Detailed Activities Phase Wise

Detailed Activities Phase wise
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B-PILLAR GATEWAY WISE
Milestone Input Received Activities Deliverables
• VS1 initial CAD data  PMXU Verification  CAD Data Transfer to Supplier
• VS2 CAS surfaces - Carryover & Unique classification as per packaging  DMU Reports
• PMXU/ Preliminary BOM using initial CAD data  Regulations and Manufacturing check reports
• RMDV tests for VS2  Master section creation  Fixing Request sheet
• Benchmark vehicle information  Surrogate CAD Generation & saving the data in the Tce with  Updated BOM
• Materials database information correct names as per PART DATABASE  Program Approval documentation
• Carryover CAD data From L460  Interfaces & Gap Plan Review  Engineering CAD Model with tooling information
• Initial Gap Plan from benchmarking  B- Pillar to Headliner Interface developed & proposal 1. Initial Fixing strategy
• C & T MATRIX provided to studio 2. package feasible models with UPV1 inputs
• Feature list  Engineering surface modifications 3. Input to Studio with defined initial trim lines
VS2
• Packaging targets  CDVR section cuts against studio vs CDVR Targets  RMDV Completion for VS2 (CAD CHECK)
 Engineering surface modifications for top flange of B-pillar  VS2 Checklist
to clear in draft direction.
 Any update required on Location and Fixation strategy
 DFM-Manufacturing check with Tooling Lines, Sliders,
Uniform wall thickness, No sink marks etc.
 Draft analysis part/surfaces
 DFA- Assembly sequence
 Evidence based Design checks as per Design Manual
• VS1 initial CAD data  Packaging feasibility  CAD Structure Validation Report
• VS2 CAS surfaces -Initial check for Positive fixing position & optimise the  Fixing Sheet for BIW
• PMXU/ Preliminary BOM  CAD Data Transfer to Supplier
• RMDV tests for VS2 doghouse & lifter study  DMU Reports
• Benchmark vehicle information - Initial check for fixing positions & clip  Regulations and Manufacturing check reports
• Materials database information - Initial check for Location & fixing strategy  Fixing Request sheet
• Carryover CAD data From L460 - Initial check for environment parts & BIW to optimize
• Initial Gap Plan from benchmarking the space  Engineering CAD Model with tooling information
• C & T MATRIX  Environmental Clash Check:-  Initial general notes added to cad data
• Feature list - DS-L461-010104-B0100-22_CLSG_BODYSIDE_ASSY  RMDV Completion for VS2 (CAD CHECK)
VS2 - DS-L461-010104-B0110-22_REINF_BODYSIDE_ASSY
• Packaging targets  EBER Completion for VS2 Offshore
 CAD PACKAGE for all digital validations such
 CDVR checks:-
as CAE
- B-pillar to B-pillar intermediate (0.5mm Gap)
 VS2 Checklist
- B-pillar to Headliner (-2mm Gap & -1.5 mm flush)
- B-pillar to Seatbelt bezel (0.5mm Gap)
 Regulation check:- ECE R-21

 Seat belt zone clash check
VS2 B-PILLAR CHALLENGES THE SOLUTION
Design of Ramp
• Studio top flange surface
• Design of ramp Top flange surface Given feedback to Studio
is not cleared in to update the surface as
• Seal section area tooling (7 deg.) per the engineering
surface provided
THE CHALLENGE
 Performance – The Design should
Seal section area
comply with all CAE requirements
Seal section is not
 Standard Meet– Design should as per the BOD. Given feedback to Studio
Standard values to update the surface to
meet the BOD requirements provided in BOD meet the BOD
are not matching in requirements.
actual CAD model
Clash with curtain air bag

is removed and
B-pillar ramp is maintained BOD
clashing with the guidelines. Also provided
curtain air bag. the enough clearance by
Need 3mm of considering flight path
clearance between
CAB and B-pillar
THE RESULT • Packaging

• Ergonomics requirements met
All Packaging Targets met
• Manufacturing requirements met as per guidelines
VS2 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
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
Uniform wall thickness, No sinkmarks etc Draft analysis for grained and non grained parts/surfaces
DFA- Assembly sequence,flight Path Design for Performance
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
 Studio feasibility:-
- Draft analysis and Surface tangency check
- Curvature analysis
 CAD Data Transfer to Supplier
• VS2 all Inputs - CDVR check
 DMU Reports
• VS3 CAS surfaces - Band analysis
 Regulations and Manufacturing check reports
• DVA reports  Interfaces & Gap Plan Review
 Fixing Request sheet
• Agreed Gap Plan  Any update required on Location and Fixation strategy
 Updated BOM
• Supplier Feedback for DFM - Optimized the doghouse as per L-460 to get clear in tooling
 Program Approval documentation
VS3 • RMDV tests for VS3 - Provided new coat hook position to C/O the coat hook from L-460
 Engineering CAD Model with tooling
• Supplier Design Guidelines  Actual CAD Data check against CDVR gap plan
information
- Air Bag packaging reviewed & provided feed back
 Initial drawings with general notes
 Environmental Clash Check, Regulations
 RMDV Completion for VS3 (CAD CHECK)
 DFM-Manufacturing check with Tooling Lines, Sliders, Uniform wall
 VS3 Checklist
thickness, No sink marks etc
 DFA- Assembly sequence, flight Path
 Evidence based Design checks as per Design Manual
 Environmental Clash Check:-  CAD Data Transfer to Supplier

• VS2 all Inputs
- DS-L461-010104-B0100-22_CLSG_BODYSIDE_ASSY  DMU Reports
• VS3 CAS surfaces - DS-L461-010104-B0110-22_REINF_BODYSIDE_ASSY
 Regulations and Manufacturing check reports
• DVA reports
 CDVR checks:-  Fixing Request sheet
• Agreed Gap Plan
- B-pillar to B-pillar intermediate (0.5mm Gap)  Updated BOM
• Supplier Feedback for DFM
 Program Approval documentation
VS3 • RMDV tests for VS3
- B-pillar to Headliner (-2mm Gap & -1.5 mm flush)
- B-pillar to Seatbelt bezel (0.5mm Gap)  Engineering CAD Model with tooling
• Supplier Design Guidelines
information
 Regulation check:- ECE R-21  Initial drawings with general notes
 Seat belt zone clash check  RMDV Completion for VS3 (CAD CHECK)
 VS3 Checklist
VS3 B-PILLAR CHALLENGES THE SOLUTION
Design of Ramp Ramp is modified to Also provided the enough
• Design of ramp remove the clash clearance by considering
• Air bag cap with BIW & B-post the flight path. Optimized
B-pillar ramp is
Bracket in flight path. the clearance between B-
clashing with the BIW
• B-pillar ramp clash with BIW and B-post Bracket in
Also added return pillar ramp and B-pillar
flange to reduce the bracket to avoid the
flight path.
gap between B-pillar catching of airbag during
Clearance required:- and BIW deployment.
THE CHALLENGE 3mm
 Performance – The Design should

Air Bag Cap
comply with all CAE requirements
Given feedback to Studio Requirements to meet the
 Standard Meet– Design should Air bag cap is not
to update the B-pillar BOD:-
as per the BOD
meet the BOD requirements surface in Air bag cap • Gap -0.3mm
area to meet the BOD • Flush -0.5mm
guidelines.
B-pillar ramp clash with BIW
B-pillar ramp is B-pillar is updated Clash is removed by checking the

clashing with the by removing clash flight of B-pillar.
BIW with BIW. Minimum clearance required
between B-pillar and BIW :- 3mm
THE RESULT • Packaging

• Ergonomics requirements met
All Packaging Targets met
• Manufacturing requirements met as per guidelines
VS3 ACTIVITIES
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
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
SC CC Document Support for defining Critical/Special Characteristics

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
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.
 Studio feasibility:-
- Draft analysis and Surface tangency check
- Curvature analysis
- CDVR check
- Band analysis
• CAD Data Transfer to Supplier
• VS3 all Inputs • Interfaces & Gap Plan Review
• DMU Reports
• FDJ CAS surfaces  Any update required on Location and Fixation strategy
• Regulations and Manufacturing check reports
• DVA reports - Optimized the doghouse as per CAE feedback.
• Fixing Request sheet
• Agreed Gap Plan - Modified the B-pillar ramp for easy deployment of curtain air bag
• Updated BOM
• Supplier Feedback for DFM also optimized the clearance between B-pillar ramp to B-post
• Program Approval documentation
FDJ • RMDV tests for FDJ Bracket( from 2.5mm to 0.8mm during flight path)
• Engineering CAD Model with tooling
• Supplier Design Guidelines • Actual CAD Data check against CDVR gap plan
information
• Environmental Clash Check, Regulations
• Initial drawings with general notes
• DFM-Manufacturing check with Tooling Lines, Sliders, Uniform wall
• RMDV Completion for FDJ (CAD CHECK)
thickness, No sink marks etc
• FDJ Checklist
• Draft analysis part/surfaces

• DFA- Assembly sequence, flight Path
• Design for Performance- All CAE Analysis Data readiness
• Evidence based Design checks as per Design Manual
 Environmental Clash Check:-

• CAD Data Transfer to Supplier
• VS3 all Inputs - DS-L461-010104-B0100-22_CLSG_BODYSIDE_ASSY
- DS-L461-010104-B0110-22_REINF_BODYSIDE_ASSY • DMU Reports
• FDJ CAS surfaces
• Regulations and Manufacturing check reports
• DVA reports
 Seat belt zone clash check • Fixing Request sheet
• Agreed Gap Plan
• Updated BOM
• Supplier Feedback for DFM  CDVR checks:-
• Program Approval documentation
FDJ • RMDV tests for FDJ - B-pillar to B-pillar intermediate (0mm Gap)
• Engineering CAD Model with tooling
• Supplier Design Guidelines - B-pillar to Headliner (-2mm Gap & -1.5 mm flush)
information
- B-pillar to Seatbelt bezel (0.2mm Gap)
• Initial drawings with general notes
• RMDV Completion for FDJ (CAD CHECK)
 Regulation check:- ECE R-21
• FDJ Checklist

FDJ B-PILLAR CHALLENGES THE SOLUTION
Design of Ramp
• Design of ramp
Ramp need to Increased B-pillar
• Air bag cap modify for smooth
B-pillar Ramp
ramp angle and
modified for smooth
deployment of length in X-direction.
• B-pillar ramp area clash with deployment of
So it can help for
curtain air bag. curtain air bag
easy deployment
Door seal Increase length and
and guide to curtain
angle in X-direction.
• Coat hook air bag
THE CHALLENGE Air Bag Cap

Air bag cap is not as
 Performance – The Design should per the BOD. Air bag cap area COC & CQ team agreed
CDVR targets are engineering surface to new CDVR targets:-
comply with all CAE requirements difficult to achieve in provided and COC & CQ • Gap -0.3mm
every section of Air is agreed to the solution. • Flush -0.4mm
 Standard Meet– Design should bag cap and B-pillar
meet the BOD requirements due to surface
curvature
 Manufacturing feasibility –supplier
confirmation needed for changes B-pillar ramp area clash with Door seal
B-pillar is updated Provided the
B-pillar ramp is by removing clash required clearance
clashing with the with door seal and between Door seal
Door Seal provided the and B-pillar:- 3mm
required clearance.
Coat Hook
THE RESULT Coat hook is C/O from Given feedback to Studio

to update the B-pillar
Since the coat hook is C/O
from L-460 we need exact
L-460. Therefore need
exact same surface in surface in Coat hook area same surface of L-460 in
All Packaging Targets met L-461 studio to C/O the to meet the BOD coat hook area to use the
coat hook in L-461 guidelines. C/O coat hook.
FDJ ACTIVITIES
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
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
SC CC Document Support for defining Critical/Special Characteristics

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
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.

Detailed Activities Phase Wise

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Detailed Activities Phase Wise

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Detailed Activities Phase wise

 Regulation check:- ECE R-21

Clash with curtain air bag

THE RESULT • Packaging

CAD Data check against

 Environmental Clash Check:-  CAD Data Transfer to Supplier

 Regulation check:- ECE R-21  Initial drawings with general notes

 Performance – The Design should

B-pillar ramp clash with BIW

B-pillar ramp is B-pillar is updated Clash is removed by checking the

THE RESULT • Packaging

CAD Data check against

 Environmental Clash Check:-

THE CHALLENGE Air Bag Cap

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

CAD Data check against

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