Car Development

Procedure & Process

The flow of car development
until its completion.

Compiled & Edited

by
Sivaraman Velmurugan

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The flow of car development until its
completion

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1. DEVELOPMENT PLANNING
The development planning department is the first step for
creating an actual vehicle based on the planning or the styling.
Image of the future bringing people inspiration.

A. BASIC LAYOUT,
B. STYLING,
C. DIGITAL DEVELOPMENT,
D. COMPETITIVE CAR ANALYSIS.

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1. DEVELOPMENT PLANNING (Contd.)
A. BASIC LAYOUT
Summarize the overall vehicle’s general layout by studying the
engine room layout and a lot of functions required for cars, such
as driving performances, interior space, exterior, etc.

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1. DEVELOPMENT PLANNING (Contd.)
B. STYLING
Make the car’s styling sketches, and study the styling with
computer graphics or clay models to create 3D-CAD data.

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1. DEVELOPMENT PLANNING (Contd.)
C. DIGITAL DEVELOPMENT
Create a new development process by using the digital
technologies. In addition, conduct the vehicle verification
virtually to develop a process sharing the information of
designing, testing, and production engineering.

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1. DEVELOPMENT PLANNING (Contd.)
D. COMPETITIVE CAR ANALYSIS
To plan the development concept or the target performances,
analyse the competitive cars’ features from various viewpoints
according to the measurement or the teardown investigation of
those to evaluate the performances or ease of use.

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2. DEVELOPMENT DESIGNING
Carry out consistently the process of the concept making
through to the production drawing fix in conformity with the
corresponding vehicle concept.
The development designing department makes the basic
concept about parts/system’s specifications and performances,
cost, etc., reviews and makes drawings of the structure and
shape, and then fixes the production drawings consistently.
The development designing department makes drawings by
optimizing the structure and shape with the digital technology,
and then feeds back the test and evaluation results, etc. of the
prototype parts to seek higher quality and performances.

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2. DEVELOPMENT DESIGNING (Contd.)

A. BODY / DOOR / EXTERIOR DESIGNING,

B. INTERIOR DESIGNING,
C. ELECTRONICS / ELECTRICAL SYSTEM DESIGNING,
D. CHASSIS DESIGNING,
E. ELECTRIC VEHICLE DESIGNING,
F. POWERTRAIN DESIGNING,
G. ACCESSORIES/SPECIAL MODIFICATION VEHICLE DESIGN.

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2. DEVELOPMENT DESIGNING (Contd.)
A. BODY / DOOR / EXTERIOR DESIGNING
Design body, door, exterior parts, wiper, lamp, glass, etc. by
studying various requirements of styling, performances, structure,
strength, rigidity, operability, etc. via CAD/CAE.

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2. DEVELOPMENT DESIGNING (Contd.)
B. INTERIOR DESIGNING
Design instrument panel, air bag, seat, seat belt, upholstery parts,
air-conditioner parts, etc., which are the most familiar parts for
customer, by the repeated study of those structure and
performances.

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2. DEVELOPMENT DESIGNING (Contd.)
C. ELECTRONICS / ELECTRICAL SYSTEM DESIGNING
Conduct control design of respective ECUs in the
body/powertrain system which are brains of cars, and of various
devices such as car navigation, audio, etc., or design
circuits/layout of harnesses which are blood vessels of cars,
meters/switches, etc.

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2. DEVELOPMENT DESIGNING (Contd.)
D. CHASSIS DESIGNING
Study underbody parts concerned performances and structure
and design parts such as suspension, steering wheel, brake, tire
and wheel which are deeply related to the basic performances
“Drive”, “Turn”, and “Stop” of cars.

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2. DEVELOPMENT DESIGNING (Contd.)
E. ELECTRIC VEHICLE DESIGNING
Study performances, layout/structure, and design parts such as
motor system, charger, battery pack, invertor, etc. which are the
basics of electrical vehicles.

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2. DEVELOPMENT DESIGNING (Contd.)
F. POWERTRAIN DESIGNING
Analyse performances, study structure, plan layout, and design
parts such as engine, transmission, drivetrain system, fuel system,
etc. which are the heart of cars.

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2. DEVELOPMENT DESIGNING (Contd.)
G. ACCESSORIES/SPECIAL MODIFICATION VEHICLE
DESIGN
Design and develop accessory parts for exterior parts, interior
parts, electronic/electrical parts, navigation/audio, etc., and
design and develop special modification vehicles such as vehicle
for disabled persons.

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3. DEVELOPMENT TESTING
Improve a vehicle thoroughly to respond to our customer’s joy
for driving.
The development testing department consists largely of the
testing of function, vehicle, and powertrain, and plays a role in
evaluation, verification, and improvements of design quality with
a mutual cooperation.
If the development designing department is a parent of creating
cars, the development testing is, as it were, a foster parent who
trains and brings up the vehicles.
A. FUNCTION TESTING,
B. VEHICLE TESTING,
C. POWERTRAIN TESTING.
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3. DEVELOPMENT TESTING (Contd.)
A. FUNCTION TESTING
Conduct the development related to safety such as impact
safety, braking, strength, etc. the vehicle should provide,
quietness, vehicle handling, etc.

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3. DEVELOPMENT TESTING (Contd.)
B. VEHICLE TESTING
Conduct the overall vehicle development such as emission
performance in compliance with each nation’s regulation, as
well as responding to our customer’s driving pleasure for
practicality, driving performances, environmental performances
durability, etc.

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3. DEVELOPMENT TESTING (Contd.)
C. POWERTRAIN TESTING
Conduct the development related to performances, function,
durability, and reliability of engines, transmissions, driveline, and
EV components that support the vehicle’s driving performances.

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4. PRODUCTION ENGINEERING
Plan/conduct/support the human and environment friendly
production line with efficiently controlled cost.
The production engineering department begins with planning
and reviewing the powertrain and vehicle production line,
designs the production facilities, machines, tools and jigs,
prepares the production plant related documents, and supports
the mass-production.
In addition, the production engineering department strives for
power and energy conservation to minimize environmental
impacts.

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4. PRODUCTION ENGINEERING (Contd.)

1. PRODUCTION PROCESS PLANNING,

2. DESIGNING OF PRODUCTION FACILITIES, MACHINES, TOOLS
AND JIGS,
3. CONSTRUCTION OF PRODUCTION LINE,
4. PRODUCTION SUPPORT.

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4. PRODUCTION ENGINEERING (Contd.)
A. PRODUCTION PROCESS PLANNING
Plan the production processes with the people - and
environmental - friendly production line in mind, while efficiently
keeping the cost low. Structural study, Plant layout, Process
plan/man-hour planning, Production line planning, Equipment/jig
planning.

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4. PRODUCTION ENGINEERING (Contd.)
B. DESIGNING OF PRODUCTION FACILITIES, MACHINES,
TOOLS AND JIGS
Design using the latest digital technologies with the accumulated
know-how. Electrical control designing, Die designing,
Equipment/jig designing, Stamping die/plastic mold designing.

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4. PRODUCTION ENGINEERING (Contd.)
C. CONSTRUCTION OF PRODUCTION LINE
Supervise and construct to enable the secure production start
within the determined period. Construction management,
Construction work.

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4. PRODUCTION ENGINEERING (Contd.)
D. PRODUCTION SUPPORT
Conduct the quality creation and the production support to enable
the delivery of the stable- quality vehicle to our customer.
Vehicle quality build-in, Plant production related documents,
Establishment of inspection system.

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4. PRODUCTION ENGINEERING (Contd.)

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THANK YOU VERY MUCH… … …

Reference : -

Mitsubishi Automotive Engineering

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