Unit 1 Basic Concepts and Consideration in BIW

REQUIREMENT SPECIFICATION IN PRE PROGRAM STAGE: -

Identify the key points required to generate the basic program information
INTRODUCTION TO PRE-PROGRAM STAGES:

1) Voice of Customer
2) Competitor Insight
3) Innovation
4) Project and Quality Planning
5) Legislation
Which defines a strategy and leads to the final product?

1) VOICE OF CUSTOMER
VOC is the customers voice, expectations, preferences, comments of a product or of a service in
discussion. In short it is the statement made by customer on a particular product or service.
Or VOC is the customer service expectations references comments of product or service in discussion
it is the statement metabolic the customer on particular product or service.

This study investigates internal and external sources of innovative ideas and the use of voice of
customer (VOC) methods in the German automotive industry. This implies actual needs and wants of
customer.

There are different techniques to find out the voice of customer some of these are explained below
–
Methods of data collection
 2) COMPETITOR INSIGHT
It is identifying your competitors and evaluating their strategies to determine their
strength and weakness relative to those of your own product or service. or
Based on customers’ needs and reviews of competitive products, the team /OEM
establishes the target specifications at the prospective new product.
Definition: -
Identifying your competitors and evaluating their strategies to determine their
evaluating their strategies to determine their strength and weakness relative to
those of your own product or service.
A competitive analysis is critical part of your company marketing plan.
It is a common market research activity that is performed to identify opportunities
and risks associated with strategies such as a new product.
It's a study and research of the automobile available in the market based on
features, comfort, cast and safety etc.
SWOT ANALYSIS: -
A study undertaken by an organization to identify its internal strengths and
weakness, as well as its external opportunities and threats related to business
competition or project planning.
It is intended to specify the objectives of the business venture or project and
identify the internal and external factors that are favorable and unfavorable to
achieving those objectives. Users of the SWOT analysis often ask and answer
questions to generate meaningful information for each category to make the tool
useful and identify their competitive advantage. Swot has been described as the tried
and true tool of strategic analysis.
1. STRENGTHS: -

1) We have superior customer service

2) qualified mechanics

3) quality repair services at better value

4) trusted repairs with large customer base

5) well-known brand name

6) abundant financial resources

7) better marketing skills

8) committed employees

2. WEAKNESS: -

1) high liability

2) risks involved with unsupervised work

3) possible injuries due to equipment involved

4) open to law suits if not careful

5) weak or less spending on R and D

6) higher costs

7) limited management skills

8) limited financial resources

9) poor marketing skills

10) under trained employees

3. OPPORTUNITIES: -

1) The increase in evolution of cars often times resort to specialized training. Repair shops can gain an
edge by staying current.

2) Hybrid and electrical vehicles are bringing new opportunities to the market

3) service providers can influence and gain marketing efficiency

4) rapid market growth

5) changing customer needs

6) new uses for product discovered

7) sales decline for a substitute product

4. THRETS: -

1) Labor and overhead cost

2) competitiveness in the automotive industry

3) economy

4) financial stability

5) entry of foreign competitors

6) introduction of new substitute products

7) product life cycle is decline

EVOLUTION IN CAR
 3) INNOVATIONS
It is an idea which makes existing things smarter, better and faster.

Let's see the innovation ERAS of an automobile

1)R AND D: - The most important aspect was the evolution in the engine

2) embedded ERA: - company started adding entertainment system and various sensors

3) infotainment ERA: -navigation and tracking, company added the GP’s system in the vehicle

4)V2X ERA: -vehicle to vehicle communication using sensors

5) new mobility ERA: - IN near future we will see the self-driving cars

10 INNOVATIONS IN THE AUTOMOBILE INDUSTRY 2014

1) Google driverless cars

2) automated manual transmission (AMT)

3) v 2 v communication

4) pre collision technology

5)smart cars

6) Ford aluminum truck

7) start stop technology (I smart)

8) bus powered by human waste

9) Land Rover invisible car

10) Toyota's hovering car

VEHICLE 2 VEHICLE COMMUNICATION

DRIVERLESS CAR

4) PROJECT AND QUALITY PLANNING (PQP)

1. Quality management plan
2. Quality assurance plan
3. Project quality management plan

Is a project specific quality plan that describes the activities, standards, tools and processes
necessary to achieve quality in the delivery of a project?

Why it is required because

1) 8 defines plan and organizes problems which will occur in future

2) establishes a schedule and plan

3) manages resources
4) controls cost

5) manages product quality

Continuous monitoring and controlling of a planning and execution gives the quality product.

5) LEGISLATION
There are various norms and regulations which are defined by ISO, for every part of the vehicle.

Governmental standards dictate the production of automobiles by regulating engineers and

designer’s creativity.

The main role of these standards is to increase driver and passenger safety (both on road and against
theft) and to control the environmental impact of vehicles.

Each country has its own regulations. This implies that car companies should adopt their production
standards in order to distribute their products in different markets around the world.

(|) Safety: -
 • Seat belts: - AIS:005
• Side impact: -FMVSS201,205
• Interior fittings: -CMV rule96

(||) Lighting: -

• Automatic lamps. :-AIS :057

• Signaling devices :- CMV Rule 102
and indicators
• Parking lights :- CMV Rule 109

(|||) Environment: -

• Noise / silencers: - IS:3028

• Emissions :- CMV rule 115
• Exhaust gases. :- CMV rule 122

(|V) Other requirements: -

• Warning triangle: - AIS :002 Forward / backward

• motion :- CMV rule 99
• Overall dimensions. :- CMV rule 93

We looked at various types of inputs that will give us the broad product specifications. Each of these are
worked out, in various engineering stages.
: PRODUCT LIFE CYCLE AND IMPORTANT GETAWAYS:

PRODUCT LIFE CYCLE MANAGEMENT

PLM is a process of managing the entire life cycle of product from inception and through
engineering design and manufacture to service and disposal of manufactured products.
PRODUCT LIFE CYCLE

1) design milestones

2) types of builds

3) launch of vehicle

Definition: -

In industry, PLM is the process of managing the entire life cycle of product from inception (concept of
product development) and to engineering design and manufacture. (where the concept is in engineered
and manufactured), to service and disposal of manufactured products. This entire process is called PLM.

Flow chart of PLM: -

Design gateways

Thus, initial design goes from 1 design phase to the next becoming more mature until it is made into a
product. This this is called as design gateways.

• OEM can hare n. No. Of gateways

• different OEM'S have different no. Of gateways depending on their product.

PRODUCT LIFE CYCLE: -

PLC is the course that a product sales and profit take over its lifetime.

It shows the stages that products go through from development to decline from the market.

Why PLC?

1) PLC determines revenue earned

2) contributes to strategic marketing planning

3) helps the firm to identify when a product needs support, redesign, withdrawal etc.

4) helps in planning for the new product development

5) helps in forecasting and managing cash flow.

The phases of the PLC

1) product development

2) introduction / launch

3) growth

4) maturity

5) decline
SALES AND PROFITS OVER THE PRODUCTS LIFETIME.

1) PRODUCT DEVELOPMENT: -

1) new ideas

2) market survey- is it required? Can it be produced at a profit?

3) product development and refinement

3) test marketing

4) analysis of test marketing results

5) preparation for launch, publicity, marketing campaign

2) INTRODUCTION /LAUNCH: -

1) introduction of the product into the market

2) it may be new product or old product to the new market

3) demand is low

4) high cost/low sales

5) advertisement and promotion

6) monitor initial sales

3) GROWTH
1) this period is the time to improve efficiency and product availability as well as service

2)cost efficiency, time to market, pricing and discount policies are the major factor in gaining customer
confidence

3) increased consumer awareness

4) sales growth rate increases because of limited or no competition

5) revenue increases

4) MATURITY: -

1) this period is the period of the highest returns from the product

2) sales reach peak

3) marketing cost of the product declines

4) ratio of revenue to cost high

5) sales growth likely to be low

6) competition likely to be greater

7) monitor market changes/new strategies?

5) DECLINE: -

1) competitors enter the market with

a) better product feature

b) advance technology

c) reduced prices

2) sale starts declining

3) marketing cost of product rises

4)decision to withdraw may be dependent on availability of new products and whether fashions /trends
will come around again?

INTRODUCTION PHASE: -

Characteristics and objectives

• Sales: - Low
• Cost: - High cost/ customer
• Profits: - Negative
 • Marketing: - create product awareness
objectives

GROWTH PHASE: -

Characteristics and objectives

• Sales: - rapid raising

• Costs: - cost / customer avg
• Profits: - rising
• Marketing: - maximize market share
objectives

MATURITY PHASE: -

Characteristics and objectives

• Sales: - peak
• Costs: - low cost / customer
• Profits: - high
• Marketing: - maximize profits while
Objectives defending marketing share

DECLINE PHASE: -

Characteristics and objectives

• Sales. :-. Declining

• Costs: - low cost/ customer
• Profits: -. declining
• Marketing: - reduce expenditure and
Objectives Milk the brand

VIRTUAL BUILD
Virtual Builds enables OEMs to validate and optimize the (final) assembly process in a
completely virtual environment representing the product, the processes and the production
systems in great detail.
This is again one of the most important phases in PLM. What is the virtual build? is simulation of digital
data which is carry over through digital input like CAD (3D) data. when final 3D CAD data is available
then it is taken in more advanced software’s of the latest technology and uses to visualize the entire
product in 3D environment.
By using software, you can look inside the vehicle in 3D environment. This saves cost to manufacturer
because you can check components size, packing physibility with virtual model. This this is the latest
technology which OEMs are using.

Virtual builds enable OEMs to validate and optimize the (final) assembly process in a completely virtual
environment representing the product, the process and the production system in great detail.

1)outstanding interactive visualization performance :- there is no other tool on the market that allows
to visualize the same amount and complexity of product and production system data interactively in real
-time.

2) real time simulation of rigid and flexible part behavior: - to understand and validate the
manufacturability of a certain component at a given step in the process requires realistic behavior of the
component in its context.

3) modelling of process: - from a process engineering perspective one wants to model and validate the
entire sequence and resolve dependencies to optimize the process in its specific production system
context.
PROTOTYPE BUILD
A prototype is an early sample, model, or release of a product built to test a concept or process
or to act as a thing to be replicated or learned from.
After the virtual build a prototype is made. This prototype is just a replica of final product. The main
purpose of prototype is to test the concept or process. Prototype is tested for crash, durability and NVH.
this is one of the important phases of PLM.

Visual prototyping is a software-based engineering discipline that entails modelling a mechanical

system, simulating and visualizing its 3D motion behavior under real-world operating conditions and
refining / optimizing the design through interactive design studies prior to building the first physical
prototype.

MASS PRODUCTION: -

After the prototype testing the designs are verified to be feasible then product goes into mass
production. mass production is the manufacturing of large quantities of standardized products. it refers
to the process of creating large numbers of similar products efficiently. Frequently utilizing assembly line
technology.

Example: -assembly line- Toyota Kirloskar four-wheeler.

LAUNCH OF VEHICLE: -
After the mass production and prototype testing the final product is launched.

Number of activities are performed before launch

1) experiments, design verifications, quality consideration, quality aspects to be considered for the
vehicle to be launch and norms on the pilot product vehicles.
2) norms mainly government norms related to crash or NVH Which are to be satisfied in order to
vehicle to be launched in that particular country.
3) after the satisfy all this criterion’s and tested on the pilot product or prototype build, the final
product is ready to be launch.

FINAL PRODUCT
Introduction:- Body in white (BIW) refers to the stage in the automobile
manufacturing in which a car body's components have been joined together, using
one or a combination of different techniques: welding (spot, MIG/MAG), riveting,
bonding, laser brazing etc.
BIW is termed before painting and before the engine, chassis sub-assemblies, or trim
(glass, door locks/handles, seats, electronics, etc.) have been assembled in the frame
structure.

BIW Commodities
Closures
Closures are all components not part of the inherent body structure, i.e., those parts welded or bolted on to
the underlying structure of the vehicle. These include not only highly style-sensitive components such as
doors, trunks, tailgates and hoods, but also a variety of crash management parts like door impact beams and
structural parts like roofs.

1. Front Door
Following are the primary functions of Doors
1.To give confirmable entry and exit to the user.
2.To protect the user in side impact.
3. To protect the user from environment and to ensure sufficient outside view.
4. Also it provides the attachment for other features like glass, window windowing mechanism,
water bottle holder, speaker.
5. Door also plays important role in styling of vehicle; features lines of vehicle are present on class
‘A’ surface of door.
 2. Rear Door
Following are the primary functions of Doors
1.To give confirmable entry and exit to the user.
2.To protect the user in side impact.
3. To protect the user from environment and to ensure sufficient outside view.
4. Also it provides the attachment for other features like glass, window windowing mechanism,
water bottle holder, speaker.
5. Door also plays important role in styling of vehicle; features lines of vehicle are present on class
‘A’ surface of door.
3. Bonnet

1. To cover the engine compartment.

2. Styling features carried by bonnet class ‘A’ surface.
3. To provide easy access during servicing.
4. To support accessories like pedestrian air bag, wind screen, washing nozzle.
5. Also, it plays major role in aerodynamic stability of vehicle.

4. Tailgate/ Deck lid

1. To cover the luggage compartment.

2. Styling features carried by tailgate class ‘A’ surface.
3. To provide easy access during luggage loading and unloading.
4. To support accessories like tail lamp.
5. To protect the user in rear collision.
6. Also, it plays major role in aerodynamic stability of vehicle.
Body Shell Less Door
1.Underbody

1.1 Front Floor

1. To support the occupant load.

2. Seat mounting
3. Support and mounting for exhaust piping.
4. Support to carpet.
5. Mounting for wiring harness.

1.2 Rear Floor

1. To support the occupant load.

2. Seat mounting
 3. Support and mounting for exhaust piping.
4. Support to carpet.
5. Mounting for wiring harness, spear wheel, Battery, Luggage.

2. Firewall (Dash and Cowl)

1. Part of the automobile body that separates the engine compartment from the passenger
compartment.

2. The inner and outer surfaces of all the firewall are often coated with noise, vibration and
harshness (NVH) absorber to prevent, most engine noise from reaching the passenger
compartment.
Upper body
1. Body side Outer
1. Provides stiffness to the structure.
2. Aesthetics: - to provide a pleasing overall appearance.
3. To support the weight of the transported passengers and loads.
4. To supply easy access and adequate room for the driver,
passengers and goods.
5. Body side outer panel is one of the single biggest panel of
vehicle.
Roof

1. Primary function is of compartment shielding and connection of body sides,

front and rear roof cross members.
2. In case of roll over, to avoid ejection of passenger.
3. A sunroof is an operable metal panel in a car roof that slides back to let in
light and air.
4. A moon roof is a similar panel but the difference is its glass and it can let
light in even when closed.
Sill
1. Sills are lower horizontal members extending from the front wheel arches to
the rear wheel arches.
2. The sills should be strong and rigid enough to prevent midbody deflection of
the vehicle due to vertical loads.

Cant Rail
1. Cant rail is the longitudinal side member above the doors to which the roof panel is attached.

2. It provides support for roof reinforcements.

Body Side Reinforcement
1. Body side reinforcement can be divided into different components: -

A- Pillar, B- Pillar, C- Pillar and Rear quarter etc.

2. Pillars are vertical supports on a vehicle, adding structural integrity to a vehicle, primarily the
roof. They are located around all the glass on an automobile. They are important for holding
glass in place.
The ‘A’ pillar holds the windshield in place.

‘B’ pillar starts at the end of the first door.

They usually offer substantial structural support for a vehicles roof.
‘C’ and ‘D’ Pillar hold a vehicles rear window in place.
Roof Cross Member
1. Supporting member for roof, they play major role in structural rigidity of
vehicle.
2. Also they support other components mounted on roof like headliner,
overhead console, Roof lighting system.

Body Shell Less Door

Front End
Front Longitudinal
1. Front frame is the assembly between firewall and front bumpers.
2. This frame surrounds and supports the powertrain and its auxiliaries.
3. Components fitted to the front frame are front suspension links, steering box,
parts of the air conditioning system and front lamps.
4. Front frame is responsible for absorbing crash energy and impact loads.
Front Shock Tower
1. Are used as mounting for front suspension.
2. Is one of the major load bearing components of vehicle.

Front End Carrier

1. Supports the frontal module, including fixings for the headlights, latch,
radiator, motor fan unit, bumpers, etc.
2. Is also part of the car’s safety concept both with respect to the protection
of the vehicle and its occupants in a collision as well as with respect to
pedestrian protection.
Front Bumper Armature
1. Bumper systems were originally installed to protect the engine and
radiator at the front of the vehicle.
2. They protect the hood, trunk, grill, fuel exhaust and cooling system as
well as safety related equipment such as parking lights, headlamps and
taillights, etc.
Design Concepts and Considerations in BIW
1. What is BIW?
2. BIW Parts
3. What Drives a BIW Design?
4. Design Considerations for Sheet Metal Parts
4.1 Sheet Metal Design Considering Manufacturing
4.2 Sheet Metal Design Considering Assembly
4.3 Sheet Metal Design Considering Part Location on Vehicle
What is BIW?
Body In White is mainly structural part of a Car which undergoes a pre-
painting process where its dipped into a solution which gives it a white
color.
BIW Parts

• Automotive Includes Following Manufactured Parts

1. Sheet Metal (Most Common)
2. Extrusion
3. Cast Part
4. Insert Molding/ Over Molding

What drives A BIW Design?

1. Package Space: - Space available in the area of Design

2. Master Sections: - Typical sections in the area of Design

3. Cost: - Involved in manufacturing and Assembly

4. Weight: - part weight

5. Assembly Process: - Ease of assembly

6. Manufacturing Method: - Best Suited

7. Vehicle Regulations: - e.g. For Safety

Design Considerations for Sheet Metal Parts

With Respect To
1. Manufacturing
2. Assembly
3. Part Location on a Vehicle

Sheet Metal Design Considering Manufacturing

Is based on following points
1. Position of Hole
2. Minimum Hole Diameter
3. Bend Radius
4. Distance Between Two Holes
5. Flange Length
6. Hole Flange Length
7. Bend Relief
8. Effect of Grain Direction in Sheet Metal Bending
9. Hole/Slot Distance from Bend Edge

1. Position of Hole
Position of hole from edge = 1.5T or 2T preferred
If it is less than 1.5T or 2T, it may tear.
2. Minimum Hole Diameter

Minimum Hole Diameter = 2T or more for alloy.

If it is less, the punch which is used will break.

Small sizes punches are more prone to failure during punching operation.
Therefore, for softer materials, recommended hole minimum diameter should
be equal to sheet thickness but for harder materials it should be equal to two
times of sheet thickness.
3. Bend Radius

Bend Radius = 2T
If it is less, it will tear while bending.
 5. Distance Between Two Holes
1. If the distance is less than 2T, then might be a tearing between
two holes.
2. If the distance is very less than if you want to punch out holes
in a single stroke, then in the die these holes are very close to
each other and there is a possibility that it will break the die
while punching.

6. Flange Length

Flange length = 3T after the fillet

Minimum flange Bend length is maintained to avoid cracks in bending area. It
shall be equal to three times of sheet thickness plus bend radius.
Min. flange Bend length = 3X Sheet Thickness + Bend Radius
 7. Hole Flange Length
Hole Flange Length = 2.5*T including the thickness itself.

8. Bend Relief

When we are having intermediate bend as shown in fig. in that case, we

need to have a relief after the bend, if you are not having this relief
then while there is a load applied on this part the part may tear at the
bend, if the relief is not applied.
Bend relief is provided at the end of bending edge to avoid any crack
tearing at the corner.
Height of the relief is generally kept greater than two times of sheet
thickness plus bend radius.
8.Effect of Grain Direction in Sheet Metal Bending
During sheet metal processing operation, sheet metal grains are arranged in the
direction of rolling.
When Sheet metal is bend perpendicular to rolling direction grain rearranges.
That has negligible effect on part strength.
But bending parallel to rolling direction can lead to cracks because of destruction
in grain structure.
9.Hole/Slot Distance from Bend Edge

Minimum distance between hole/slot edge to bend edge is maintained to

avoid metal distortion, deformation and fracturing.
Recommended minimum distance between hole /slot edge to bend shall be
equal to three times the sheet thickness plus bend radius.
3. Sheet Metal Design Considering Assembly
Different joining Processes: -
Spot Welding: -
1. Two different sheet metal parts of same material were assembled by using
spot welding.
2. Spot weld should be at a distance of minimum 9mm from the edge.
3. So, while designing we need to consider the overlap between the two parts
also the length required after the spot.

Spot welding is one of the oldest welding processes. It is used in a wide range
of industries but notably for the assembly of sheet steel vehicle bodies. This
is a type of resistance welding where the spot welds are made at regular
intervals on overlapping sheets of metal.

Spot-Welding Process
The spot-welding process involves A series of precisely controlled
events. This sequence normally consists of Five time periods, which
are set on the spot-welding timer/ controller
1. Squeeze time: - Time set to ensure predetermined welding force
is achieved before current flow; some timers are also equipped
with a pre-squeeze time setting.
2. Weld Time: - time for which welding current is switched on.
3. Hold Time (forge): - time electrodes are held together under
pressure after weld time.
4. Cool Time: - current off time between successive current pulses in
pulsation or seam welding.
5. Off Time: - time used for repeat welding such as stitch welding;
time between end of hold time on one weld and start of squeeze
time on the next, during which electrodes are re-positioned.
4. Sheet metal design considering Part Location on Vehicle
If the part is located some area where it is directly coming in
contact with customer so like we have door area inside, that area
should be protected and it should be bend or just called Hemming.
Hence it will not affect on the customer, directly when he is coming
in contact with the part.
BIW refers to the stage in automobile manufacturing in which car body's
components have been joined together, using either welding, riveting, brazing,
laser etc. BIW is termed before painting and before the engine, chassis etc. have
been assembled in the frame structure.