• Introduction to Vehicle Electrical Distribution System (EDS) 
• Introduction to wiring harness assembly
• Wiring harness design process for New Product Development (NPD)
• Introduction to CATIA V5 electrical workbench

• Customized settings for electrical environment
• Wiring harness routing process for CATIA V5
• CATIA V5 – electrical part design

• Clip/clamps/support part definition
• Backshell definition
• Protective covering definition

• Preparation of harness assembly
• Creating the wire harness geometrical bundle
• Inserting harness components into geometrical bundle
• Positioning your inserted electrical parts
• Connecting & Disconnecting electrical components
• Defining the wiring harness routing

• Wiring harness routing on external references 
• Modifying the wire harness bundle segments
• Wire harness protective coverings
• Use of electrical splices
• Bundle continuity check/analysis
• Geometrical bundle warnings
• 3D annotation

• Modifying the wire harness bundle segments
• Modifying the branch point location
• Deleting bundle segment
• Bundle continuity check/analysis
• Geometrical bundle warnings
• 3D annotations
• Important commands, tips, & techniques

• Wiring harness flattening workbench

• Flattening workbench settings

• Flattening the 3D harness assembly

• Modify flatten assembly

• Saving the flatten Files

• Drawing, creation & contents

• Wiring harness component specifications & selection parameters
• Available suppliers in market (India)

• Definitions
• Routing & packaging process
• Design criteria (generic) for wiring harness 
• Packaging rules & best practices
• Guidelines for battery cables routing

• Clearance management
• Water ingress protection
• Thermal protection management
• Chaffing protection
• Vibration protection
• Routing on/near dynamic parts ( engine, wheel)
• Harness bending rules (harness & battery cables)
• Interconnection connector parking

• Definition of BIW, Jigs & Fixture
• BIW-Nomenclature
• Types of Fixtures & their applications
• BIW Stations & their uses
• Basic terminologies

• Project Activities
• Different Welding Processes
• 3-2-1 Principle
• Body Planes

• Design Methodology
• Structuring a design tree
• Different types of fixture units

• Different types Pin Unit Design
• Different types of Clamp Unit Design
• Different types of rest unit design

• Dump Unit Design
• Slide Unit Design
• Base Unit Design

• 3D-Finish
• Rough Locators
• Pneumatic routing
• Valve Banks & Selection
• Gun Study
• Sensors & selection

• Drawing Templates
• Angles of projection
• Basic GD&T used in Fixturing
• Scaling & Views
• Various Detailing Patterns

• Key Sheet detailing
• Unit detailing
• Child Parts detailing

• Child Parts detailing continued
• Material Selections
• BOM preparation

• Design Terminologies
• Sequence sheets
• Clamp Validations sheets
• Ergo-Sheets
• Poka-yoke
• Fixture Process sheet
• Cycle time study

This will be an introductory session where the basics of the automobiles and types of car bodies are explained. The complete vehicle development process which will explain the stages crossed by a car before it reaches the customer. The complete 3 years of development activity will be explained.

This will be an introductory session where the basics of the automotive BiW is taught. The basics of steel and its properties are covered in major, as steel is an important component used in the cars. Steps followed in the selection of the material is discussed. Also, the cross-functional teams are explained and the need to coordinate with them is explained with the master sections and 3D components of the parts for easy and clear understanding.

Out of all the BiW components, we will focus our attention on the Hood, Fender, Roof, Side and Back doors. The design procedures for all the afore-mentioned parts can be summarized as follows.

• Design Requirements
• Functional Requirements
• Regulations
• Gap and Flushness requirements
• Safety requirements

In this, we will present a real-life scenario where the effect of converting an inner panel from aluminum cast to the Steel Deep Draw part will be presented. Here is a quick summary of this case. The following design parameters were identified as critical and hence were fully described:

• Seal Surface Width was the same as the aluminum liftgate
• Tailgate outer parting was maintained the same
• Liftgate thickness was modified
• Gap and flushness were maintained

When you enroll in this course, you will be able to clearly understand these design parameters and the decisions that were made. In this case study, the design guidelines were set through a series of CAE simulations.

• In this module, you will first learn the anatomy of a Locker and Striker Mechanism. In order to be a successful product development engineer, it is very important to understand in detail the development process and design requirements for even the tiniest components. In this module, we will be analyzing the locker and striker mechanism in detail.

• In this module, we will look at two case studies. Both of these studies focus on supplier manufacturing practices. We will discuss the design challenges faced by two Asian Automotive suppliers and then go over the solution methodologies

• Some Old school phenomena of Physics-related to lighting
• How basic physics use into real-time application
• Basic name and application of Automobile lighting Ex –Headlight, tail light etc. 
• The function of light, example  - turn indication, High beam, Low Beam
• CATIA basic model, workbench, some basic command  (in CATIA)
• Some practice session on basics features, Like, boss, Locators (in CATIA)

• Information about regulations and its function
• Start making Lamp (Class A analysis) (in CATIA)
• B surface creation (all into separate parts in CATIA) 
• Feature implementation (in CATIA)
• More deep information for Regulation and How to Check into 3D
• Draft analysis, Basic check for Model(in CATIA)

• Basic Plastic, understanding  while designing parts (in CATIA)
• Making joining section (Glue, hot plate, Vibration etc)
• Making all in single files (in CATIA)
• Publish command in CATIA and join all parts together
• Making mounting concept with 3,2,1 Principle surrounding check (in CATIA)
• C regulation into 3D (in CATIA

• Checking all data as per tooling requirement( only basic) in CATIA
• Start making a 2D drawing from 3D ((in CATIA)
• Tolerance, Dimension (in CATIA)
• Complete revision (basic only)
• Making small Lamp again as per regulation, plastic and Tooling requirement
• Understanding Industry requirements, Optics, thermal, RFQ and other key elements to getting into this domain  

• Product Life Cycle
• Design Life Cycle

• Types of plastics (Thermoset Plastics, Thermoplastic)
• Engineering plastic Materials
• Manufacturing Process
• Injection Molding

• Basic commands and operation.
• Save, pan, rotate etc.

• Commands, 
• Rules to follow
• Working in exercise

• Pad, pocket
• Working on exercise

• Boolean operations
• Working on Boolean exercise
• Working on After Tool Go modification on Automotive components. (OEM Working procedures)

Create a PCB Bracket using Boolean operations

• Commands (Types of Sweep)
• Working on exercise
• Draft analysis
• Working on surface exercise

• Commands 
• Creation of Closed body, Thickened body
• Parting line, parting surface

• How to create tooling direction and do the draft analysis to ensure the part can be taken out of tool?
• Adding right thickness to the part and solve the issues
• Create the parting line for the bezel

• In this section we will learn on what is a mounting feature
• How to create a locator and dog house?
• Integrating the mounting features to the base part with Boolean operations

• We will learn what is the Clip mounting feature is in Plastic design.
• Design considerations for creating this feature
• Tooling analysis for the clip feature

• Drafting work bench.
• Creation of detail drawing for the Components
• Views creations (basic view & section views)
• Application of GD&T in drawings
• Template settings

• Creation of Paring line
• Creation of Tooling axis
• What is undercut and how to solve it

• Creation of simple mold for the Rear quarter trim Cup holder
• What is core and cavity
• Stripper, ejection and system
• Draft analysis
  

Designing a mold gives a good working understanding in the molding aspects of a component

• Instrument panel bezel with undercut
• Creation of mold with side core, and lifter
• Clear picture of undercut and other tooling complications
• Draft analysis for complex part

• Plastic defects faced in automotive design
• Real-time examples and solution for these designs

• Component out of Complex Class A surface
• Solving Class-A before starting Design (OEM Procedure)
• Complex surfaces that cannot be thickened easily
• Draft analysis to check the part for tooling.
• OEM Standard output presentation

Assemble Automotive Sub-assemblies including Child part, Screws,  

How to create Assemblies in CATIA?

Creating Constraints

Assembly sectioning analysis

Proximity analysis and output preparation.

Compare analysis of 2 similar components OEM Working procedure

• Develop door trim from surfaces, and Master section
• Develop Fixation and feature from door trim
• Develop switch bezel from studying master section.  
• Gap and Flush analysis
• OEM Standard output presentation

• Front Row Components 
• Rear Row Components

• How many types of Foam are available
• Design Standard for Foam
• Methods of foam development/Manufacture
• Defects in Foam

• Types of Structure
• Component of Structure
• Design guideline
• The material used in manufacturing
• Methods used to develop structure

In this section, you will learn the following.

• Types of Headrest used in automotive seats.
• Components used in making headrest
• Use of Headrest

• Types of Trims used in Automotive
• The terminology used in Trims
• Defects during the development of trim
• Methods to assemble trims

Following points will be covered during the section:

• Types of Plastic ( Material/Usage differentiation)
• Nomenclature of plastic parts in the seat
• Efficient ways to use plastic in a seat
• Defects occur on plastic components

In this section, you will learn the following.  

• Types of Armrest
• Mechanism of Armrest
• Components of an Armrest
• Manufacturing Defects of Armrest

In this course we will brief about details of all the mechanism used in Automotive passenger seats including types of Mechanism used and nomenclature:

• Recliner – Work/Function and detail study
• Track – Work/Function and detail study
• Height Adjuster – Work/Function and detail study

• Safety related Test
• Regulatory related Test

• Comfort mechanism
• New Innovation Idea
• Comfort layouts of Seats

This section of the course will not be only generalized to seating but this method can be used all over the globe in any domain to solve a problem:

• 8D
• Fish Bone Diagram
• 5D
• Man-Machine Diagram

• What are DFMEA and PFMEA
• The process to prepare DFMEA and PFMEA
• Different Review points of DFMEA and PFMEA

This section of the course will not be only generalize to seating but this methods can be used all over globe in any design related program :

• Introduction to GD&T
• Usage of GD&T in seats
• Different examples to define GD & T with exercise to do

This section of the course will not be only generalized to seating but this method can be used all over the globe in any program :

• Life Cycle of a program
• Different stages a program goes
• Mile Stones of Customers