A systems approach to the development and use of FMEA in complex automotive applications

YesThe effective deployment of FMEAs within complex automotive applications faces a number of challenges, including the complexity of the system being analysed, the need to develop a series of coherently linked FMEAs at different levels within the systems hierarchy and across intrinsically interlinked engineering disciplines, and the need for coherent linkage between critical design characteristics cascaded through the systems levels with their counterparts in manufacturing. The approach presented in this paper to address these challenges is based on a structured Failure Mode Avoidance (FMA) framework which promotes the development of FMEAs within an integrated Systems Engineering approach. The effectiveness of the framework is illustrated through a case study, centred on the development of a diesel exhaust aftertreatment system. This case study demonstrates that the structured FMA framework for function analysis supports an effective decomposition of complex interdisciplinary systems facilitating the DFMEA deployment through a series of containable, structured DFMEAs developed at successive system levels, with clear vertical integration of functional requirements and critical parameters cascade. The paper also discusses the way in which the approach supports deployment across engineering disciplines and domains, ensuring the integrity of information flow between the design and manufacturing activities

Integrated Environmental Process Planning for the Design & Manufacture of Automotive Components

Advanced Product Quality Planning (APQP) logic is widely used by manufacturers for the design and manufacture of automotive components. Manufacturers are increasingly finding difficulties to incorporate environmental considerations in the broad range of products that they manufacture. Therefore, there is a need for a systematic method for environmental process planning to evaluate product configurations and their associated environmental impact. The framework and models discussed in this paper can deal with a variety of product characteristics and environmental impacts through a selection of Environmental Performance Indicators (EPIs) for a final product configuration. The framework and models have been applied in a real-life application and have proven that changes in product design or process selection can reduce the product's environmental impact and increase process efficiency. Hence, manufacturers can use the framework and models during the Advanced Product Quality Planning (APQP) process to benchmark each product variation that they manufacture in a standardised manner and realise cost saving opportunities

Efficient Memory-Protected Integration of Add-On Software Subsystems in Small Embedded Automotive Applications

Current innovations in the automotive industry evolve mainly in the electronics and software domain. This leads to an increasing integration of additional software subsystems into already existing electronic control units (ECUs) to cope with the raised amount and complexity of present ECUs in modern high-end vehicles. This paper discusses different approaches which are required to integrate such add-on software subsystems in an isolated memory domain, and considers particularly the special needs of small embedded systems—including the limited hardware support. Special focus is brought to the efficient detection of malicious memory accesses, as well as the benefits of a thereupon possible and adaptable failure-handling strategy. All investigations are based on a developed memory-protection framework which has been tailored to the special needs of a sample vehicle dynamics control system. Its usage allows the combination of. integrating additional subsystems without reducing the main application’s availability

An assembly oriented design framework for product structure engineering and assembly sequence planning

The paper describes a novel framework for an assembly-oriented design (AOD) approach as a new functional product lifecycle management (PLM) strategy, by considering product design and assembly sequence planning phases concurrently. Integration issues of product life cycle into the product development process have received much attention over the last two decades, especially at the detailed design stage. The main objective of the research is to define assembly sequence into preliminary design stages by introducing and applying assembly process knowledge in order to provide an assembly context knowledge to support life-oriented product development process, particularly for product structuring. The proposed framework highlights a novel algorithm based on a mathematical model integrating boundary conditions related to DFA rules, engineering decisions for assembly sequence and the product structure definition. This framework has been implemented in a new system called PEGASUS considered as an AOD module for a PLM system. A case study of applying the framework to a catalytic-converter and diesel particulate filter sub-system, belonging to an exhaust system from an industrial automotive supplier, is introduced to illustrate the efficiency of the proposed AOD methodology

Framework for the Integration of Service and Technology Strategies

Organised by: Cranfield UniversityAfter sales service is a highly profitable business for manufacturers of technology-driven products. Due to this fact competitors want to share in high profit margins. At the same time after sales business has to deal with an increasing range of variants of products and technologies, shorter life cycles and changing customer demands. In spite of these manifold challenges, often neither after sales departments are involved in the early product development stage nor are customer demands and technical parameters considered in the service development processes entirely. Therefore an integration of service and technology strategies is necessary. This paper presents a framework for this integration that visualises the complex interdependencies and interfaces between service as well as product and motor vehicle workshop technologies.Mori Seiki – The Machine Tool Compan

East Midlands Transport Equipment Sector Strategy

Transport equipment has been identified as a key sector in the East Midlands economy. This strategy sets out a vision for the development of the sector and how it can contribute to the attainment of regional economic development objectives

Product to process lifecycle management in assembly automation systems

Presently, the automotive industry is facing enormous pressure due to global competition and ever changing legislative, economic and customer demands. Product and process development in the automotive manufacturing industry is a challenging task for many reasons. Current product life cycle management (PLM) systems tend to be product-focussed. Though, information about processes and resources are there but mostly linked to the product. Process is an important aspect, especially in assembly automation systems that link products to their manufacturing resources. This paper presents a process-centric approach to improve PLM systems in large-scale manufacturing companies, especially in the powertrain sector of the automotive industry. The idea is to integrate the information related to key engineering chains i.e. products, processes and resources based upon PLM philosophy and shift the trend of product-focussed lifecycle management to process-focussed lifecycle management, the outcome of which is the Product, Process and Resource Lifecycle Management not PLM only