Automotive Development Processes

Julian Weber

Automotive Development
Processes
Processes for Successful Customer Oriented
Vehicle Development

123
Dr. -Ing. Julian Weber, Adjunct Associate Professor (Clemson University)
Strategy Manager
Product Strategy Vehicles
BMW Group
80788 Munich
Germany
julian.weber@bmw.de

ISBN 978-3-642-01252-5 e-ISBN 978-3-642-01253-2

DOI 10.1007/978-3-642-01253-2
Springer Dordrecht Heidelberg London New York

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Foreword

The global crisis the automotive industry has slipped into over the second half of
2008 has set a fierce spotlight not only on which cars are the right ones to bring to
the market but also on how these cars are developed. Be it OEMs developing new
models, suppliers integerating themselves deeper into the development processes
of different OEMs, analysts estimating economical risks and opportunities of
automotive investments, or even governments creating and evaluating scenarios
for financial aid for suffering automotive companies: At the end of the day, it is
absolutely indispensable to comprehensively understand the processes of automo-
tive development – the core subject of this book.
Let’s face it: More than a century after Carl Benz, Wilhelm Maybach and
Gottlieb Daimler developed and produced their first motor vehicles, the overall
concept of passenger cars has not changed much. Even though components have
been considerably optimized since then, motor cars in the 21st century are still
driven by combustion engines that transmit their propulsive power to the road sur-
face via gearboxes, transmission shafts and wheels, which together with spring-
damper units allow driving stability and ride comfort. Vehicles are still navigated
by means of a steering wheel that turns the front wheels, and the required control
elements are still located on a dashboard in front of the driver who operates the car
sitting in a seat.
However, what has changed dramatically are processes involved in vehicle de-
velopment. What used to be solely the work of one brilliant engineer over several
years is achieved today by a highly interlaced co-operative network of specialists
coming from a variety of disciplines. The process of vehicle development has be-
come a complex interplay of decentralized sub-processes which are steered on a
relatively high level. Even though this has been the dream of automotive devel-
opment managers for years, there is no such thing as a completely detailed process
model. On one hand, if there were one, it would be out-of-date the day after it was
completed. On the other hand, on the operational level, real vehicle development
“happens” to a certain extent according to individual experience, preference, and
current necessities, rather than following a meticulously detailed plan. Even at the
most efficient carmakers in the world, it is, to a surprisingly high extent, an ad-hoc
process. After all, automotive development is about people.
It is that twofold challenge, to both technically integrate separate components
to create a complete vehicle, and at the same time to orchestrate the cooperation of
thousands of people from different companies and different professional, cultural
and social backgrounds, which makes automotive development so challenging and
fascinating. The graduate course in Automotive Development Processes which I
have had the opportunity to teach at Clemson University’s International Campus
for Automotive Research (ICAR), and which is the basis for this book, focuses on
two topics: first, the realization of customer relevant vehicle characteristics, and
VI Automotive Development Processes

second on the people involved: their personal objectives, their way of thinking and
their interaction. I hope this book reflects and summarizes all of the fruitful dis-
cussions I have had with automotive experts from the most diverse areas, as well
as my own personal experience gained over many years in the field of product de-
velopment.
In this sense, this book is a personal report rather than a manual for vehicle de-
velopment. It immerses the reader in the wide range of automotive development
processes: from project milestones down to virtual collision checking; from prod-
uct strategy to production and service integration; from agility to sustainability;
and from E/E architecture to embedded software. My intention is to make the
reader familiar with the entirety of what people really do in contemporary automo-
tive development, rather than to discuss technical details in-depth. For example,
for a passive safety engineer, the chapter on passive safety might only reflect his
or her basic knowledge, but by reading through other chapters he or she can gain
insight into the processes and the driving forces of neighboring departments and
eventually get a better understanding of his or her job in the global context of
automotive development.
Compared to other publications on automotive development, the approach fol-
lowed in this book reflects a customer’s rather than an engineer’s point of view. It
is my strong conviction that in automotive development, customer relevant vehicle
characteristics must steer the concept and components, not the other way round. If
eventually functions and properties such as agility, passive safety, cabin comfort
or even cost suit the customers’ requirements, the underlying technical solutions,
such as the chassis concept, are of minor importance.
I hope that this book will help managers, specialists, consultants, analysts, stu-
dents or anyone else interested in the field of automotive development, to better
understand the overall process of motor vehicle development; and to recognize the
technical and human relationships, dependencies and conflicts between the differ-
ent sub-processes and the people involved. And lastly, I hope to share my fascina-
tion for this exciting profession.

Munich Julian Weber

Acknowledgements

After teaching a graduate course in Automotive Development Processes at Clem-

son University’s International Campus for Automotive Research (ICAR) for two
years, it was the faculty at ICAR that gave me the igniting spark for this book. I
would like to thank Dr. John Ziegert for his ongoing support over the past years,
and especially for reviewing the book both in terms of content and language. I
would also like to thank Dr. Imtiaz-ul Haque, Dr. Thomas Kurfess, and Dr. Geor-
ges Fadel for their continuous involvement and encouragement.
A comprehensive characterization of automotive development processes is not
base upon a single person’s expertise. Numerous contributions from industry ex-
perts provide the intellectual foundation which made this book possible. The fol-
lowing people have especially shared their vast knowledge: Rainer Andres, Hans
Baldauf, Dr. Jens Bartenwerfer, Dr. Jochen Böhm, Dr. Andreas Goubeau, Dr. Mi-
chael Haneberg, Dr. Florence Hausen-Mabilon, Dr. Dieter Hennecke, Martin
Hofer, Reinhard Hoock, Dr. Todd Hubing, Gerd Huppmann, Benoît Jacob, Tho-
mas King, Klaus Kompass, Carl-August von Kospoth, Wolfgang Kühn, Johannes
Meisenzahl, Reinhard Mühlbauer, Dr. Herbert Negele, Dr. Ulf Osmers, Andreas
von Panajott, Dr. Steffen Pankoke, Michael Pfunder, Dietger Pollehn, Kristina
Posse, Dr. Friedrich Rabenstein, Dr. Günter Reichart, Tim Rhyne, Dr. Erich Sa-
gan, Harald Schäffler, Axel Schröder, Dr. Verena Schuler, Hans Schwager, Dr.
Rudolf Stauber, Wolfgang Thiel, Hoang Phuong Than-Trong, Dr. Gerhard Thoma,
Volkmar Tischer, Dr. Ulrich Veh, Erich Wald, Cornelia Würbser, Hannes Ziesler,
Andreas Zimmermann.
In addition to individual contributions, many companies and institutions have
supported through allowing the usage of proprietary documents. Foremost, I would
like to thank the BMW Group of Munich, Germany, for their strong cooperation
and permission to publish relevant development material. Other intellectual prop-
erty documents are reprinted with the kind permission of the following companies
and institutions: Allgemeiner Deutscher Automobil Club (ADAC), Association for
the Advancement of Automotive Medicine (AAAM), Autoliv, AUTOSAR GbR,
AZT Automotive GmbH, California Air Resources Board (CARB), Carnegie Mel-
lon University Software Engineering Institute, Dr. Ing. h.c. F. Porsche Aktienge-
sellschaft, dSPACE, Inc., EFQM, Environmental Protection Agency (EPA), Euro
NCAP, First Technology Safety Systems (FTSS), FORD, Gesamtverband der
Deutschen Versicherungswirtschaft e.V. (GDV), Group Lotus Plc., Human Solu-
tions GmbH, Interbrand Zintzmeyer & Lux AG, International Organization for
Standardization (ISO), International TechneGroup Incorporated (ITI), J.D. Power
and Associates, Lamborghini SA, MAGNA Steyr, Original Equipment Suppliers
Association (OESA), Pierburg Instruments, Relex Software Corporation, Renault
Deutschland AG, Securmark AG, Shell Deutschland Oil GmbH, Tesla Motors,
Inc., The Motor Insurance Repair Research Centre (MIRRC), Toyota Deutschland
VIII Automotive Development Processes

GmbH, United Nations Economic Commission for Europe (UNECE), VDI Verein
Deutscher Ingenieure e. V., Verband der Automobilindustrie e.V. (VDA), Volks-
wagen AG, Wölfel Beratende Ingenieure GmbH & Co. KG, ZF Lenksysteme
GmbH.

Additional Remarks

The tables and text in Sect. 5.2.8, pages 74 through 77 (the “Adapted Material”) have been cre-
ated from the Technical Report, CMMI® for Development, Version 1.2, CMU/SEI-2006-TR-
008, (c) 2006 Carnegie Mellon University and special permission to create and use the Adapted
Material has been granted by the Software Engineering Institute of Carnegie Mellon University.
CMMI and Capability Maturity Model are registered trademarks of Carnegie Mellon University.
Any Carnegie Mellon University and Software Engineering Institute material contained herein is
furnished on an “as-is” basis. Carnegie Mellon University makes no warranties of any kind, ei-
ther expressed or implied, as to any matter including, but not limited to, warranty of fitness for
purpose or merchantability, exclusivity, or results obtained from use of the material. Carnegie
Mellon University does not make any warranty of any kind with respect to freedom from Patent,
Trademark, or Copyright infringement. The Software Engineering Institute and Carnegie Mellon
University do not directly or indirectly endorse nor have they reviewed the contents of this book.
Figure 6.12 taken from ISO 9001:2000 Quality Management Systems – Requirements is re-
produced with the permission of the International Organization for Standardization (ISO). This
standard can be obtained from any ISO member and from the Web site of the ISO Central Secre-
tariat at the following address: www.iso.org. Copyright remains with ISO.
EFQM Excellence Model (Fig. 6.13) is the copyright and trademark of EFQM.
The picture of the Bentley Arnage interior shown in Fig. 7.6 has been taken by Jim Cal-
laghan.
Tables 7.7 and 7.8 are reprinted with permission from the Association for the Advancement
of Automotive Medicine (c) AAAM.
Contents

1 Vehicle Development Projects - An Overview ................................................. 1

1.1 Categories of Vehicle Development Projects .............................................. 1
1.1.1 Design Level ........................................................................................ 1
1.1.2 Design Content..................................................................................... 2
1.1.3 Innovation Level .................................................................................. 2
1.1.4 Options and Country Versions ............................................................. 3
1.2 Platforms and Model Lines.......................................................................... 4
1.2.1 Platforms .............................................................................................. 4
1.2.2 Model Lines ......................................................................................... 5
1.2.3 Side Effects / Restrictions .................................................................... 6
1.3 The Product Evolution Process (PEP) ......................................................... 6
1.3.1 Phases of the PEP................................................................................. 8
1.3.2 Processes of the PEP ............................................................................ 9
1.3.3 The V-Model of Product Development.............................................. 11
1.4 Vehicle Project Management..................................................................... 12
1.5 Aspects of International Development Projects......................................... 13
References ....................................................................................................... 15

2 Product Strategy............................................................................................... 17
2.1 Cars that Topped and Cars that Flopped.................................................... 17
2.1.1 Tops.................................................................................................... 18
2.1.2 Flops................................................................................................... 20
2.2 Factors of Success in the Automotive Industry ......................................... 21
2.2.1 Worldwide Market Presence .............................................................. 21
2.2.2 Model Mix.......................................................................................... 22
2.2.3 Brand Profile ...................................................................................... 25
2.2.4 Product Profile ................................................................................... 26
References ....................................................................................................... 28

3 Phases of the Product Evolution Process........................................................ 29

3.1 Initial Phase ............................................................................................... 29
3.1.1 Technical Feasibility .......................................................................... 30
3.1.2 Economic Feasibility.......................................................................... 31
3.2 Concept Phase............................................................................................ 33
3.2.1 Vehicle Concept Design..................................................................... 33
3.2.2 Target Agreement............................................................................... 35
3.3 Series Development Phase......................................................................... 36
3.3.1 Component Design............................................................................. 36
3.3.2 Complete Vehicle Integration ............................................................ 36
X Automotive Development Processes

3.3.3 Prototype Build ..................................................................................36

3.3.4 Launch Preparation.............................................................................39
3.4 Series Support and Further Development ..................................................39
References........................................................................................................40

4 Virtual Car Process ..........................................................................................41

4.1 Building Virtual Cars.................................................................................41
4.1.1 Purpose and Benefits ..........................................................................41
4.1.2 Required IT System Environment ......................................................42
4.1.3 Specification.......................................................................................43
4.1.4 CA Data Provision..............................................................................44
4.2 Geometric Integration ................................................................................45
4.2.1 Collision Detection.............................................................................45
4.2.2 Ensuring Functional Clearance...........................................................48
4.3 Further Functional Geometry Evaluation ..................................................50
4.3.1 Storage of Personal Items...................................................................50
4.3.2 Evaluation of Vehicle Kinematics......................................................50
4.4 Virtual Build Groups .................................................................................51
References........................................................................................................52

5 E/E System Development .................................................................................53

5.1 From Machinery to E/E Systems ...............................................................53
5.1.1 A New and Different World ...............................................................53
5.1.2 Automotive E/E Systems....................................................................54
5.2 Systems Engineering Processes .................................................................56
5.2.1 A Clash of Cultures ............................................................................56
5.2.2 Systems Engineering ..........................................................................57
5.2.3 Requirements Engineering .................................................................58
5.2.4 System Architecture and Design ........................................................60
5.2.5 Component Development...................................................................64
5.2.6 Systems Integration and Validation....................................................68
5.2.7 Supporting Management Processes ....................................................72
5.2.8 CMMI.................................................................................................74
References........................................................................................................77

6 Management Processes for Complete Vehicle Development ........................79

6.1 Target Management ...................................................................................79
6.1.1 Complete Vehicle Requirements ........................................................79
6.1.2 Target Agreement...............................................................................81
6.1.3 Sign-off Process .................................................................................84
6.2 Design Problem Management....................................................................85
6.3 Release and Change Management .............................................................88
6.3.1 Releases..............................................................................................88
6.3.2 Design Changes..................................................................................89
6.3.3 Change Management..........................................................................91
 Contents XI

6.4 Quality Management ................................................................................. 92

6.4.1 Definition of Quality .......................................................................... 92
6.4.2 Pre-delivery (Internal) Quality Assessment ....................................... 93
6.4.3 Post-delivery (External) Quality Assessment..................................... 95
6.4.4 Quality Management Systems............................................................ 98
6.4.5 Quality Costs.................................................................................... 103
References ..................................................................................................... 105

7 Primary or Customer Relevant Complete Vehicle Characteristics ........... 107

7.1 Registrability ........................................................................................... 110
7.1.1 Legal and Customer Requirements .................................................. 110
7.1.2 Component and System Design ....................................................... 113
7.1.3 System Integration and Validation ................................................... 114
7.2 Total Vehicle Costs.................................................................................. 116
7.2.1 Legal and Customer Requirements .................................................. 116
7.2.2 Component and System Design ....................................................... 117
7.2.3 System Integration and Validation ................................................... 120
7.3 Design Appeal ......................................................................................... 121
7.3.1 Legal and Customer Requirements .................................................. 121
7.3.2 Component and System Design ....................................................... 127
7.3.3 System Integration and Validation ................................................... 134
7.4 Cabin Comfort ......................................................................................... 140
7.4.1 Riding Comfort ................................................................................ 140
7.4.2 Acoustic Comfort ............................................................................. 146
7.4.3 Thermal Comfort.............................................................................. 151
7.4.4 Value Perceived ............................................................................... 156
7.5 Infotainment............................................................................................. 159
7.5.1 Legal and Customer Requirements .................................................. 159
7.5.2 Component and System Design ....................................................... 161
7.5.3 System Integration and Validation ................................................... 164
7.6 Agility...................................................................................................... 166
7.6.1 Legal and Customer Requirements .................................................. 166
7.6.2 Component and System Design ....................................................... 169
7.6.3 System Integration and Validation ................................................... 183
7.7 Passive Safety .......................................................................................... 188
7.7.1 Legal and Customer Requirements .................................................. 188
7.7.2 Component and System Design ....................................................... 195
7.7.3 System Integration and Validation ................................................... 201
7.8 Theft Deterrence ...................................................................................... 209
7.8.1 Legal and Customer Requirements .................................................. 209
7.8.2 Component and System Design ....................................................... 214
7.8.3 System Integration and Validation ................................................... 218
7.9 Reliability ................................................................................................ 219
7.9.1 Legal and Customer Requirements .................................................. 219
7.9.2 Component and System Design ....................................................... 222
XII Automotive Development Processes

7.9.3 System Integration and Validation ...................................................234

7.10 Sustainability .........................................................................................242
7.10.1 General Aspects..............................................................................242
7.10.2 Energy Consumption and Tailpipe Emissions................................244
7.10.3 Evaporative Emissions ...................................................................265
7.10.4 Noise Emissions .............................................................................268
7.10.5 Electro-magnetic Emissions ...........................................................271
7.10.6 Treatment of End-of-life Vehicles..................................................272
7.10.7 Pre-usage Sustainability .................................................................279
References .................................................................................................282

8 Secondary Complete Vehicle Characteristics ..............................................287

8.1 Production Integration .............................................................................287
8.1.1 Legal and Internal Customer Requirements .....................................287
8.1.2 Component and System Design........................................................289
8.1.3 System Integration and Validation ...................................................291
8.2 Service Integration...................................................................................294
8.2.1 Legal and Internal Customer Requirements .....................................294
8.2.2 Component and System Design........................................................295
8.2.3 System Integration and Validation ...................................................297
References .................................................................................................297

Abbreviations.....................................................................................................299

Index ...................................................................................................................305