Benchmarking

 

Body in White (BIW) Benchmarking. Teardown Benchmarking + Body Engineering = BIW Benchmarking With the expertise in teardown benchmarking and the experience in body engineering Advanced Structures' supports OEMs', BIW teams in development, weight reduction, value engineering and more with our BIW benchmarking solution.

 

 

 

 

 

Teardown Benchmarking + Body Engineering = BIW Benchmarking With the expertise in teardown benchmarking and the experience in body engineering Advanced Structures’ supports OEMs’, BIW teams in development, weight reduction, value engineering and  more with our BIW benchmarking solution.

Our BIW Benchmarking Solution Includes

1. CAD Engineering
2. Bill of Material (BOM) Generation
3. Data Analytics and Inferences
4. Part Level Thickness Mapping
5. Weld Mapping
6. Material Mapping
7. Mounting Details
8. CAE Meshing
9. 360° views of BIW interior and exterior

Our BIW CAD engineering helps in understanding weight/material distribution philosophy, performing CAE analysis, check section modules, study yield and cut sections to see profile, packaging and thickness. The major deliverables are

• 3D CAD Data
• 2D Sections

It includes all the categorized outputs or deliverables in digital format (CATIA/NX/Solid Edge/Solid Works) achieved through automotive reverse engineering that can be readily accessible to design engineers during design process. For more detailed information regarding our Body in white (BIW) CAD engineering, please refer our blog Biw Benchmarking.

After the CAD engineering we tear down the BIW by dis-assembling all the child assemblies and child components from their parent assembly in a strategic manner. Along the process, we map all the critical information and provide:

• Consolidated BOM including all the parameters on one sheet with all parts, sub-assemblies and assemblies. The list of parameters can vary from 10 to 100 based on the depth of analysis & data mapping required. To know the list of parameters collected during our teardown process,
• Hierarchy wise Individual Input Sheet and High-Quality view images on grid sheet.
• 2D CAD with thickness and profile details of the all the required sections.

The outputs from this activity are utilized for following purposes:

1. Should costing
2. Input for design engineer
3. Supply chain complexity study
4. Production engineering inputs
5. Reference for focused automotive cost reduction projects (VA/VE)

Before we jump on to the details of the alternate approach to benchmark BiW in least time at least cost, shown below is the list of individual studies that can be conducted on BiW to extract information that can be used as engineering intelligence to answer key questions.

1. Energy management study

In order to study the load path for different load case scenarios (Frontal, Offset, Side Impact), energy flow diagram on the BiW is created to identify the critical sections which are the key contributors for meeting crash norms. In the end of this activity, multiple flow diagrams for different load cases with critical sections (>120 areas) are identified for further detailed study.

 

2. Critical sections preparation

Based on sections identified, 1:1 CAD files of the sections are prepared after physically cutting them from the BiW assembly. This data mapping exercise is required to reinforce the energy management study with additional key information such as profile shape, panel thickness, coating layer details & section modulus. On overlapping the flow diagram of the competition vehicle with the 2D sections in place the deviations and gaps can provide insights on the competitor philosophy of either transfer of energy or absorbing it at that zone.

3. Raw Material Analysis

Raw material distribution along with physical properties (Tensile Strength, Vickers hardness, % elongation and ultimate strength), chemical properties & thickness film analysis to understand the various layer of coating (paint, ED & Galvanisation). Based on the test lab results the data is triangulated with the standard material library to assess the exact grade of materials, in case of grades that are not matching with the existing grades are assigned specific special grade and material cards are generated. This data helps in understanding the strength of the regions/modules within the BiW, overall engineering philosophy & material library to benchmark.

4. Assembly sequence & process mapping

Dis-assembly map of all parts in a structured way is made to understand how parts are joined (sealant, adhesive, spot weld, arc weld, hemming, laser welding etc.). This map also helps in understanding the complexity of the overall assembly in terms of total no of parts and joining method.

5. Sealant & Adhesive details

Considering the huge cost of sealants & adhesives, it is critical to study the application areas, quantity & type of adhesive or sealant used in BiW. It is also important that we study the reasons behind usage of sealants & adhesives in order to understand the thought process of the OEM.

 

6. Welding information

Strength of BiW depends on how the panels are held together, in general a BiW has approximately 3000 spot welds that holds 3 ply,2 ply or 4 ply panels with nugget diameter of 6-8 mm with pitch between 20-150 mm. The general information is good to know the facts but specific spot weld location, dia, ply thickness, & pitch is very critical from the strength perspective. The behaviour of BiW undergoing torsion, bending or Frontal crash will entirely change if you change the position or size of the welds.
To deliver this information, shell scan of the BiW is done and at all spot weld locations spheres are created in 3D cad and shared with the client.

7. Bill of material

The bill of material contains >35 parameters mapped per part with hierarchy mapped as it is on the BiW. These parameters mapped here help in understanding the weight distribution, quantity, purpose, coating types & thickness, part’s box size & joinery types etc… Basically, all parameters that either impact cost or the function of the part is mapped and later utilized for VA-VE activity, directional costing & engineering inputs.

8. Thickness Map

In order to understand the thinning percentage, thickness is mapped for all the parts that are formed during stamping process. Thinning reduces the strength of the local region; hence it is critically planned while simulating the formability of steels. Parts should thin in the non-safety or non-strength critical areas only.

9. Full Reverse Engineering

The competitor BiW & all 6 door closures are scanned and re-surface modelling is done for all A, B & C class surfaces. The entire CAD with all parts assembled and weld information mapped is created in 3D modelling software with BOM. This data is along with RM properties is used to simulate the model for crash and other load cases and benchmark results for better design of BiW.

10. Mounting Philosophy

Around 20% of the parts in BiW are there to integrate other system parts on to the frame. The mounting philosophy report is generated for all the parts that are mounted on the BiW with fastener types, spacing, datum identification & packaging efficiency information. This information is used for VA-VE exercise reasoning or feasibility of the proposal generated while doing the idea generation workshop.

11. Directional Costing

Without having cost estimates, it is difficult to quantify the worth of a VA-VE activity. With our xcPEP tool we are able to estimate cost of all the components with certain assumptions on the process, location, labour rates & tooling investment side. This assumptions sheet is configurable and flexible enough to update the calculations with a few clicks on the software.

 

12. Data Analytics

Once all the data is mapped, analysis is the next step. Based on the list of parameters that are mapped, analysis can be customised to answer questions specific to either cost saving, weight saving, parts standardisation, commonisation & others. Our xcPEP tool supports here in writing analysis algorithms quickly and executing them on the data mapped for the activity.

Few outputs of the data analytics activity are 

• Weight analysis
• Material distribution analysis
• Manufacturing Process analysis
• Complexity analysis and more

In our BIW benchmarking solution we also provide the details about material usage in the form of 

1. Material Distribution Sheet
2. Chemical Composition
3. Physical Properties

We also provide details like mounting method for parts mounted on BIW, location and complexity of mounts which can be used by design engineers for generating mounting method ideas and for space utilization and part integration philosophy

Apart from the above we also perform Part level Thickness Mapping and Weld mapping For detailed information regarding our solutions Weld Mapping, Material Mapping etc please read our blog.

 

xcPEP is our Proprietary Product Engineering Platform with inbuilt tools backed by machine learning trained on automotive component data, to compare data and generate cost reduction ideas thus giving a huge advantage to ASI in Reverse engineering & benchmarking

1. xcPEP is noticeable for data entry of dis-assembly/set-up and barcode is being tagged in all parts in order to identify it easier irrespective of its importance.
2. Relevant data is accessed on the first attempt and doesn’t require any quality checks.
3. It has other advantages such as accumulated data (can be used extensively for ML data entry) availability of all benchmarked vehicles for directional costing for analysing the ide.

Hyundai_VENUE_S_TURBO (SUV)

ABOUT ENGINE

 

CAPACITY OF CAR

 

SUSPENSIONS AND BRAKING SYSTEM OF CAR

 

SAFETY OF CAR 

LOCKING SYSTEM OF CAR 

 

COMFORT OF THE CAR

PROS AND CONS OF CAR

 

TATA NEXAN XE (SUV)

ABOUT ENGINE

CAPACITY OF CAR

 

SUSPENSIONS AND BRAKING SYSTEM OF CAR

 

SAFETY OF THE CAR

 

BREAKING SYSTEM

FEATURES OF THE CAR

PROS AND CONS

 

HONDA WR-V (SUV)

 

 ABOUT ENGINE

FUEL TYPE

 MAX. POWER

 MILEAGE AND DRIVING RANGE

 TRANSMISSION 

CAPACITY OF CAR

 

 PROS AND CONS

MARUTI SUZUKI S CROSS SIGMA (SUV)

 

ABOUT ENGINE

MILEAGE OF CAR

 FEATURERS OF CAR

 SAFETY OF CAR

 ENTERTAINMENT

PROS AND CONS

 

COMPARING FOUR CARS

 ON ROAD THIS VEHICLE COMES APPR.10 LAKHS

                                                                                                                                                                                                                                                                                                                  

CONCLUSION

I LL SUGGEST HONDA WR-V FOR Mr. D.S. Pughazhyendhii

WHY HONDA WR-V

I LL SUGGEST HONDA WR-V CAR FOR Mr. D.S. Pughazhyendhii,WHY BECAUSE OF GOOD MILEAGE,LOW MAINTAINENCE COST THAN OTHER CARS,HONDA WR-V HAVING AUTOMATIC CLIMATE CONTROL,EPS MEANS ELECTRIC POWER STEERING WHICH PROVIDES BETTER FUEL ECONOMY,AND IT HAVING ELECTRIC SUN ROOF, AND ITS [ACE] ADVANCED COMPATIBILITY ENGINEERING THAN OTHER CARS,HONDA WR-V HAVING MULTI VIEW REAR CAMERA AT FRONT MIRROR,INTELLIGENT PEDALS AND COMES WITH EASY HORN,BOOT SPACE IS HIGHER THAN 4 CARS,HONDA WR-V HAVING REMOTE FUEL LID OPENER,VANITY MIRROR AND ALSO TAILGATE AZAR IN IT.

HONDA WR-V COMES WITH GOOD MILEAGE,COMFORT FOR TRAVELING,ITS EASY TO TRAVEL 500 KM AND ALSO FOR DRIVING CITIES,EASY TO PARK AND ALSO ITS COMES WITH GREAT FEATURES AND COMFORT,I WILL RECOMMEND THIS CAR TO MR PUGHAZHYENDHII.

WHAT IS TAILGATING 

Tailgating is when a driver drives behind another vehicle while not leaving sufficient distance to stop without causing a collision if the vehicle in front stops suddenly. ... Some jurisdictions may require a minimal gap of a specified distance or time interval.