members feel very proud of their accomplishments It should enhance the reputation of the company for creating exciting new vehicles and thus, lead the company to achieve inancial success beyond its imagination in terms of rev-enues, proits, and return on investments
custom-The formula for creating successful automotive products lies in the creation of a well-coordinated product development process, using the right tools and techniques,
a dedicated team of highly motivated multidisciplinary professionals, and very portive senior management
sup-This book is about understanding “the big picture” of how automotive products need to be developed with the sole purpose of satisfying their customers The book resulted from my deep desire to understand how automotive products are developed,
to understand the many challenges facing the auto industry, to study the methods currently used in designing automotive products, and to make our future automo-tive engineers realize that their main job is to satisfy the customers who use their products
We teach our engineers to be proicient in applying specialized techniques in narrowly specialized areas such as structural analysis, vehicle dynamics, powertrain eficiency analysis, aerodynamic drag reduction, and electrical architecture design But they need to realize that the customer buys the “whole” car, not just a collection
of systems and components that they helped design, such as four wheels, a steering wheel, pedals, seats, vehicle body, lamps, wiring harnesses, and fuel tanks All vehi-cle systems and their subsystems and components must “work together” to provide the “desired” feel to the customer—so that he or she is either “completely” or “very” satisied with the vehicle
Engineers working in the automotive industry may claim that they currently have the necessary knowledge in areas such as system design speciications, design tools, veriication test procedures, test equipment, and subsequent data analysis methods However, many cars and trucks currently satisfy only about 60%–80% of their cus-tomers; that is, the vehicles do not achieve the high scores, such as over 90%, desired
by the customers and the senior management of the automobile companies This gap between the high levels of customer satisfaction “desired” by the customers and the management and those “actually achieved” by the current automotive products in various market research surveys is largely because of failure to understand customer
Trang 21This book is divided into three parts The irst part provides an in-depth standing of the various phases of the product development process and the steps involved in implementing the systems engineering process Strict and thorough implementation of the systems engineering process is a prerequisite for achieving success in any automotive product program Otherwise, the vehicle development program may exceed its budget or time schedule, and/or the designed product may fail to meet its customer satisfaction target The second part of the book covers many important tools and methods used in the vehicle development process The third part provides many examples and case studies generated during the past several years of
under-my teaching graduate courses in the Automotive Systems Engineering program at the University of Michigan-Dearborn
The auto industry is facing ierce competition and unending pressure to reduce program timings and costs This results in further pressure to minimize or even to eliminate many of the systems engineering tasks, and thus, endanger the success-ful completion of vehicle programs The complexity of the vehicle programs is also increasing due to rapid advances in technologies, the large number of variables con-sidered in many analyses, and our inability to measure a number of key variables, which still rely on subjective judgments Subjective measures are used in evaluations
of many vehicle attributes, such as styling, drivability, performance feel, ics, interior spaciousness, and quality It is hoped that this book will help in address-ing many of the challenging issues facing the industry
ergonom-WEBSITE MATERIALS
The following iles are in the Download section of this book’s web page on the CRC Press website (http://www.crcpress.com/product/isbn/97814987068100)
A Computer programs and models
1 Automotive Product Development Chart with Present Value Calculations
2 Program for Cost Flow by Months
3 Program for Cost Flow by Quarters
B Slides for Chapters 1 to 25
Trang 22Acknowledgments
This book is a culmination of my education, experience, and interactions with many individuals from the automotive industry, academia, and government agencies While it is impossible for me to thank all the individuals who inluenced my career and thinking, I must acknowledge the contributions of the following individuals
My greatest thanks go to the late Professor Thomas H Rockwell of the Ohio State University Tom got me interested in human factors engineering and driving research He was my advisor and mentor during my doctoral program I learned many skills on how to conduct research studies and analyze data, and more impor-tantly, he introduced me to the technical committees of the Transportation Research Board and the Society of Automotive Engineers, Inc
I would like to thank the late Lyman Forbes, Dave Turner, the late Eulie Brayboy, and Bob Himes from Ford Motor Company Lyman Forbes, manager of the Human Factors Engineering and Ergonomics Department at the Ford Motor Company in Dearborn, Michigan, spent hours with me discussing various approaches and methods
to conduct research studies on crash-avoidance research and development of motor vehicle safety standards Dave Turner, director of the Advanced Design Studios in the Ford’s Design Staff, got the Human Factors Engineering and Ergonomics depart-ment irmly anchored in the automotive design process He also helped establish a Human Factors Group within Ford of Europe when he was the director of Ford’s European Design Centre Eulie Brayboy, chief engineer, Design Engineering in the Corporate Design, always provided support in implementing human factors inputs into the automotive design process Bob Himes, chief engineer of the Advanced Vehicle Engineering staff, helped in incorporating ergonomics and vehicle pack-aging as a vehicle attribute in systems engineering implementation in the vehicle development process
The University of Michigan-Dearborn campus provided me with unique tunities to develop and teach various courses Our Automotive Systems Engineering and Engineering Management programs allowed me to interact with hundreds of graduate students, who in turn implemented many of the techniques taught in our graduate programs when solving problems within many other automotive origi-nal equipment manufacturers and supplier companies I would to thank Professors Pankaj Mallick and Armen Zakarian for giving me opportunities to develop and teach many courses in the Automotive Systems Engineering and Industrial and Manufacturing Systems Engineering programs Roger Schulze, director of our Institute for Advanced Vehicle Systems, got me interested in working on a number
oppor-of multidisciplinary programs in vehicle design Together, we developed a number
of vehicle concepts, such as a low mass vehicle, a new Model “T” concept for Ford’s 100th anniversary, and a reconigurable electric vehicle We also developed a num-ber of design projects by creating teams of our engineering students with students from the Product Design and Transportation Design department from the College for Creative Studies in Detroit, Michigan I must also thank my students for working
Trang 23I would like to also thank Cindy Carelli from CRC Press—a Taylor & Francis Company—for encouragement in preparing the proposal for this book, and her pro-duction group for turning the manuscript into this book.
Finally, I want thank my wife, Rekha, for her constant encouragement and her patience while I spent many hours working on my computers, writing the manuscript and creating igures included in this book
Vivek D Bhise
Ann Arbor, Michigan
Trang 24Vivek D Bhise is currently visiting professor/Lecturers’ Employee Organization lecturer and professor in post-retirement of industrial and manufacturing systems engineering at the University of Michigan-Dearborn He received his B.Tech in Mechanical Engineering (1965) from the Indian Institute of Technology, Bombay, India, his M.S in Industrial Engineering (1966) from the University of California, Berkeley, California, and a PhD in Industrial and Systems Engineering (1971) from the Ohio State University, Columbus, Ohio
During 1973–2001, he held a number of management and research positions at the Ford Motor Company in Dearborn, Michigan He was the manager of Consumer Ergonomics Strategy and Technology within the Corporate Quality Ofice, and the manager of Human Factors Engineering and Ergonomics in the Corporate Design of the Ford Motor Company, where he was responsible for the ergonomics attribute in the design of car and truck products
Dr Bhise is the author of recent books entitled Ergonomics in the Automotive Design Process (ISBN: 978-1-4398-4210-2 Boca Raton, FL: CRC Press, 2012) and Designing Complex Products with Systems Engineering Processes and Techniques
(ISBN: 978-1-4665-0703-6 Boca Raton, FL: CRC Press, 2014.)
Dr Bhise has taught graduate courses in Vehicle Ergonomics, Vehicle Package Engineering, Automotive Systems Engineering, Management of Product and Process Design, Work Methods and Industrial Ergonomics, Human Factors Engineering, Total Quality Management and Six Sigma, Quantitative Methods in Quality Engineering, Energy Evaluation, Risk Analysis and Optimization, Product Design and Evaluations, Safety Engineering, Computer-Aided Product Design and Manufacturing, and Statistics and Probability Theory over the past 36 years (1980–
2001 as an adjunct professor, 2001–2009 as a professor, and 2009–present as a ing professor in post-retirement) at the University of Michigan-Dearborn He also worked on a number of research projects in human factors with the late Professor Thomas Rockwell at the Driving Research Laboratory at the Ohio State University (1968–1973)
visit-His publications include over 100 technical papers on the design and evaluation
of automotive interiors, parametric modeling of vehicle packaging, vehicle lighting systems, ield of view from vehicles, and modeling of human performance in differ-ent driver/user tasks
Dr Bhise has also served as an expert witness on cases involving product safety, patent infringement, and highway safety
He received the Human Factors Society’s A R Lauer Award for Outstanding Contributions to the Understanding of Driver Behavior in 1987 He has served on a number of committees of the Society of Automotive Engineers, the Transportation Research Board of the National Academies, and the Human Factors and Ergonomics Society
Trang 25Section I
Automotive Product Development Process
Trang 26C OMPLEX P RODUCT , M ANY I NPUTS , M ANY D ESIGNERS AND E NGINEERS
Designing and producing an automotive product is a horrendously complicated undertaking The automotive product itself is very complex It involves many sys-tems: body system, powertrain system, suspension system, electrical system, climate control system, braking system, steering system, fuel system, and so on All the systems must work together under all possible combinations of road, trafic, and weather conditions to satisfy drivers and users with varied characteristics, capabili-ties, and limitations The automotive product development (PD) process requires many resources over several years and includes many intricate, coordinated, and costly design, evaluation, production, and assembly processes The complex automo-tive product must also meet hundreds of requirements to satisfy customers, appli-cable government regulations, and the goals and needs of company management.Developing a new automotive product requires the eficient execution of a number
of processes, and the implementation of systems engineering is essential to coordinate varied technical and company management needs The proper implementation of sys-tems engineering ensures that the right product is developed within the planned timing schedule while avoiding costly budget overruns To understand the complexity in the PD process, we will begin this chapter with a clear explanation of processes, systems, and systems engineering and then proceed with the details of the automotive PD process
BASIC DEFINITIONS OF PROCESS, SYSTEM,
AND SYSTEMS ENGINEERING
of the tasks The process can be studied and also deined by following a component (e.g., a part, an assembly, a transaction, a tracking paper, a drawing, a computer-aided design [CAD] model), or a person (e.g., one who moves from a workstation to other
Trang 274 Automotive Product Development: A System Engineering Implementation
workstations and performs one or more tasks at each workstation) through a series
of steps or tasks The beginning and ending points of each process must be clearly deined The purpose of the process, that is, the reason for the creation of the process, and its function, that is, what work is performed in the process, must be also clearly deined and documented
To create (i.e., to design and produce) a product (e.g., a vehicle), many processes are required (e.g., the customer needs determination process, the vehicle concept development process, the detailed engineering process, the systems veriication pro-cess, the production tools development process, and the vehicle assembly process)
S YSTEM
A system consists of a set of components (or elements) that work together to perform one or more functions The components of a system generally consist of people, hardware (e.g., parts, tools, machines, computers, and facilities), or software (i.e., codes, instructions, programs, databases) and the environment within which it oper-ates The system also requires operating procedures (or methods) and organiza-tion policies (e.g., documents with goals, requirements, and rules) to implement its processes and get its work done The system also works under a speciied range of environmental and situational conditions (e.g., temperature and humidity condi-tions, vibrations, magnetic ields, power/trafic low patterns) The system must be clearly deined in terms of its purpose, functions, and performance capability (i.e., abilities to perform or produce output at speciied level in a speciied operating environment)
Some deinitions of a system are
1 A system is a set of functional elements organized to satisfy speciied tives The elements include hardware, software, people, facilities, and data
objec-2 A system is a set of interrelated components working together toward some common objective(s) or purpose(s) (Blanchard and Fabrycky, 2011)
3 A system is a set of different elements so connected or related as to perform
a unique function not performable by the elements alone (Rechtin, 1991)
4 A system is a set of objects with relationships between the objects and between their attributes (Hall, 1962)
The set of components has the following properties (Blanchard and Fabrycky, 2011):
1 Each component has an effect on the whole system
2 Each component depends on other components
3 The components cannot be divided into independent subsystems
S YSTEMS E NGINEERING (SE)
Systems engineering (SE) is a multidisciplinary engineering decision-making cess involved in designing and using systems and products throughout their life
Trang 28Introduction
cycle The implementation of SE is very beneicial, as without it, the likelihood of creating the “ right system or product” that the customers really want (in terms of its attributes, such as performance, safety, styling, and comfort) within the targeted timings and costs can be substantially reduced (see INCOSE [2006], NASA [2007], and Kmarani and Azimi [2011] for more information on SE)
Systems Approach
The word “ systems” in “ systems engineering” is used to cover the following aspects
of different systems in an automotive product:
1 An automobile product is a system containing a number of other tems (e.g., body system, powertrain system, chassis system, and electrical system)
2 Thus, the design of the whole automobile will involve designing all the systems within the automobile such that the systems work together (i.e., the systems are interfaced or connected with other systems, and each system performs its respective functions) to create a fully functional vehicle and meet customer needs
3 Professionals from many different disciplines (e.g., industrial design, mechanical engineering, electrical engineering, physics, manufacturing engineering, product planning, inance, and business and marketing) are required to design (i.e., to make decisions related to the design of) all the systems in the vehicle
4 The vehicle has many different attributes (i.e., characteristics that its tomers expect, such as performance, fuel economy, safety, comfort, styling, and package) Simultaneous inputs from professionals from many disci-plines and specialists with deep knowledge about each of the vehicle sys-tems are required to make decisions about proper consideration of levels of all the attributes and trade-offs between the attributes in designing all the systems within the vehicle
cus-5 The automotive product is a component of other, larger systems (e.g., one or more vehicle platforms [which may be shared with other vehicle models], the highway transportation system, the petroleum consumption and fuel distribution system, the inancial system, and so forth)
6 The automobile works within different environmental and situational ditions (e.g., driving on a winding road at night in a thunderstorm)
con-7 All phases of the life cycle, from conceptualization of a new tive product to its discontinuation (i.e., its disposal, scrappage, recycling, replacement, plant dismantling or retooling), must be considered during its design
automo-Thus, the systems approach comprises simultaneous consideration of many tems, many attributes, trade-offs between the attributes, life cycle, disciplines, other systems, and working environments in solving problems (i.e., decision making) The systems approach is thus a primary and necessary part of SE
Trang 29sys-6 Automotive Product Development: A System Engineering Implementation
Multidisciplinary Approach
SE is a multidisciplinary approach, that is, it obtains inputs from people from many different disciplines working together and considering many design and operational issues and trade-offs between different issues, to enable the realization of a success-ful product or a system It is important to realize here that even when one discipline, such as electrical engineering, has the primary responsibility for designing an elec-trical system, other disciplines can raise a number of issues related to the design and operation of the system and thus assist in the design of the system by simultaneous consideration of multiple views and issues
SE involves both technical and management activities from the early conceptual stage of a product (or a system) to the end of the life cycle of the product (i.e., when the product is removed from service and disposed of) The management activities help ensure that all requirements and design considerations are taken into account along with the key goals of meeting the product performance, developmental sched-ule, and budget of the product program
Customer Focused
SE begins with an understanding of customer needs and development of an able concept of the product (or system) It focuses on deining customer needs and required functionality early in the development cycle, documenting requirements, and proceeding with the design synthesis and system (product) validation while con-sidering the problem as a whole (INCOSE, 2006)
accept-The objective of SE is to ensure that the product (or the system) is designed, built, and operated so that it accomplishes its purpose of satisfying customers in the most cost-effective way possible by considering performance, safety, costs, schedule, and risks
Basic Characteristics of SE
The basic characteristics of the SE approach are
It involves a collection of disciplines throughout the design and ment process It involves professionals from different disciplines working together (simultaneously and preferably co-located under one roof), con-stantly communicating, reviewing the design issues, and helping each other
develop-on all aspects of the product The types of disciplines to be included depend
on the type and characteristics of the product and the scope of the product program
For example, SE application for developing an automotive product will require personnel from many disciplines, such as engineers (including many specializations within engineering, e.g., mechanical, materials, elec-trical, computer and information science, chemical, manufacturing, indus-trial, human factors, quality, and SE), scientists (e.g., in physics, chemistry, and the life sciences) for research related to the design and production of new technological features of the vehicle, industrial designers (who deine the sensory form and craftsmanship characteristics of the vehicle, i.e., the
Trang 30Introduction
look, feel, and sound of the interior and exterior of the vehicle, such as the styling and appearance of surfaces of the vehicle, the touch feel of the sur-face and material characteristics, the sounds of operating equipment, and the smell of materials), market researchers (who deine the customers, mar-ket segment, customer needs, market price, and sales volumes), manage-ment (e.g., program and project management personnel, including product planners, accountants, controllers, and managers), plant personnel involved
in manufacturing and assembly, distributors, dealers, and even insurers to ensure that costs associated with ixing a vehicle damaged in an accident can be reduced and covered by the insurer
It is important to get inputs from all the disciplines that affect or are affected by the characteristics and uses of the vehicle at the early stages of the PD This ensures that their needs and concerns, and trade-offs between different multidisciplinary issues, are considered and resolved early, and costly changes or redesigns in the later phases are avoided
the product design should not deviate from satisfying the needs of the tomers The customers should be identiied and involved in deining the vehicle speciications and designing the vehicle, and in subsequent evalua-tions, to ensure that the vehicle being designed will meet their needs The customer needs are translated into vehicle attributes, and attribute require-ments are developed to ensure that each vehicle attribute is managed (i.e., reviewed, veriied, and validated) during the life cycle of the vehicle pro-gram The vehicle attribute requirements process is described in Chapter 2
deinition of the requirements at the overall product (i.e., the “ whole” cle) level For example, at the product level, the requirements for an auto-motive product will be based on all the basic attributes (derived from the needs of its external and internal customers) of the vehicle, such as safety, fuel economy, drivability (ability to maneuver, accelerate, and decelerate, and cornering or turning), seating comfort, thermal comfort, body-style, styling, costs, size, and weight
It is important to realize that the customer buys the vehicle for his/her use as a “ whole” product, not as a mere collection of the many components that form the product (Note that an automotive product typically contains about 6,000– 10,000 components.) Thus, the requirements for the systems, subsystems, and components of the product should be derived only after the product-level requirements are clearly understood and deined This issue
of cascading of the product-level attribute requirements to the system and lower-level entities is covered in Chapters 2 and 9
life cycle of the product being designed— through all stages from “ Concept Development to Disposal of the Product” (from lust to dust) Thus, it is the applications of all relevant scientiic and engineering disciplines in all the phases of the product, such as concept development; designing, manufac-turing, testing and evaluation; uses under all possible operating conditions;
Trang 318 Automotive Product Development: A System Engineering Implementation
service and maintenance; and disposal or retirement from service, that the product encounters throughout its life cycle
the product (or the entire system) as a whole and then sequentially breaks down (or decomposes) the product into its lower levels, such as systems, subsystems, sub-subsystems and components Thus, the lower-level systems are designed to meet the requirements of the higher-level systems (Note that if a manufacturer decides to use a carryover [i.e., existing] component
or system in a new product, the top-down approach will need to be ied This issue is covered in Chapter 2.)
pro-cess It involves making all the technical decisions related to the product during its life cycle as well as management of all the tasks to be completed
in a timely manner to implement the SE process and apply the necessary techniques
necessary to transform the operational needs of the customers into a design
of the product (or system) with proper size, coniguration, and capacity (e.g., performance level) It creates a documentation of the product requirements and drives the entire technical effort to evolve and verify an integrated and life cycle– balanced set of solutions involving the users and the product in its usage situations
assess-ing costs and risks, providassess-ing needed resources, integratassess-ing the ing specialties and design groups, maintaining coniguration control, and continuously auditing the effort to ensure that cost, schedule, and technical performance objectives are satisied to meet the original operational need
engineer-of the product and the product program
implementation (such as steps, methods, procedures, team structure, tasks, and responsibilities) depend on the program objectives, the product being produced (i.e., its characteristics), and the organization (company) produc-ing it (i.e., different companies generally have somewhat different processes, timings, organizational responsibilities, and brand-speciic requirements)
PRODUCT DEVELOPMENT
The majority of PD programs do not involve designing a product from “ scratch” (i.e.,
a totally new product) or a product of a type that did not exist before The process of
designing a product is therefore typically called the product development process in most industries (including the automotive industry) rather than the product design process However, the terms product development and product design are inter-
changeable and are used in the same context in many industries (After the product has been designed, the process of producing the product [i.e., manufacturing various systems and assembling the systems to create the whole product] is generally called
the production process [see Figure 1.1].)
Trang 32Introduction
P ROCESSES AND P HASES IN P RODUCT D EVELOPMENT
It is important to realize that any work is generally performed by using one or more processes A process usually involves inputs (e.g., raw materials, energy), equipment (one or more workstations with tools, machines, robots, or computers), and human operators that are conigured in a sequence of steps (operations or tasks) to produce
a speciied output Designing a product is also performed by using a process (deined earlier as the PD process) The PD process, depending on the complexity of the prod-uct, can involve many processes within and outside the organization (e.g., suppliers)
Customers
Customer needs government requirements business needs
Vehicle concept development
Design production, service, and marketing processes
Resources, e.g., people, equipment, $
Customer feedback
on vehicle concepts from market research clinics and user experience
Design production equipment and plant
Vehicle marketing, distribution and sales
Detailed design and engineering
Customer uses and experience
FIGURE 1.1 Flow diagram of automotive product development and production processes.
Trang 3310 Automotive Product Development: A System Engineering Implementation
responsible for developing the product PD processes vary due to differences in the products (i.e., their characteristics, functions, features, and demand volume), the type of PD program (e.g., refreshing an existing product or designing a totally new product), and the design organization (or company)
A generic process of product creation and use involves the entire product life cycle, which generally includes the following phases:
1 Pre-concept or pre-program (pre-program planning)
2 Product concept exploration (alternative concepts development)
3 Product deinition and risk reduction (feasibility analyses, preliminary design, and risk analysis)
4 Engineering design (detailed engineering design including testing)
5 Manufacturing development (process, tooling, and plant development)
6 Production (manufacturing and assembly)
7 Product distribution, sales, marketing, and operational support
8 Product updating or discontinuation and disposal
The irst ive of the above phases can be deined as the PD process, and the ifth and sixth phases can be considered as the production process It should be noted that the ifth phase of manufacturing development can be considered as the transi-tion from PD to manufacturing It is very important to include product manufactur-ing considerations (e.g., applications of “ design for manufacture” and “ design for assembly” methodologies) very early during the product design (i.e., during Phases
1 to 4, by implementing simultaneous [concurrent] engineering) to ensure that the transition in the ifth phase (involving designing of manufacturing processes and the creation of required tools and equipment in the manufacturing plants) occurs seam-lessly without changes in the PD in the later phases to meet production needs.The work in each of these phases is performed by undertaking specialized pro-cesses For example, the pre-concept phase can involve a process of understanding the customer, corporate needs, and regulatory requirements to decide on the type and characteristics of the new product (i.e., product speciication) and preparing a plan for the subsequent activities
Ulrich and Eppinger (2015) described the generic PD process with the following phases:
Trang 34Introduction
veriication tests (i.e., performance, reliability, and durability) and reinements of assembly processes, including training of the production workforce The production ramp-up phase involves the evaluation (validation tests) of early production outputs and the beginning of full operation of the production system
AUTOMOTIVE PRODUCT AS A SYSTEM
An automotive product is considered as a system that involves a number of lower- (or second-) level systems: the body system, the chassis system, the powertrain system, the fuel system, the electrical system, the climate control system, the braking sys-tem, and so on Each of the systems within the automotive product can be further decomposed into subsystems, sub-subsystem, sub-sub-subsystems, and so on, till the lowest-level components are identiied For example, the body system includes the body frame subsystem, the body panels subsystem, the closure subsystem (which includes the hood sub-subsystem, the doors sub-subsystem, and the trunk or liftgate sub-subsystem), the exterior lamps subsystem, the seats subsystem, the instrument panel subsystem, the interior trim components subsystem, and so forth
Table 1.1 illustrates the major systems, subsystems, and sub-subsystems or ponents within a typical automotive product The deinitions and contents of the various vehicle systems illustrated in this table can vary somewhat between differ-ent vehicle makes and models Further, the implementation of different technolo-gies used in performing different vehicle functions can have a major effect on the design of any vehicle system In fact, one of the challenges facing vehicle engineer-ing groups is how to divide the entire vehicle into different systems, subsystems, sub-subsystems, and so on and to assign design responsibilities to various engineer-ing teams This issue of division or decomposition of an automotive product for management of various PD activities and their interfaces is covered in Chapters 7, 8, and 12 and Appendix I
com-The key tasks of systems designers are to ensure that each system performs its functions and that the systems, through their interfaces with other systems, work harmoniously to meet the customer needs of the whole product Thus, the task of designing the vehicle requires a lot of understanding of systems and coordination between systems, their functions, and trade-offs between vehicle attributes to come
up with a balanced vehicle design, This issue is covered in more detail in Chapters 2 and 8
AUTOMOTIVE PRODUCT DEVELOPMENT PROCESS
W HAT IS A UTOMOTIVE P RODUCT D EVELOPMENT ?
The automotive PD process involves the designing and engineering of a future motive product The automotive product (i.e., a vehicle) can be a car or a truck or a variant such as a station wagon, a sports utility vehicle (SUV), or a van The manufac-turing and assembly operations are generally assigned to different groups However, selected representatives from manufacturing and assembly operations must actively participate in the teamwork during the PD process
Trang 35auto-12 Automotive Product Development: A System Engineering Implementation
TABLE 1.1
Major Systems and Their Subsystems in a Typical Automotive Product
Vehicle System
Subsystems of the
Body system Body-in-white Body frame, cross members, body panels, front and
rear fascia/bumpers Closures system Doors (door frame, exterior panels, hinges, latches,
inside trim panel power window mechanisms, door handles, window and mirror controls), hood and trunk-lid (or liftgate)
Seat system Driver’ s seat, front passenger seat, and rear seat(s) Instrument panel Instrument panel fascia, instrument cluster, switches,
glove box, brackets (for other components such as climate controls, entertainment and navigation controls and displays, passenger airbag) and trim components
Exterior lamps Front lighting system (headlamps and front signal
lamps), rear signal system (tail lamps, stop lamps, turn signal lamps, back-up lamps, license plate lamps, rear relectors), and side marker and clearance lamps
Glass system Windshield, backlite, side window glasses (also
called glazing surfaces )
Rear vision system Inside mirror and outside mirrors, camera systems,
and rear and side target sensing systems Chassis system Underbody frame work Front subframe, rear subframe (cradle), cross
members for mounting other chassis systems such
as steering system and brake system Suspension system Front and rear suspensions (includes arms, links,
knuckles, joints, springs, shock absorbers) Steering system Steering linkages, steering column, steering wheel
and stalk controls Braking system Brake disks/drums, brake pads and actuators, master
cylinder, and pedal linkages Wheels and tires Wheels and tires
Powertrain system Engine Engine block and cylinder heads, power conversion
system (pistons, connecting rods, crank shaft, bearings), intake and exhaust system, fuel supply system, engine electrical and control system, cooling system, and lubrication system Transmission Transmission casing, gears and shafts, clutches,
valves and linkages, sensors, lubrication and oil cooling system
Shafts and joints Drive shaft, universal joints, convel joints and
bearings Final drive and axles Differential casing, shafts, gears, and bearings
(Continued)
Trang 36Fuel system Fuel tank Tank, fuel system module (fuel pump, pressure valve,
fuel ilter, fuel level sensor), carbon canister, iller pipe and fuel cap
Fuel lines Fuel lines, hoses, and connectors Electrical system Battery Battery
Alternator Casing, rotor, and stator Wiring harnesses Wiring harnesses, connectors, and clips Power controls Switches, sensors, relays, electronic control units,
fuse box and fuses Climate control
system
Heater Heat exchanger, blower, air ducts, valves, and hoses Air conditioner Heat exchanger, compressor, valves, tubing, hoses,
and refrigerant Climate controls Controls and displays (for setting temperature, fan
speed, and mode) Safety and
security system
Air bag system Air bag units, sensors and actuators, wiring,
electronic control units Seat belt system Seat belts, belt anchors, belt buckles, belt movement
control mechanisms, sensors, and wiring Wiping and defroster
systems
Windshield wipers, wiper motors, wiper control system, defroster system, and defroster control system
Security lighting and locking systems
Exterior courtesy lamps, door locks, locking mechanisms, theft protection system, wiring and control units
Driver assistance systems
Collision avoidance systems such as automatic braking, lane-departure warning system, driver alertness system, and adaptive cruise control system Driver interface
and infotainment
system
Primary and secondary vehicle controls and displays
Driver controls and displays, wiring, and connectors
Audio system Audio controls and displays, audio chassis and circuit
board, antenna, wiring, USB port Navigation system Microprocessor, display, wiring, antenna, map
database, and data ports CD/DVD player CD/DVD player chassis and mechanism,
microprocessor, wiring, USB port
Trang 3714 Automotive Product Development: A System Engineering Implementation
“ fun to drive and use,” and “ pleasing” to the customers The vehicles also must have essary characteristics such as performance (i.e., operating capabilities), styling/appear-ance (form), quality (customer satisfaction), and craftsmanship (perception of being well made) The customers must “ enjoy owning the vehicles” — that is, the vehicles must have all the necessary attributes and the right features to meet their lifestyles
nec-F LOW D IAGRAM OF A UTOMOTIVE P RODUCT D EVELOPMENT
The vehicle development process generally begins with understanding customer needs and ends with the customers providing their feedback after using the vehicle Figure 1.1 shows the major phases in the vehicle development process along with the production, marketing, sales, and vehicle usage phases Based on an understanding
of customer needs, government requirements, and the business needs of the pany, a design team consisting of members from different disciplines (e.g., industrial designers, product architects, engineers, manufacturing personnel, product planners, and market researchers) generally develops attribute requirements at the vehicle level and creates the vehicle speciications The information is used by the team to develop one or more vehicle concepts (in the form of sketches, drawings, CAD models, mock-ups, or bucks) The vehicle concepts are iteratively improved by using customer feedback and suggestions by different team members and are market researched
com-to determine whether a leading concept can be selected for the detailed design and engineering work Based on the selected product design, manufacturing processes and suppliers are selected The production equipment and plants are designed and built or modiied for manufacturing and assembly Marketing, sales, and distribution plans are developed The early production parts and systems are assembled into pro-totype vehicles All entities, from components to major vehicle systems, are tested
to verify that they meet their respective requirements The assembled systems are installed into vehicle bodies, and prototype vehicles are created These prototype vehicles are further tested to verify and validate vehicle-level requirements Final approval to produce the vehicle is given by senior management, and the vehicle is
“ launched” (i.e., production begins) The produced vehicles are shipped to the erships for sale As the purchased vehicles are used by the customers, feedback from the customer experience (i.e., data from ield operating performance, customer likes/dislikes, vehicle repairs, and warranty work) are continuously collected and pro-vided for improving existing products and designing future products
deal-To support the entire vehicle development process, resources (e.g., dollars, people, equipment, and facilities) are needed Budgets and schedules are created to manage the entire PD process The organization begins to make money from revenues gener-ated from the vehicle sales The program management and inancial analysis issues are covered in Chapters 12 and 19
T IMING C HART OF A UTOMOTIVE P RODUCT D EVELOPMENT
Figure 1.2 provides a timing chart illustrating various activities during major phases
of an automotive PD program The length and location of the horizontal bars indicate duration and beginning and ending times of each activity within each program phase
Trang 38Introduction
2016 2017 2018 2019 2020 2021 Pre-program planning
Trang 3916 Automotive Product Development: A System Engineering Implementation
Automotive PD and subsequent life-cycle processes typically include the ing major phases, shown in Figure 1.2:
statement for the vehicle program, (b) determination of customer needs for the proposed vehicle, and (c) creation of basic speciications for the pro-posed vehicle Market research is conducted to determine market potential, customer needs, and characteristics of the proposed vehicle The vehicle deinition is reined and provided to the vehicle development team
made, the program manager and team members for vehicle development are selected The team gathers customer needs data, selects suppliers for key vehicle systems, and develops several alternate concepts (or theme vehicles) The vehicle attribute requirements and a business plan providing more detailed information about the proposed vehicle are developed (see Chapter 5 for more information on the business plan)
The design department develops a number of alternate concepts of the posed vehicle by creating many exterior and interior sketches and CAD drawings or models The package engineering department provides engi-neering support in terms of values of important exterior and interior dimen-sions to ensure that adequate space is provided for accommodating people, vehicle systems, and luggage/cargo areas To enable better visualization of alternate concepts, mock-ups and full-size exterior and interior bucks are created
from various management and technical reviews of the alternate concepts (including feasibility analyses) are discussed with the company senior manage-ment, and a vehicle concept is selected for detailed development in the subse-quent phases
conducted to ensure that all vehicle systems can be conigured and designed
to it within the exterior and interior surfaces created in the selected vehicle concept Detailed design and engineering of all systems and their lower-level systems and components are completed, and veriication tests are con-ducted to ensure that all attribute requirements are met
tools, equipment, and facilities needed to produce the vehicles are designed and constructed Installation and testing of production and assembly equip-ment in plants are completed to ensure that all entities within the vehicle can
be manufactured and assembled to produce vehicles at the planned tion rate and high quality (e.g., meeting all manufacturing tolerances and it and inish requirements) Early prototype/production vehicles are used for validation testing to ensure that the right product was produced
provided with the necessary information and training for sales, marketing, maintenance, and repair work of the vehicles
Trang 40Introduction
the vehicles meet all the attribute requirements Customer and management reviews are completed Plant equipment calibrations and production output quality are monitored during production The plant output is adjusted on an ongoing basis to match the vehicle demand through dealer orders and sales forecasts
retooled for the next vehicle model Obsolete and unneeded equipment is removed and disposed of
Preparation of vehicle and systems development timing plans is a very important activity in managing vehicle programs A proper amount of time must be allocated
to accomplish the hundreds of tasks performed by various design and ing departments The tasks must be carefully analyzed and selected to ensure that they are needed, and the time required for each of the tasks should be estimated by experienced and specialized professionals from each activity The product planning department generally takes the time estimates from all key design and engineering activities and creates an overall program timing chart, such as the one shown in Figure 1.2
engineer-UNDERSTANDING CUSTOMER NEEDS
The SE work begins with the deinition of the vehicle to be developed The vehicle deinition should include a description of its type (body-style), size (overall dimen-sions), and market segment (i.e., the market location and customer characteristics) The description should be as detailed and speciic as possible, as it will be used by all the team members (designers and engineers) involved in the vehicle development process
For the vehicle to be successful in the market, the vehicle deinition should be based on the needs of its customers This means that its prospective customers should be identiied, and their demographic and ergonomic characteristics and needs for speciic vehicle characteristics and features must be determined and used during the vehicle development process The description of the customer needs should be comprehensive and complete, in the sense that all aspects of the vehicle covered
by all the attributes of the vehicle must be obtained The customer needs should
be focused on the vehicle as a whole and not on its lower-level entities Chapter 3 provides more information on how customer needs and other needs arising from government requirements and corporate business needs are obtained and used in the
PD process
PROGRAM SCOPE, TIMINGS, AND CHALLENGES
S COPE OF V EHICLE D EVELOPMENT P ROGRAMS
An automotive PD program is initiated to modify and improve an existing vehicle design or to replace it with a totally new vehicle The modiications or changes can