CFT approach to establish Fit

& Finish in S101

CFT comprises of
1. CME – Lead role
2. Design (Respective System in charge)
3. CDMM (Respective System STA)
4. STYLING

Copyright © 2012 Mahindra & Mahindra Ltd. All rights reserved. 1

 Exterior stack up activities
Reviewed with CFT (Design, CME, Styling & CDMM)
Supplier Feedback for
Tolerance Stack up Checking Fixture
Exterior Parts analysis for defined Strategy and Required
Datum Definition gap and flush Tolerance

Stack Up Analysis Tolerance Stack Up

CFT Exterior Parts Checking
Result Discussion Analysis Result - revision
Fixture Strategy and
with Styling with supplier feedback
Tolerance Sign Off
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 Methodology
Target Setting (Nominal values) for
Benchmarking
Final Gap and Flush

jazz i10 Fabia WagonR Beat

Primary PLP/ Assembly Process
Conceptualization CFT discussion (Lead: CME)

Making the Loop / Chain of tolerance

for desired gap (Stack up analysis)
CFT discussion (Lead: CME)

Input part tolerances in parametric Supplier Feedback for the Optimize the Revise PLP /
excel sheet / 3D model Part level Tolerances and Tolerance after Assembly Process
Checking Fixture Concept discussion with
as per PLP Definition Supplier
2nd 1st
Compare
result with
target If all iterations not yielded targeted Visualize the
If not within 3rd tolerances, then Back to Styling team for
If styling not Gap/Flush in
agreeing for proto vehicle
If within Target limit changing the Nominal values / Tolerance & Plan for Tool
change of
Target limit For Example: 4.0 ± 0.7 4.5 ± 1.0 tolerance or correction
(CDMM)
Finalize the Gap and Panel level nominal value
tolerances after Styling team review
Process
Optimization
Part Level Tolerances and Checking
Fixture Concept CFT Sign off Sign off by STA, Design & CME Tolerance
Optimization
Part level Checking Fixture measuring Styling
methodology at Supplier end
Review
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 Benchmarking & S101 Nominal Gap
& Flush Target Setting
- Minimum Gap - Maximum Gap

Rear Door Front Door Rear Door Rear Door Front Door Front Door
to Side to Fender to Front to Front to Side to Side
Outer Door Door Panel Panel
(below ( above ( above ( below
OEM Models Remark
waist line ) waist line) waist line) waist line )

Hyundai i10 3.5 3.5 3.5 4.5 4.5 5.5

Sash
Door
Honda Jazz 4 4 4 4 5.5 7

Skoda Fabia 4 4 4 4 - 5.5

Maruti Wagon R 4.5 4.5 4.5 4.5 4.5 5.5 Full Door

Chevrolet
GM 4 4 4 4 4 6
Beats

S101
Mahindra 3.5 3.5 3.5 4 4.5 4.5 Sash Door
Proposed
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 BIW Panels PLP Scheme

- All Panel PLPs included in data before CP

- Hot forming Panel PLP finalized after discussion with M/s Benteler on 7th Nov. 2012
- Sash PLP finalized after discussion with M/s Track Components on 4th Dec. 2012

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 Definition of Datum scheme for
Exterior parts
X Z
X
X X Z X
Y X
X X
Y Y

Y
Y X

Y X Y

Y
X
X

X X
X
X

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Process Flow definition

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Hanging scheme definition

8
BIW Product Design Feedback
for process feasibility

9
General BIW Process and Panel
Tolerance Aggrement

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Exterior part Supplier feedback for
considered Tolerance

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Stack Up Analysis for each gap and flush
( with general agreed tolernaces )

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 If Calculated Tol. < Targeted Tol.
Go for Styling Review

On the basis of Styling confirmation , Gap status will be made green

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If Calculated Tol. > Targeted Tol.
Step 1- Process Change / Datum
Change / Design Changes

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If Calculated Tol. > Targeted Tol.
Optimizing tolerances after discussing
with supplier

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 Styling Review
If Calculated Tol. < Targeted Tol.

On the basis of Styling confirmation , Gap status will be made green.

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 Styling Review
If Calculated Tol. > Targeted Tol.

On the basis of the Team confidence with fine tuning ,irrespective of the
calculated Tolerance is more than the targeted tolerance
( up to 10-20 % ) and targeted tolerance confirmed by styling, still the
Gap status can be made yellow and will continue with the same
Targeted Tolerance 17
 Styling Review
If Calculated Tol. > Targeted Tol.

1. Targeted Tolerances will be increased without changing the nominal

value of Gap/ Flush , with styling agreement
2. Targeted Tolerance will be increased with changing the nominal value of
Gap/ Flush , with styling agreement

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Tolerance change - Example

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Nominal Change - Example

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 Checking Fixture Concept and
Tolerance Sign off

- After all the Gap and Flush status made Green / Yellow , CFT will do the
Part/ Panel Level Tolerance sign off and Global Checking Fixture Strategy
- Signed of Panel Level Tolerances will be implemented in Design Data.

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