Automotive product development : A systems engineering implementation

Automotive Product

Development

Automotive Product

Development

A Systems Engineering Implementation

by

Vivek D. Bhise

CRC Press

Taylor & Francis Group

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Library of Congress Cataloging- in- Publication Data

Names: Bhise, Vivek D. (Vivek Dattatray), 1944- author.

Title: Automotive product development : a systems engineering implementation

/ Vivek D. Bhise.

Description: Boca Raton : Taylor & Francis, a CRC title, part of the Taylor &

Francis imprint, a member of the Taylor & Francis Group, the academic

division of T&F Informa, plc [2017] | Includes bibliographical references

and index.

Identiiers: LCCN 2016037644| ISBN 9781498706810 (hardback : alk. paper) |

ISBN 9781498706841 (ebook : alk. paper)

Subjects: LCSH: Automobiles--Design and construction. |

Automobiles--Technological innovations. | Systems engineering.

Classiication: LCC TL240 .B54 2017 | DDC 629.2068/5--dc23

LC record available at https://lccn.loc.gov/2016037644

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v

Contents

Preface.....................................................................................................................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

vi Contents

Importance, 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

Contents vii

Chapter 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

viii Contents

Chapter 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

Contents ix

Concluding 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

x Contents

Product 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

Contents xi

Program 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

xii Contents

Scope 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

Contents xiii

SECTION 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

xiv Contents

AHP 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

Contents xv

Costs 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