A-Pillar Activities 02-05-2020

Detailed Activities Phase wise
© Copyright 2020 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 1
A-PILLAR GATEWAY WISE
Milestone Input Received Activities Deliverables
• VS2 CAS surfaces  PMXU Verification  CAD Data Transfer to Supplier
• PMXU/ Preliminary BOM - Carryover & Unique classification as per packaging  DMU Reports
• DVA reports using initial CAD data  Regulations and Manufacturing check reports
• RMDV tests for VS2 L460 A-Pillar MTG Bracket verification & suggested to make  Fixing Request sheet
• Benchmark vehicle information Carryover.  Issue escalation mechanism
• Materials database information L460 A- Pillar Air Bag CAP Verification & suggested to make 1. Issue tracker for general as well as
• Carryover CAD data From L460 Carryover. packaging issues
• Initial Gap Plan from benchmarking  Master section creation  Updated BOM
• Feature list 461_22MY_CDVR section cut against studio vs CDVR Targets  Program Approval documentation
And provided feedback to Studio  Engineering CAD Model with tooling information
 Surrogate CAD Generation & saving the data in the Tce with 1. Initial Fixing strategy
correct names as per PART DATABASE 2. package feasible models with UPVO inputs
VS2  Interfaces & Gap Plan Review 3. Input to Studio with defined initial trim lines
 Engineering surface modifications
 CDVR section cuts against studio vs CDVR Targets  RMDV Completion for VS2 (CAD CHECK)
 Wrapping area definition  VS2 Checklist
 Z Locator Tab added as per L460
 Air Bag cap area as per L460
 Any update required on Location and Fixation strategy
 Environmental Clash Check, Regulations
 DFM-Manufacturing check with Tooling Lines, Sliders,
Uniform wall thickness, No sink marks etc.
 Draft analysis part/surfaces
 DFA- Assembly sequence
Milestone` Input Received Activities Deliverables
• VS2 CAS surfaces  Packaging feasibility  CAD Structure Validation Report
• PMXU/ Preliminary BOM -Initial check for Roof &Cabin Harness & optimise the  Fixing Sheet for BIW
• DVA reports  CAD Data Transfer to Supplier
• RMDV tests for VS2 doghouse  DMU Reports
• Benchmark vehicle information - Initial check for Air Bag package & highlighted the  Regulations and Manufacturing check reports
• Materials database information issue  Fixing Request sheet
• Carryover CAD data From L460 - Initial check for Darian tube & wash system
• Initial Gap Plan from benchmarking - Initial check for A-Pillar MTG bracket & Roof &Cabin  Engineering CAD Model with tooling information
• Feature list Harness & Drain tube package space & clearance &  Initial general notes added to cad data
provided the feed back to respective commodity  RMDV Completion for VS2 (CAD CHECK)
VS2
 EBER Completion for VS2 Offshore
 Local area thickness reduction to the B-side of the part for  CAD PACKAGE for all digital validations such
warping to the wind screen area to avoided the sink mark as CAE
due to welding ribs for the fabric  VS2 Checklist
VS2 A-PILLAR CHALLENGES THE SOLUTION
• PMXU Verification for A-Pillar
MTG Bracket PMXU Verification
• PMXU Verification Air Bag CAP • With number of iterations,
defined new tooling direction
for A Pillar Trim to suit L460
bracket.
THE CHALLENGE • Carry over bracket used
without affecting the
 Performance – The Design should performance.
comply with all CAE requirements • Provided feed back and make
the A- Pillar Bracket carryover
 Standard Meet– Design should from L460
meet the BOD requirements``
PMXU Verification Air Bag CAP
• With number of iterations, defined the
Air Bag Cap Position & provide the
JLR Proposal for A Pillar Trim & Carry
over Air Bag Cap used without
affecting the performance.
• Check DC tool Access & min agreed
clearance to be maintained.
• Provided feed back studio to make it
necessary changes in studio surface
to achieve CDVR Targests.
THE RESULT • Packaging

• Ergonomics requirements met
All Packaging Targets met
• Manufacturing requirements met as per guidelines
IHI – For A- Pillar have checked The A pillar A surface from JLR3575644
• IHI – For A- Pillar rev 2 the minimum distance to the BIW flange is now
40.924mm
Unfortunately the Mark up robustness for the AP2
point is questionable so this will have to be referred to
the vehicle safety team.
As per the instructions from the user guide
THE CHALLENGE
 Performance – The Design should
comply with all CAE requirements
 Standard Meet– Design should
Seal section area
meet the BOD requirements The Vehicle safety team has to be consulted
regarding mark- up robustness.

UPV2 ACTIVITIES
Deliverable Activity
BOM update Tree structure update as per latest PMXU
CAD Structure and naming convention setup correctly As per Std Cad Structure
Material selection agreement Applying selected Materials agreed with Supplier/COC recommendation
Interfaces & Gap Plan Review Finalisation of Optical Quality
Standard CAD methodology with PI Tools Use of standard CAD methodology along with power copies, blitz tool bar etc
Packaging requirements compatibility Check Confirm the package targets are meeting in CAD as per the requirements
Master Section through all fixings and interfaces compatible Master Section through all fixings and interfaces compatible
Check Studio surface feasibility with respect to
CAS Studio surface Feasibility Check Design in context-Packaging Checks , Environmental Clash Check,Regulation Check
DFM- Draft, Curvature analysis
DFA- Assembly sequence.
Issue Escalation Mechanism Highlight major issues and concerns of commodity
Engineering CAD Model Creation [Input to Studio] Engineering CAD Model creation inline with latest CAS Studio and engineering requirements
Location and Fixation Strategy update Review and update Location and Fixation Strategy if any according to latest package and DVA Study
Concept is locked with no major strategy changes. Moving from Compatibility to Completeness in design
3D Model Update with CAE Feedback engineering
3D model update as per latest CAS compatible with environmental data and packaging requirements and
latest CAE results
Fixing Request sheet update Update on Fixing Request sheet as per latest package if any
CAD Data check against

Design in context-Packaging Checks , Environmental Clash Check,Regulations
CAD data Analysis DFM-Manufacturing check with Tooling Lines,Sliders, formability/stamping
Uniform wall thickness, No sinkmarks etc Draft analysis for grained and non grained parts/surfaces
DFA- Assembly sequence,flight Path Design for Performance- All CAE Analysis
Evidence based Design checks as per Design Manual
Data Frozen for VS2 CAD Data release for VS1 with appropreate review mechanism with Customer/LE.
Data Sharing to CAE CAD Data sharing to CAE for next phase deliverables
 Interfaces & Gap Plan Review

1. Local area thickness reduction in the seal area to achieve
headliner Crush condition
1..A –Pillar MTG Bracket modified to achieve the Flight path &
 CAD Data Transfer to Supplier
• VS2 all Inputs Two way locator.
 DMU Reports
• VS3 CAS surfaces 2. provided the proposal for IP Interface & develop the design
 Regulations and Manufacturing check reports
• DVA reports surface & requested to develop studio to merging surface
 Fixing Request sheet
• Agreed Gap Plan between studio & IP interface
 Updated BOM
• Supplier Feedback for DFM  Actual CAD Data check against CDVR gap plan
 Program Approval documentation
VS3 • RMDV tests for VS3  Environmental Clash Check, Regulation
 Engineering CAD Model with tooling
• Supplier Design Guidelines 1. Air Bag Clash & packaging reviewed & provided feed back
information
DFM-Manufacturing check with Tooling Lines, Sliders, Uniform wall
 Initial drawings with general notes
thickness, No sink marks etc.
 RMDV Completion for VS3 (CAD CHECK)
 VS3 Checklist
 DFA- Assembly sequence, flight Path
 Design for Performance- All CAE Analysis Data readiness
 Evidence based Design checks as per Design Manual
A- Pillar Mtg Bracket for L460 & L461
• Flight Path A- Pillar Mtg
• With number of iterations, bracket design
bracket changes to
change for A Pillar Trim to suit L460 & L461 &
communize for L460 & L461 for the flight path issue for L461 clip tower is
• Seal area definition function as Two way locator to achieve the
fixing & location
THE CHALLENGE
meet the BOD requirements
• Local area thickness reduction in
the seal area to achieve headliner
Crush condition

• A- Pillar Hardliner Interface A- Pillar Hardliner Interface
• IP Interface
THE CHALLENGE
IP Interface
create a surface change proposal to create
0.5mm gap with IP but the modified surface
could be considered as a visible surface. Also,
it is difficult to merge this smoothly with A pillar
main A surface without changing the block
surface.
& suggest we get this resolve from studio or
have an agreement on 0.1mm gap
between IP and A pillar.

UPV3 ACTIVITIES
Deliverable Activity
CAD Structure Validation CAD Structure Validation
Interfaces & Gap Plan Review Review of Actual CAD vs Released Optical Quality
Packaging requirements Ensure the latest CAD meets package targets
Master Section update through all fixings and
interfaces compatible Update on Master Section through all fixings and interfaces compatible
Check Studio surface feasibility with respect to
CAS Studio surface Feasibility Check Design in context-Packaging Checks , Environmental Clash Check,Regulation Check
DFM- Draft, Curvature analysis DFA- Assembly sequence, Flight Path
Issue Escalation Mechanism Highlight major issues and concerns of commodity and provide technical solution
Engineering CAD Model Creation [Input to Engineering CAD Model creation inline with latest CAS Studio and engineering requirements
Studio]
Location and Fixation Strategy update Review and update Location and Fixation Strategy if any according to latest package and DVA Study
For Completeness in design engineering,
3D Model Update with CAE Feedback 3D model update as per latest CAS compatible with environmental data and packaging requirements and latest CAE results
Fixing Request sheet update Update on Fixing Request sheet as per latest package if any
SC CC Document Support for defining Critical/Special Characteristics
CAD Data check against

Design in context-Packaging Checks , Environmental Clash Check,Regulations
CAD data Analysis DFM-Manufacturing check with Tooling Lines,Sliders, Uniform wall thickness, No sinkmarks etc
Draft analysis for grained and non grained parts/surfaces DFA- Assembly sequence,flight Path
Design for Performance- All CAE Analysis
Evidence based Design checks as per Design Manual
Mule Build Support CAD Data release for first mule build
Data Frozen for VS3 CAD Data release for VS2 with appropriate review mechanism with Customer/LE.
Data Sharing to CAE CAD Data sharing to CAE for next phase deliverables
© Copyright 2020 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners. 10 10
 Interfaces & Gap Plan Review

1. VS3 all Inputs  CAD Data Transfer to Supplier
2. FDJ CAS surfaces  DMU Reports
 Actual CAD Data check against CDVR gap plan
3. DVA reports  Regulations and Manufacturing check reports
 Environmental Clash Check, Regulations
4. Agreed Gap Plan  Fixing Request sheet
 DFM-Manufacturing check with Tooling Lines, Sliders, Uniform wall
5. Supplier Feedback for DFM  Updated BOM
thickness, No sink marks etc
FDJ 6. RMDV tests for FDJ  Program Approval documentation
7. Supplier Design Guidelines  Engineering CAD Model with tooling information
 DFA- Assembly sequence, flight Path
 Initial drawings with general notes
 Design for Performance- All CAE Analysis Data readiness
 RMDV Completion for FDJ (CAD CHECK)
 Evidence based Design checks as per Design Manual
 FDJ Checklist

FDJ A-PILLAR CHALLENGES THE SOLUTION
Design of Ramp
• Design of ramp
• Air bag cap Ramp need to B-pillar Ramp
modify for smooth modified for smooth
• B-pillar ramp area clash with deployment of deployment of
curtain air bag curtain air bag
Door seal
• Coat hook
THE CHALLENGE Air Bag Cap
Air bag cap is not Air bag cap area
comply with all CAE requirements as per the BOD engineering surface
provided and COC & CQ
 Standard Meet– Design should is agreed to the solution.
 Manufacturing feasibility –supplier
confirmation needed for changes B-pillar ramp area clash with Door seal
B-pillar ramp is
clashing with the B-pillar is updated
Door Seal by removing clash
with door seal and
provided the
required clearance.
Coat Hook
THE RESULT Coat hook is C/O from Given feedback to Studio

to update the B-pillar
L-460. Therefore need
exact same surface in surface in Coat hook area
All Packaging Targets met L-461 studio to C/O the to meet the BOD
coat hook in L-461 guidelines.

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Detailed Activities Phase wise

THE RESULT • Packaging

THE RESULT • Packaging

CAD Data check against

 Interfaces & Gap Plan Review

THE RESULT • Packaging

THE RESULT • Packaging

CAD Data check against

 Interfaces & Gap Plan Review

THE RESULT Coat hook is C/O from Given feedback to Studio

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