After Teardown & Bill of Material generation, the mapped parameters can be utilized to perform various studies and analysis. The study reports and inferences from the analysis can be utilized by the representative of following departments of an OEM
- Cost Management Cell
- Engineering Design Team
- Program Team
- Production Engineering Team
This Part-3 of the blog will focus on the outputs from Data Analytics, BIW specific Weld & Thickness Mapping & Mounting philosophy for individual parts.
Based on the 20-25 parameters that are mapped for all the components in the entire bill of material, a list of analytics activities can be designed and later used to draw conclusion for weight saving & cost saving ideas.
For instance, we conducted detailed analysis on Door System and concluded many interesting value improvement ideas.
Following parameters were analyzed on 2 Vehicles (refer Fig 2 & 3):
Analysis on every parameter almost resulted in concluding at least 5 Value improvement ideas each. Out of all, one of the most critical observation is presented below, this idea was accepted and resulted in 17.8% cost reduction from the current design in the new vehicle design.
The above infographics (Fig 4) clearly shows that even though the Total Weight of Client’s Door Assembly is lower than the competitor, there is a huge potential of cost savings if we dig deep and look at the mounting hinges.
- To hang a 45Kg door assembly the competitor has used just 1Kg weight of hinges & on the other hand, the client is hanging the same door on the BIW using 1.9 Kg hinges.
- Now, if we look at the complexity the client is having a more complicated Door Assembly as it is using 16 mounting bolts on one side which the competitor is easily doing with 10 bolts of the same size.
The above 2 inferences show that there is potential for weight and cost savings by optimizing the design for the best use. As the 2 benchmarked vehicles are sold in the same region, the use cases will also be similar.
Similarly, when we analyze all the parameters in depth, we can come up with various mind-boggling ideas which can have huge cost benefits.
Spot welding is the dominant joining method in BIW assembly, the position, shape, and sequence of welding has a huge impact on the quality (Dimensional Stability) of the final BIW ready for paint. Also, if the quality does not match the exact design, the deviation might result in a bad correlation between the simulation and actual crash CAE results. Hence, our analysis or rather data mapping of weld info for the entire BIW and individual parts can help in understanding how the competitor is planning to avoid any such manufacturing errors. It also helps in optimizing the no. of spot welds, weld length and weld size and provide thickness and position benchmark values of spot welds for design engineers.
Following (Fig: 5) is a small example that showcases the data that we map from individual parts:
If required, the weld location can be analyzed for HAZ (Heat Affected Zone), microstructure analysis, weld material identification etc.
Work hardening and thinning behavior of BIW panels have a huge impact on crash performance and durability of BIW assembly. OEM’s spend a huge amount of time in ensuring that while designing the effects of formability is considered. Few OEM’s have started controlling the thinning % and wrinkling effect with quantified targets on BIW panels. As the thickness profile of all the strategically placed panels in a BIW is critical, we have started studying the thinning behavior of sheet metal panels and showcase them in the following manner. Ultrasonic thickness gauge or microscopic thickness layer study is used from case to case basis to study thickness map. The main focus is on use of advanced material for weight saving by thickness reduction. Refer the Fig: 5 for sample Thickness Mapping data.
With the competition growing, OEM’s can’t take a chance of losing customers due to increased waiting period of its models. In order to have a quick delivery time, the production in sync needs to be faster. Hence, there is a constant quest for reducing the total no of parts per vehicle (complexity reduction) & making the design such that it is easy to assemble and leads to reduced takt time. Now, in this section we provide a study that deals with the mounting philosophy of components on the BIW. This includes, locus of assembly, tool utilization, no of steps for assembly, no of mounts etc. This provides mounting method ideas to design engineers.
The following 2 examples show the brief idea about the mounting philosophy study (refer Fig 6 & 7). Detailed time & production engineering specific study can be conducted and presented on demand.
With all the information that we produce while BIW teard0wn activity, the data can be utilised as a benchmark to reduce the overall automotive product development time by 23.7%. The activities are agile and very specifically designed based on the final objective.