introduction to automotive industry 28/08/2003coy013.pdf · vw brasil prevost dina masa ... gm ford...

Introduction to Automotive Industry 28/08/2003

Chalmers International Masters Program -Automotive Engineering 1

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Chalmers University of TechnologyGöteborg, Sweden

© Urban KristianssonMachine and Vehicle Design

Course “MMF001Introduction to Automotive Engineering”

Automotive AreasAn Automotive Company

Product & Process Development Organisation

Development of a Product

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Automotive EngineeringAutomotive Areas

• Transports

• Companies / Products– Buses– Cars– Construction Equipment– Fork Lifts– Military– Trucks

Not Covered- Agricultural- Forrest- Gardening- Mining- ...

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Automotive Engineering ? Automotive Areas

Transports, page 1(4)

Traffic &Infrastructure

GroundVehicles

Transportof

Humans &Goods

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Transports ? Humans & Goods, page 2(4)

Humans Goods

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Transports ? Traffic & Infrastructure, page 3(4)

On-Road

Off-Road

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Transports ? Ground Vehicles, page 4(4)

Vehicles

Components



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Automotive Engineering ? Automotive Companies & Products

Companies / Products ? Buses, page 1(4)

Citybuses

MicrobusSchoolbus

Coaches

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Companies / Products ? Bus Production, page 2(4)

Daimler- Volvo MAN RVIChrysler

25

20

15.103

10

5

Heavy Medium Midi Mini Micro>16 12-16 8-12 5-8 3,5-5

100

.103

50

World MarketProduction >12 tons

Excl. Producers in E.Europe, China & India

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Companies / Products ? Bus Brands (>12 tons), page 3(4)

HinoIsuzuIveco

MANDaimlerChrysler

RVI

ScaniaVolvo

Nova Bus

VW Brasil

Prevost

DINAMASA


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Companies / Products ? Bus Groups (>12 tons), page 4(4)

VW Brasil

VolvoCarrus

HenleysNova Bus

MASAPrevost

Steyr BusVolvo

RVIKarosaHeulitzRenault

IVECOFiat

MagirusPegaso

DAIMLER-CHRYSLER

MercedesSetra

Hino

IsuzuMAN

DinaDinaMCI

EvoBus =

IVECO + RVI = IRIS

Scania


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Companies / Products ? Cars, page 1(4)

Sedan

Pick-up Truck

Sport-Wagon Sport-Utility

Mini Van

LuxurySedan

Estate

Racing

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Companies / Products ? Car Production, page 2(4)

GM Ford Toyota Volkswagen Daimler-Chrysler

390 345 70 310 460 .103 Employees

8

6.106

4

2

1999

1998



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Companies / Products ? Car Brands, page 3(4)

AcuraDaihatsuHondaInfinityIsuzuLexusMazda

MitsubishiSubaruSuzukiNissanToyota

Alfa Romeo Ferrari

FiatLamborghini

LanciaMasserati

AudiBMWFordOpel

Mercedes PorscheSmart

VolkswagenCitroënRenaultPeugeotTalbot

SaabVolvo

Seat

Skoda

Aston MartinBentleyJaguar

Land RoverLotusMini

Rolls RoyceRover

Vauxhall

Buick Cadillac

Chevrolet ChryslerDodgeFordGM

GMCJeep

Lincoln Mercury

OldsmobilePlymouth

PontiacSaturn

Daewoo Hyundai

KiaSamsung

A Brand haveseveral Models

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Companies / Products ? Car Groups, page 4(4)

Porsche

InfinityNissanRenault

Samsung

Hyundai

FORDAston Martin

FordJaguar

Land RoverLincolnMazda

MercuryVolvo

PSACitroënPeugeotTalbot

VWAudi

BentleyLamborghini

SeatSkoda

Volkswagen

BMWMini

Rolls RoyceAlfa Romeo Fiat

LanciaMasserati

DAIMLER-CHRYSLER

DodgeChrysler

JeepMercedes

Mitsubishi MCPlymouth

Smart

TOYOTADaihatsu

LexusToyota

Lotus

DaewooKia

AcuraHonda

Ferrari

GMBuick

CadillacChevrolet

GMCIsuzu

OldsmobileOpel

PontiacSaab

SaturnSubaruSuzuki

Vauxhall

The Global Five

Rover

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Companies / Products ? Construction, page 1(3)

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Companies / Products ? Construction Brands, page 2(3)

Hitachi Komatsu

Volvo

CaterpillarDeere

Case New HollandIngersoll-Rand / Melroe

Terex

JCBLiebherr

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Companies / Products ? Construction Groups, page 3(3)

Komatsu

Deere

JCB

Liebherr

Caterpillar

Melroe 2)

Hitachi

Others

Market Shares 1999

Volvo

Terex

CNH Global 1)1) Case New Holland Global2) Ingersoll-Rand / Melroe

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Companies / Products ? Fork Lifts, page 1(4)

Electric or InternalCombustion Engine

Counterbalance

Warehouse



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Companies / Products ? Fork Lift Production, page 2(4)

100.000

Counterbalance with Internal

Combustion Engines

Counterbalance with Electric Propulsion

Warehouse

Global MarketUnits 1998

100 000

400 000

400 000

Ware - Counter-house balance

West Europe 230 220North America 170 250Rest of World 10 20

Source BT

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Companies / Products ? Fork Lift Brands, page 3(4)

KomatsuToyota

AtletBT

Kalmar

JHLinde

ClarkNACCO

MCF

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Companies / Products ? Fork Lift Groups, page 4(4)

JHFenwick (E)

JungheinrichLancer Boss

MICSteinbock

LindeBaker

FenwickFiat OMLansingLinde

PimespoSaxby

StillWagnerAtlet

ToyotaBT

CesabLift -Rite

Prime-MoverRaymond

Toyota

KalmarAllis-Chalmers

ClimaxIrion

KalmarLarfSisu

NACCODeca

HysterNissanOrmicYale

MCFCaterpillarMitsubishi

ClarkBlue Giant

ClarkSamsung

Komatsu

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? / Products ? Military, page 1(1)

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Companies / Products ? Trucks, page 1(4)

Light Trucks<12 ton

Heavy Trucks>16 ton

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Companies / Products ? Heavy Truck Production, page 2(4)

DaimlerChryslerVolvo (+RVI)

PACCARNavistar

ScaniaMANIveco

Mitsubishi Fuso T&BHino

Nissan DieselIsuzu

CumminsCat/Perkins

Volvo (+RVI)Detroit Diesel

DaimlerChryslerScaniaIsuzu

MANIvecoDAF

Mitsubishi Fuso T&BNissan Diesel

Hino

50 100 150 200Heavy Trucks Diesel Engines

50 100 150




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Companies / Products ? Heavy Truck Brands, page 3(4)

HinoIsuzu

Mitsubishi Fuso T&BNissan Diesel

Iveco

MANMercedes

Renault VI

ScaniaVolvo

FodenFreightlinerKenworth

MackNavistarPeterbiltSterling

DAF

TelcoAshok Leyland

Excl. Producers in E.Europe & China

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Companies / Products ? Heavy Truck Groups, page 4(4)

Nissan Diesel

VolvoMack

Renault VIVolvo

Ashok LeylandIveco

DAIMLER-CHRYSLER

FreightlinerMercedesSterling

Telco

Hino (Toyota)

PACCARDAF

FodenKenworthPeterbilt

Navistar

Mitsubishi Fuso T&B

Isuzu

Scania

Excl. Producers in E.Europe & China

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Companies / Products ? Suppliers (a few of the big), page 1(1)

Aisin AW AlpineDensoHitachiMelco

SumitomoToshiba

Toyoda ...Yazaki

MarelliPirelli

BroseContinental

DeutzHella

MannesmannRobert Bosch

SiemensVDOZF

MichelinValeoSagem

Autoliv

LucasPilkingtonAllison

Detroit DieselCummins

DanaDelco Remy

DelphiEaton

GoodyearJohnson Controls

LearMotorola

TRWVisteon

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Automotive Areas

An Automotive CompanyProduct & Process Development Organisation


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Automotive EngineeringAn Automotive Company

• Units

• Staffs

• The Industrial System

• The Commercial System

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Automotive Engineering ? An Automotive Company

Units, page 1(1)

Staffs:* Business & Product Strategy* Human Resources* Economy & Finance* Information* Quality

ProductDesign

Product&

ProcessDevelopm.

Manu-facturing

MaterialSourcing

&Purchasing

Marketing MarketAreas

AfterSales

VehicleDistribution

CEO orPresident

Board

Industrial System Commercial System

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Staffs ? Business & Product Strategy, page 1(6)

Activities:• Make Near- & Long-Term Business Plan• Monitor Business Environment• Identify Business Ideas• Make Letter of Intent for Business Opportunities• Manage early Cross-Functional Concept Studies

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Make Near-&

Long-TermBusiness Plan

A Business Plan Focus:

• Market Plan, Incomes & Expenditures linked to Product

• Carry Through Plan, Development Cost & Investments linked to the Product

Near-Term Business Plan:

• Maintain Present Products, e.g.:

– Increase Sales in Market A & Decrease in Market B– Upgrade Vehicles with a Feature

Long-Term Business Plan:

• Develop Product Program up to 10 years ahead, e.g.:– Establish a Dealerships in a new Market

– Introduce a new Powertrain in Vehicle A

A Business Planis Based on

a Business Idea(i.e. which Advantages

will the Productgive the Company

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Suppliers

LegislationAuthorities

Competitors

CustomersGeneral Opinions

in Society

Other Forces

New TechnologyCompany

MonitorBusiness

Environment



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IdentifyBusiness

Ideas

Moral Individualist TechnologyConformity Adopters

LifestyleOrientation

SocialStatus

Upper

Middle

Lower

EstablishedElite

ReactivePragmatism

TraditionalMiddle-class Aspiring

Acquires

They are YoungThey are ManyHave God EconomyThey will want Cars with ...

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MakeLetter of Intent

forBusiness

Opportunities

Example of Content in Letter of Intent:• The Company's Current Position• Business Environment for the Company• Brand Vision and Mission• The Brands Product Profile• Business Objectives with the Proposed Product• Conditions for Success• Business Environment for the Product• Customer Description• Product Characteristics

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Manageearly

Cross-FunctionalConceptStudies

IndustrialSystem

CommercialSystem

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Staffs ? Human Resources, page 1(1)

Activities:• Assure Recruitment of Competencies

– Contacts with Schools and Students

– Training Program for Leaders and Specialists

• Co-operation with Authorities in Development of Education’s • Employer Questions

– Relations with Unions for Salaried Employees and Labours

– Policies for Salary and Wages

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Staffs ? Economy and Finance, page 1(1)

Activities:• Business Administration Process• Economic Planning and Control• Internal Revision• Business Accounting• Taxes

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Staffs ? Information, page 1(1)

Activities:• Investors Relations• Public Affairs (e.g. Authorities)• External Communication (e.g. Press and other Media)• Internal Communication (e.g. magazines)• Product Communication (e.g. a Brands Core Values)



Slide 43 /




Staffs ? Quality, page 1(1)

Activities:• Quality Development• Audits

– Internal Operations

– Customer Satisfaction

• Quality Assurance of Product Projects• Legal Requirements• Environmental Requirements

Targets&

Fulfilment

It is Not ...

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The Industrial System ? Product Design, page 1(1)

Activities:• Exterior Design• Interior Design

From “Old Fashion” Clay Modelsto

Computer Models (e.g. in Alias)

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The Industrial System ? Product & Process Developm., page 1(1)

Activities:• Secure Long-term Industrial Competence via

Research & Advanced Engineering• Carry Through Industrial Part in Product Projects

– Develop and Verify the Product– Develop and Verify the Production Process

Product & ProcessRequirements

Product & ProcessDevelopment

Theoretical & PracticalVerifications:

* Proving Grounds* Crash* EMC

* …* Pilot Plant

Design &Documentation of

* Hardware* Software

* TestQuality Assurance

Documentationfor

MaterialSourcing

&Purchasing

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The Industrial System ? Material Sourcing & Purchasing, page 1(1)

Activities:• Procure Material for Product and Production Process• Logistics

– Material Supply to Factories

– Material Supply of Spare Parts

• Quality Assure Suppliers

VehicleManufacturing

2nd TierSuppliers

Service &Repair

1st TierSuppliers

Raw Material

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The Industrial System ? Manufacturing, page 1(1)

Activities:• Body Assembly• Paintshop• Final Assembly

VehicleVerification

SoftwareDownload

DrivingUnit

Marriage PointBody &

Powertrain

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The Commercial System ? Vehicle Distribution, page 1(1)

Activities:• Transport Logistics• Customs• Insurance's and Claims

Adjustment



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The Commercial System ? Marketing, page 1(1)

Activities:• Brand Development• Market Research

– Customer Data

– Competitor Analyse– Sales Forecast

• Advertising & Sales Promotion• Exhibitions• Events & Sponsoring• Dealer Network Research

Examples:Internet SalesEntertainment Centres

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The Commercial System ? Market Areas, page 1(1)

Activities:• Support & Follow-up Sales Companies• Sales Companies Support & Follow-up

Dealers• Assure Brand Profile at Sales Outlets &

Workshops

Example:A Market Area is South AmericaA Sales Company is BrazilA Dealer may have Several Sales Outlets & Workshops

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The Commercial System ? After Sales, page 1(1)

Activities:• Spare Part Supply• Methods, Tools &

Equipment for Workshops

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Automotive Areas

An Automotive Company

Product & Process Development OrganisationDevelopment of a Product

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Automotive EngineeringProduct & Process Development Organisation

• Units

• Staffs

• Line Organisation

• Project Organisation

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Automotive Engineering ? Product & Process Development Organisation

Units, page 1(1)

Staffs:* Human Resources* Economy* Quality* Operational Support

CompleteVehicle

Engine &Transm .

ChassisBody Interior &Exterior

VehicleVerifi.

ProductionProcess

Electrical

Head ofProduct & Process

Development

ProjectOffices

Project Organisation & Line Organisationuse the same Resources

Development=

ResearchAdvanced Engineering

Engineering

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Staffs, page 1(1)

Activities at Operational Support:• Product Project Support

– Entry Ticket– Product Cost

– Proposals and Orders

– Time Plans

– Resource Plan

• Variant and Product Documentation• Structure for Articles (Hardware & Software)• Standards

Activities atHuman Resources

Economy&

Qualityare almost

Similaras forStaffs

onCompany Level

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Line Organisation ? Complete Vehicle, page 1(8)

MainlyCo-ordinating

&Balancing

ofActivities

at all otherUnits

Activities• Technology Strategies• Competitor Analyse• Vehicle & Process Requirements• Vehicle & Process Concept Development

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Line Organisation ? Body, page 2(8)

Development of:• Crash Structure, Floor, Upper Body,

Corrosion, Sealing, Paint & FinishAlumina

SpaceframeAudi A8

MonococueBMW 5



Slide 61 /




Line Organisation ? Engine & Transmission, page 3(8)

Development of:• Engine• Gearbox• Axis• Differential• Cooling 2010

1990

1970

NOx

HC

CO

Slide 62 /




Line Organisation ? Chassis, page 4(8)

Development of:• Vehicle Dynamics, Brakes, Wheel

Suspension, Wheels, Steering

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Line Organisation ? Electrical Engineering, page 5(8)

Development of:• Computer/IT/Software

Network, Electric Power & Distribution, Sensors/Control Units/Actuators, Information, Audio & Communication, Electromagnetic Compatibility (EMC)

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Line Organisation ? Interior & Exterior, page 6(8)

Development of:• Dashboard, Seats, Surface Materials,

Climate, Doors, Hatches, Lighting, Glass

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Line Organisation ? Vehicle Verification, page 7(8)

Activities:• Verification of Vehicle Properties,

Requirements and Quality• Proving Grounds• Laboratories (e.g. Crash, Wind-

Tunnel, Chassis Dynamometers, EMC, Thermodynamics, Climate, Noise & Vibrations, Materials)

• Field Tests• Measurement Technology• Vehicle Workshops

Example on Tracks:High-Speed, Durability,

Skidpad, Bracking, Comfort,Corrosion, Handling, Low

friction & Handling, Slopes,Gravelroad, City traffi,

Construction site, ...

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Line Organisation ? Production Process, page 8(8)

Activities:• Development of Production Process Methods and

Equipment (e.g. Welding Machines, Robots for Painting, Gluing, Software Download)

• Verification of Production Process– Body Assembly

– Paintshop– Final Assembly



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Project Organisation, page 1(2)

Activities:• Management & Engineering of:

– Vehicles

– Production Process

– Material Supply– Service & Repair

Vehicle

Production Process

Material Supply

Service & Repair

Main Time Schedule

Slide 68 /




Project Organisation, page 2(2)

Project Organisation Line Organisation

DepartmentSectionGroup

ProjectLeader

Platform, Vehicle,Module, Component

Head of PPD

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Automotive Areas

An Automotive Company

Product & Process Development Organisation


Slide 74 /



Automotive EngineeringDevelopment of a Product

• Development Phases

• Project Follow Up ? Score Cards

• Product Requirements

• Organisation of Project Work

Slide 75 /



Automotive Engineering ? Development of a Product

Development Phases, page 1(3)

Focus:* Business Case* Project Targets

* Markets &Customers* Product

Characteristics &Functions

* Exterior &Interior Design

Concept Pre-study Industrialisation

Focus:* Project Economy &

Planning* Geometry &

Software Assurance* System &

Component Design* Production Process

Layout & Design* Supplier Structure

Focus:* Project Management

* Product, System &Component Engineering

* Production ProcessEngineering

* Supply of Material* Service & Repair Equipment* Product, Production, Supply

of Material & DealershipVerification

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Concept Pre-study Industrialisation

Development of Proposal for Next Phase(s)Agreement between Customer & Supplier for Next Phase(s)

Estimated Carry ThroughCarry Through

Slide 77 /



Pre-study



Concept Industrialisation

Important Milestones:Start Proposal Proposal S o P

Quality

Service &Repair

Production Process &Supply of Material


BusinessIdea Product

Strategy

Research & Advanced Engineeringfeed the Processes in Due Time

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Project Follow Up ? Score Cards, page 1(5)

Example on Score Cards:• Quality Status• Product Properties• Economy• Product Cost



Slide 79 /




Project Follow Up ? Score Cards, page 2(5)QualityStatus

Milestones:Start ... Prop. … Prop. ... SoP

Product StrategyEconomy

Product EngineeringProduction ProcessSupply of MaterialMarketing & Sales

Service & Repair

Deviations areExplained

Potential Risksare HighlightedCurrent Time

OkTo be ObservedCritical

Slide 80 /





ProductProperties

ReferenceWorse Vehicle Better

Quality

Crash Safety

Environment Impact

Fuel Economy

...

Ergonomics

Actual SituationRequirement

Slide 81 /





Economy

-4 -3 -2 -1 TimeStartof

Production

+1 +2 +3 +4

Cost forEmployees &

Material

Investmentsat Factories &

Suppliers

Cost forMaterial

Cost for Distribution,Sales Promotion & Taxes

Incomesfrom Sales

Cost forProduction

Slide 82 /





ProductCost

Current

Objective SituationEngine:

• Block x x

• … x x

Electrical

• Alternator x x

• … x x

Grand Total x xTime-4 -3 -2 -1

Current Time

ForecastTarget

AchievedResult

Slide 83 /




Product Requirements, page 1(10)

• Functional• Geometry• Software

• Focuses during Development Phases

Slide 84 /




Product Requirements ? Functions, page 2(10)

Example on Functional Areas and Functions:• Safety

– Safety Belt Pretension– ...

• Handling– Active Yaw Control

– …

• Powertrain– Engine Preheating

– ...

• Driver Information – Ambient Temperature– ...

• External Signals– Turn Indication

– …

• Comfort– Driver seat Heating

– ...

Thereare

SeveralHundred

Functionsina

Vehicle



Slide 85 /




Product Requirements ? Functions, page 3(10)

ECU1ECU2

ECU4

ECU3

Mechanics Mechanics El

Cust.

FKBFD

SKBSKB

SKBSD

KFKF

KFKF

CD

System

Functions

Components

Function A Function B

El

Slide 86 /




Product Requirements ? Geometry’s, page 4(10)

LegalRequirements

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ModularizationBody Architectures

PowertrainOptions

DrivingUnit

Energy Storage's

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Packaging



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SolidModels



Slide 90 /




Product Requirements ? Software, page 8(10)

ECMECMTCMTCM

ABSABS

= low speed

High speed Low speed



Slide 91 /




Product Requirements ? Software, page 9(10)

CRB SW(Change Request Board)

* Co -ordinate Testing* Recommend Release

DRM SW(Design Review Meeting)

Decide Release of Software

CRB are Logging* Version of SW in Vehicles* Problems and their Priority

Manning of CRBEach ECU (Electronic Control Unit) connected to

the Network has a Representative in CRB

Slide 92 /




Product Requirements?Focus during Development Phases, page 10(10)

Pre-studyConcept Industrialisation

FUNCTIONS

GEOMETRIES

SOFTWARE

Nomore

Changes!=

Slide 93 /




Organisation of Project Work, page 1(5)

Activities:• Design for Assembly and Disassembly• Modules and Components• Development Means

– Decision Structure– Main Time Schedule

Slide 94 /





Dealer

Disassembly1st Tier Supplier

2nd Tier Supplier

Raw Material Energy Production

Time (Each Car = New User)

Re-use

Service &Repair



Design forAssembly &Disassembly

Raw Material

Re-use

Slide 95 /






2nd TierSuppliers

1st TierSuppliers

Modules &Components

...

...

SW

Modules

DrivingUnit

Components

Slide 96 /





ProjectOrganisation

LineOrganisation

PlatformLeader

Head of PPDDevelopment Means ?

Decision Structure

Vehicle 1Leader

Vehicle 2Leader

Module 1Leader

Module 2Leader

Comp. 1Leader

Comp. 2Leader

Head of S & P

Head of Manuf.

Head of After S.

A Module Team:* Is Responsible for a Delivery Unit

to Vehicle Manufacturing* Involves Competencies from:

- Product & Process Development- Sourcing & Purchasing- Manufacturing- After Sales



Slide 97 /





Development Means ?Main Time Schedule Vehicle

Production Process

Material Supply

Service & Repair

Main Time Schedule

Every Leader has a TimeSchedule which Clarifies:* Links to Main Time Schedule* Critical Line* Milestones to be Followed -up

The Industrial part of the Main TimeSchedule Highlights:* Milestones in the Quality Assurance Plan* Verifications of:

- Test Vehicles- Material Supply- Production Process- After Sales

* Dead-lines between Suppliers & Customers* Heavy Investments

introduction to automotive industry 28/08/2003coy013.pdf · vw brasil prevost dina masa ... gm ford...

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