Detailed Activities Phase Wise

Detailed Activities Phase wise
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D-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  Engineering surface modifications 1. Initial Fixing strategy
• C & T MATRIX  CDVR section cuts against studio vs CDVR Targets 2. package feasible models with UPV1 inputs
• Feature list  Defined Location and Fixation strategy 3. Input to Studio with defined initial trim lines
VS2
• Packaging targets  DFM-Manufacturing check with Tooling Lines, Sliders,  RMDV Completion for VS2 (CAD CHECK)
Uniform wall thickness, No sink marks etc.  VS2 Checklist
 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-B0090-22_QTR ASSY  RMDV Completion for VS2 (CAD CHECK)
VS2
• Packaging targets - DS-L461-010104-B0120-22_BODYSIDE_ASSY  EBER Completion for VS2 Offshore
-DS-L461-010708-B01-22_TAILGATE_SEAL  CAD PACKAGE for all digital validations such
-DS-L461-120102-B04-22_ROW2_UPPER_DUCTING as CAE
-DS-L461-180103-E03-22_ROOF_HARNESS  VS2 Checklist
-DS-L461-180103-E16-22 TAILGATE HARNESS
 CDVR checks:-
- D-pillar to Load space Top-roll (1mm Gap)
- D-pillar to Headliner (-2mm Gap & -1.5 mm flush)
- D-pillar to D-pillar Infill (0.5mm Gap)
VS2 D-PILLAR CHALLENGES THE SOLUTION
Interface with Headliner
• Interface with Headliner There is No interface
defined between D-pillar
• Clash with Row 2 duct and Headliner. BOD is
not achieved at any Provided feedback to
section of D-pillar. Studio to update the
surface as per the CDVR
As per the BOD:- targets.
THE CHALLENGE Studio has updated the D-
• Gap -2mm pillar surface to achieve
• Flush -1.5mm
 Performance – The Design should the CDVR targets.
comply with all CAE requirements Actual Condition:-
 Standard Meet– Design should • Gap -2.2mm

• Flush -0.9mm
meet the BOD requirements
Clash with Row 2 duct
There is clash between D- Initially asked Ducting

pillar and Row 2 upper team to modify the Row 2
ducting. upper duct to have 6mm
Recommended Gap between clearance with the D-pillar.
duct and the D-pillar:- 6mm
After possible modifications of
duct the studio has modified
the D-pillar studio surface but
still it is having some clash
with the duct.
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 - Cad modifications done as per the DFM feedback received from
 Program Approval documentation
VS3 • RMDV tests for VS3 supplier.
 Engineering CAD Model with tooling
• Supplier Design Guidelines 1. Doghouse support ribs modification from ‘X’ to ‘T’ junction
information
2. Ribs in seal area modified to have 0.5mm gap between tailgate
 Initial drawings with general notes
seal and ribs
 RMDV Completion for VS3 (CAD CHECK)
3. Z-locating tabs and top roll touching ribs are added on D-pillar
 VS3 Checklist
4. 0.2mm step provided in mould separation area to avoid flash
defect
Actual CAD Data check against CDVR gap plan
 Environmental Clash Check, Regulations
 DFM-Manufacturing check with Tooling Lines, Sliders, Uniform wall
thickness, No sink marks etc
 CAD Data Transfer to Supplier
• VS2 all Inputs  DFA- Assembly sequence, flight Path
 DMU Reports
• VS3 CAS surfaces  Design for Performance- All CAE Analysis Data readiness
 Regulations and Manufacturing check reports
• DVA reports  Evidence based Design checks as per Design Manual
 Fixing Request sheet
• Agreed Gap Plan
 Updated BOM
• Supplier Feedback for DFM  Environmental Clash Check:-
 Program Approval documentation
VS3 • RMDV tests for VS3 - DS-L461-010104-B0090-22_QTR ASSY
 Engineering CAD Model with tooling
• Supplier Design Guidelines - DS-L461-010104-B0120-22_BODYSIDE_ASSY
information
-DS-L461-010708-B01-22_TAILGATE_SEAL
 Initial drawings with general notes
-DS-L461-120102-B04-22_ROW2_UPPER_DUCTING
 RMDV Completion for VS3 (CAD CHECK)
-DS-L461-180103-E03-22_ROOF_HARNESS
 VS3 Checklist
 CDVR checks:-
- D-pillar to Load space Top-roll (1mm Gap)
VS3 D-PILLAR CHALLENGES THE SOLUTION
Fixation strategy between D-pillar & D-infill
• Fixation strategy between
D-pillar & D-infill Permanent Fixing Permanent fixing have problem in flight path. D-infill is
strategy used between clashing with headliner by larger amount than
• Fixing strategy between D-pillar and D-infill. allowable. So we proposed to have separate D-infill
But this fixing strategy part. By using blade clip fixing we achieved the clash
D-pillar & BIW have issue while doing free assembly sequence.
the flight path.
• Parting line coming on fillet
Fixing strategy between D-pillar & BIW

THE CHALLENGE S-clip fixing tabs are
integrated on D-pillar
S-clip fixing clip used for
 Performance – The Design should fixing the D-pillar assy. on
previously S-clip fixing
feature is on D-infill.
comply with all CAE requirements BIW. The s-clip used is W780354 clip is used for
not compatible for the the fixing this clip is
 Standard Meet– Design should current BIW thickness. compatible with BIW
meet the BOD requirements thickness (1.4-2.5 mm)
Parting line coming on fillet
Parting line is coming

on fillet of the D-pillar. To avoid the flush (Plastic defect)
To avoid the flush we have provided 0.2mm step this
defect need 0.2mm can avoid the flush.
step.

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 Z-locator. • Updated BOM
• Supplier Feedback for DFM
- Added the two way & four way locator slots. • Program Approval documentation
FDJ • RMDV tests for FDJ
• Actual CAD Data check against CDVR gap plan • Engineering CAD Model with tooling
• Supplier Design Guidelines
• Environmental Clash Check, Regulations information
• DFM-Manufacturing check with Tooling Lines, Sliders, Uniform wall • Initial drawings with general notes
thickness, No sink marks etc • RMDV Completion for FDJ (CAD CHECK)
• Draft analysis part/surfaces • FDJ Checklist
• DFA- Assembly sequence, flight Path
• Design for Performance- All CAE Analysis Data readiness
• Evidence based Design checks as per Design Manual
Actual CAD Data check against CDVR gap plan

 Environmental Clash Check, Regulations
 DFM-Manufacturing check with Tooling Lines, Sliders, Uniform wall
thickness, No sink marks etc.
• VS3 all Inputs • CAD Data Transfer to Supplier
 DFA- Assembly sequence, flight Path
• FDJ CAS surfaces • DMU Reports
 Design for Performance- All CAE Analysis Data readiness
• DVA reports • Regulations and Manufacturing check reports
 Evidence based Design checks as per Design Manual
• Agreed Gap Plan • Fixing Request sheet
• Supplier Feedback for DFM • Updated BOM
 Environmental Clash Check:-
• RMDV tests for FDJ • Program Approval documentation
VS3 - DS-L461-010104-B0090-22_QTR ASSY
• Supplier Design Guidelines • Engineering CAD Model with tooling
- DS-L461-010104-B0120-22_BODYSIDE_ASSY
information
-DS-L461-010708-B01-22_TAILGATE_SEAL
• Initial drawings with general notes
-DS-L461-120102-B04-22_ROW2_UPPER_DUCTING
• RMDV Completion for FDJ (CAD CHECK)
-DS-L461-180103-E03-22_ROOF_HARNESS
• FDJ Checklist

 CDVR checks:-
- D-pillar to Load space Top-roll (0.75mm Gap)
FDJ D-PILLAR CHALLENGES THE SOLUTION
Fixation strategy between D-pillar & D-infill
• Fixation strategy between
By using blade clip
D-pillar & D-infill fixing we achieved the Separate D-infill part requires 2W & 4W locator to
clash free assembly locate the part on D-pillar.
• Fixing strategy between sequence. But there is We make one of the two clip tower of D-infill 4W and
no locator provided to
D-pillar & BIW (QTR assy) locate the D-Infill.
added one 2W locator.
Need 2W & 4W
THE CHALLENGE locator
 Performance – The Design should

comply with all CAE requirements
 Standard Meet– Design should Fixing strategy between D-pillar & BIW (QTR assy)
meet the BOD requirements
To reduce the clip tower
doghouse height we have added
new metal fixing bracket. This
Blade clip used for fixing bracket helps to smooth
the D-pillar assy. on BIW. assembly of the D-pillar and also
The height of the addition of this bracket we can
doghouse is too high as get some clearance between
per the toolmakers duct and doghouse
feedback.

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

comply with all CAE requirements Actual Condition:-

 Standard Meet– Design should • Gap -2.2mm

There is clash between D- Initially asked Ducting

THE RESULT • Packaging

CAD Data check against

Fixing strategy between D-pillar & BIW

Parting line coming on fillet

Parting line is coming

THE RESULT • Packaging

CAD Data check against

Actual CAD Data check against CDVR gap plan

 Performance – The Design should

THE RESULT • Packaging

CAD Data check against

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