WK#2 Development Processes and Organizations

Development
Process and
Organizations
BHA 3602
LESSON OUTCOMES
At the end of the lecture, students should be able to:
 Explain the generic development process.
 Differentiatebetween various generic product

development processes.
New Product Introduction Flow…
How to start?
Sketch
Based on what?
Survey
Trend
Demographic
Start Planning
Start sketching
STYLE
STYLE PRODUCT
ENGINEERING
STYLE PRODUCT
ENGINEERING
PROTOTYPE
STYLE PRODUCT
ENGINEERING
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
STYLE PRODUCT TOOLING
ENGINEERING
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
ENGINEERING
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
ENGINEERING
STAMPING DIES, PLASTIC MOULDS,

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
PRESSING
ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
PRESSING BODY ASSEMBLY

ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE

ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
PAINTING
ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
DISTRIBUTOR
ENGINE
CASTING
PAINTING
MACHINING
ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
DISTRIBUTOR
ENGINE
CASTING
PAINTING
MACHINING
ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
EV R
D P
PROTOTYPE
ENGINE
FINAL CASTING PAINTING
ASSEMBLY
MACHINING
ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
G
EV R
D P
IN
R
TU
PROTOTYPE
C
FA
U
N
A
M
ENGINE
CASTING
FINAL PAINTING
ASSEMBLY
MACHINING
ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
G
EV R
D P
IN
R
TU
PROTOTYPE
C
FA
U
N
A
M
DISTRIBUTOR
ENGINE
PROTON EDAR -
EON CASTING
FINAL PAINTING
ASSEMBLY
MACHINING
PRODUCT
ENGINEERING

CF, BODY ASSY JIGS
T
PM T
EN
O UC
EL OD
G
EV R
D P
IN
R
MAJOR INVESTMENT
TU
PROTOTYPE
C
TOOLINGS
FA
U
N
(Dies-Mould-Jigs)
A
M
DISTRIBUTOR
PROTON EDAR - 40% of Development Cost ENGINE
EON CASTING
FINAL PAINTING
ASSEMBLY
MACHINING
PRODUCT
Automotive Product Development Flow…
PLANNING PRODUCT STAMPING DIES PLASTIC MOULDS
STYLING
ENGINEERING
PRODUCT
DEVELOPMENT BODY ASSY
PROTOTYPE
CF TOOLING JIGS
SHOWROOM WAREHOUSE STAMPING BODY ASSEMBLY
MAINTENANCE
DELIVERY ENGINE PAINTING
TRIM & FINAL
CASTING
MACHINING
DISTRIBUTION MANUFACTURING
Automotive Product Development Flow…
PLANNING PRODUCT STAMPING DIES PLASTIC MOULDS
STYLING
ENGINEERING
MAJOR INVESTMENT
TOOLINGS
(Dies-Moulds-Jigs)
40% of Development Cost
PRODUCT
DEVELOPMENT BODY ASSY
PROTOTYPE
CF TOOLING JIGS
SHOWROOM WAREHOUSE STAMPING BODY ASSEMBLY
MAINTENANCE
DELIVERY ENGINE PAINTING
TRIM & FINAL
CASTING
MACHINING
DISTRIBUTION MANUFACTURING
PART 1
RnD Process
1st Concept Formulation…
01 : CONCEPT DEVELOPMENT

Every new vehicle development begins with Concept Formulation: a

brainstorming process placing you, the consumer, at the centre of the idea:
trying to forecast exactly what you will expect and need from your car, through

studying styling trends and product segmentation, several years before you’re
even started thinking about buying it.
Idea Sketches are hand-drawn, and modelled using computer tools like ALIAS.
Miniature Scale (1:3 ratio) are built, and upon concept approval, the concept
will progress to the Design Development phase
2nd Design Development…

• This phase of the development begins to fill in the details
of the concept car, supported by sophisticated digitising
layout planning computer modelling software which
creates external surface (A-surface) data for form and
shape.
A 1:1 full-size scale model is built, finished and painted,

and if this is approved, a Styling-Engineering Feasibility
study examines the practicality of body engineering and
car internal systems installations, while 3D computer
modelling adds refinements to the computer simulated
model, together with internal surface data (B-surface).
3rd Engineering & Testing…
03 : ENGINEERING & TESTING DEVELOPMENT

• Engineering Development. From the Model Fix, engineers
produce component drawings and simultaneously simulate the
properties of body shell rigidity, strength and crashworthiness, using
Computer Aided Engineering (CAE) to comply to safety standards.
Prototype Development. Soft Tooling parts are developed with the
specified designs & materials. PROTON’s Prototype Shop is able to
assemble and produce the Final prototype car testing & validation.
Testing Development. Offering comprehensive testing for
Component, Material, Safety, Strength and Complete Vehicle
Validation. PROTON facilities are the best in South-East-Asia, able
to conduct various validation roles ensuring vehicles meet specified
standards and safety requirements.
RnD Facilities…
Aim…Comparison Current Vs Proposed ...
0 5 10 15 20 25 30 35
10 9 16 14 23 19 36 27
MASTER SCHEDULE
Model Fix F2 drwg
F1 drwg P0 drwg P0 build SOP
F1 Drwg Prepn F2 Build P1 Build NO P2

BUILD
F1 Proto Build P0 Build PP Build
Tooling Design [8 7 Months]

TOOLING EVENTS
Tooling Fabrication [10 8 Months]
Tooling Single Tryout, EO Modify & Buy-Off [16 14 Months]
Line Trials [6 5 Months]
COURTESY OF PROTON
Vehicle Platform…
Prototype Center…
CONCEPT CAR 1:3 SCALE MODEL
Here is a 1:3 scale model of a concept car which has been finished,
painted and detailed. It provides an exact replica of what car would
look like from every angle, if it were to be produced.
THE CLAY MODELLING PROCESS
Clay modelling helps designers to process 3 - dimensional information

about car designs faster and more efficiently during the development
process.
First a white-foam core is shaped, around which the raw clay will be
machine-layered to build up the correct thickness of material.
Meticulous hand - crafting is then required, in shaping and detailing

every surface of the model to match the designers and stylists concept.
RAPID PROTOTYPING
MANUFACTURING CENTRE
These samples are from PROTON’s

cutting edge prototyping facilities,
which offer Stereo Lithography
Apparatus (SLA), Laminated Object
Manufacturing, and Rapid Mould
Making for plastic or alloy parts. This
service has become a revenue
generator in its own right, and works
with many external clients on various
types of projects.
Powertrain Engineering…
Homologation & Testing…
Components and material tests

Safety, Strength, Ride & Handling Test…
Sled Test
Multi Axial Road Simulator
4 poster
Roof Crush
Seat Belt Anchorage
White Body Test

Emission Development Test…
Chassis Dyno & Cold Chamber
Engine Dyno
Noise Lab…
Test Track…
PART 2
ManufacturingProcess
Product Manufacturing…
Engineering Design
• TOOLING (DIES/MOLD) ENGINEERING • PROCESS PLANNING
• BIW ENGINEERING • TOOL DESIGN IN 2D & 3D CAD
• PRODUCTION ENGINEERING • PROCESS SIMULATION
• PRESSING/MOULD SIMULATION
Maintenance Tool Manufacturing

• TOOL PERIODICAL / PREVENTIVE • STAMPING DIES/PLASTIC
MAINTENANCE SERVICE MOULDS
• TOOL REPAIR SERVICES • INSPECTION JIGS/ASSY JIGS
• TOOL BREAKDOWN SERVICES • CAM NC GENERATION
• NC MILLING  GRINDERLESS
• SKILLED FINISHING
• SKILLED TRYOUT
Stamping Operation
• PRESS PARTS PRODUCTION
• PRESS MACHINE MAINTENANCE
COURTESY OF PROTON
Automotive Tool Development Process…
Process Planning
CAD Modeling
Simulation Verification
Design Engineering
Program Management Validation - Prototype
Design Standards
Supplier Management
Design for Assembly
BIW Engineering
Pattern
FMC
Quality Inspection Casting
Lower Tool Upper Tool

Verification Model Machining
(Screw Body)
Maintenance
Try-Out / Services Finishing 
Bench-Work Grinderless
COURTESY OF PROTON
Production - Stamping…
Stamping of flat metal sheet to form various car body panel

Stamping…con’t
Body Assembly…
Assembly / Welding of loose stamped body panels

to form a full car body (body in white)
Body Assembly…
Body Assembly…
Painting…
Painting of Body in White in accordance to color

choice ordered by customer
Painting…
Auto Inspection
Machine
ED Coat
Color Coat
Sealing Process Second Coat

Trim and Final…
Fitting of trim & chassis components to form a

complete built automobile
Trim and Final…
Engine Fitting
Glass Fitting
Doors Fitting
Trim and Final…
QC Inspection…
OK
PASSED
Ready to be delivered…
The End…

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Development

 Explain the generic development process.

 Differentiatebetween various generic product

STAMPING DIES, PLASTIC MOULDS,

STAMPING DIES, PLASTIC MOULDS,

STAMPING DIES, PLASTIC MOULDS,

PRESSING BODY ASSEMBLY

STAMPING DIES, PLASTIC MOULDS,

PRESSING BODY ASSEMBLY

STAMPING DIES, PLASTIC MOULDS,

PRESSING BODY ASSEMBLY

STAMPING DIES, PLASTIC MOULDS,

PRESSING BODY ASSEMBLY

STAMPING DIES, PLASTIC MOULDS,

PRESSING BODY ASSEMBLY

STAMPING DIES, PLASTIC MOULDS,

PRESSING BODY ASSEMBLY

STAMPING DIES, PLASTIC MOULDS,

STAMPING DIES, PLASTIC MOULDS,

STAMPING DIES, PLASTIC MOULDS,

SHOWROOM WAREHOUSE STAMPING BODY ASSEMBLY

SHOWROOM WAREHOUSE STAMPING BODY ASSEMBLY

A 1:1 full-size scale model is built, finished and painted,

03 : ENGINEERING & TESTING DEVELOPMENT

Model Fix F2 drwg

F1 drwg P0 drwg P0 build SOP

F1 Drwg Prepn F2 Build P1 Build NO P2

F1 Proto Build P0 Build PP Build

Tooling Design [8 7 Months]

Tooling Fabrication [10 8 Months]

Tooling Single Tryout, EO Modify & Buy-Off [16 14 Months]

Line Trials [6 5 Months]

CONCEPT CAR 1:3 SCALE MODEL

Clay modelling helps designers to process 3 - dimensional information

Meticulous hand - crafting is then required, in shaping and detailing

These samples are from PROTON’s

Components and material tests

Multi Axial Road Simulator

Seat Belt Anchorage

White Body Test

Chassis Dyno & Cold Chamber

Maintenance Tool Manufacturing

Quality Inspection Casting

Lower Tool Upper Tool

Stamping of flat metal sheet to form various car body panel

Assembly / Welding of loose stamped body panels

Painting of Body in White in accordance to color

Sealing Process Second Coat

Fitting of trim & chassis components to form a

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