HOW TO TURN COMBUSTION MODEL INTO HYBRID

Scope Of Work:

Ford Mondeo Wagon – Complete trunk area re-design to accommodate and reposition 12V Battery into spare wheel area.

Development of new metal mounting structural Brackets in spare wheel and Trunk floor, carpet, EPP Spacers, Side Trims and package tray. 

Main Challenges:

  • 10 Weeks from Project Kick Off to CAD Completion
  • Common Platform to the existing Non-Electric Wagon Body Style
  • Minimum New Tooling Items investment
Achievements:
  • CAD Completion On Time
  • OK to Sell Deadline On Time
  • 7 weeks for complete Design Preassembly Checks
  • Zero DCV Prototypes
How We Did It:
  • CAD support around the clock (Itera India & Spain)
  • Design Studio proposals lead by ITERA, including A-surface generation
  • Advanced Digital Preassembly checks gateway (Simultaneous Design)
  • Enhanced testing simulation, increased confidence level at Virtual Design Validation Tests to ensure successful Product Validation Tests
Scope Of Work :

Design and development of Jaguar I-Pace Door Panels

(With Faurecia)

Inputs Received :

Styling Surfaces, Environmental Data,

 OEM Requirements

Solutions Delivered :
  • BOM creation
  • Master section creation
  • CAD Modelling
  • GD&T drawing creation
  • Fulfil OEM requirements
  • Packaging of carry over parts
  • Prototype and DV test support
  • DVP and DFMEA creation
  • Benchmarking
  • Tolerance stack

   Launch support, ICA and PCA implementation till SOP

Main Challenges:
    • Complex design for leather wrapping
    • Integrated GH and Armrest
    • Tight fit and finish requirements
    • 0 Noises requirement (electrical vehicle)
    • Light weight solutions
    • Bi-injected solutions for noise performance
    • Ambient light integration and homologation
Scope Of Work :

Design and development of Jaguar I-Pace Door Panels (With Faurecia).

Inputs Received :

Styling Surfaces, Environmental Data, OEM Requirements.

Solutions Delivered :
  • BOM creation
  • Master section creation
  • CAD Modelling
  • GD&T drawing creation
  • Fulfil OEM requirements
  • Packaging of carry over parts
  • Prototype and DV test support
  • DVP and DFMEA creation
  • Benchmarking
  • Tolerance stack

   Launch support, ICA and PCA implementation till SOP

Main Challenges:
    • Complex design for leather wrapping
    • Integrated GH and Armrest
    • Tight fit and finish requirements
    • 0 Noises requirement (electrical vehicle)
    • Light weight solutions
    • Bi-injected solutions for noise performance
    • Ambient light integration and homologation
Scope Of Work :

Design and development of Jaguar I-Pace Door Panels (With Faurecia).

Inputs Received :

Styling Surfaces, Environmental Data, OEM Requirements.

Solutions Delivered :
  • BOM creation
  • Master section creation
  • CAD Modelling
  • GD&T drawing creation
  • Fulfil OEM requirements
  • Packaging of carry over parts
  • Prototype and DV test support
  • DVP and DFMEA creation
  • Benchmarking
  • Tolerance stack

   Launch support, ICA and PCA implementation till SOP

Main Challenges:
    • Complex design for leather wrapping
    • Integrated GH and Armrest
    • Tight fit and finish requirements
    • 0 Noises requirement (electrical vehicle)
    • Light weight solutions
    • Bi-injected solutions for noise performance
    • Ambient light integration and homologation
Scope Of Work :

Design and development of Jaguar I-Pace Door Panels (With Faurecia).

Inputs Received :

Styling Surfaces, Environmental Data, OEM Requirements.

Solutions Delivered :
  • BOM creation
  • Master section creation
  • CAD Modelling
  • GD&T drawing creation
  • Fulfil OEM requirements
  • Packaging of carry over parts
  • Prototype and DV test support
  • DVP and DFMEA creation
  • Benchmarking
  • Tolerance stack

   Launch support, ICA and PCA implementation till SOP

Main Challenges:
    • Complex design for leather wrapping
    • Integrated GH and Armrest
    • Tight fit and finish requirements
    • 0 Noises requirement (electrical vehicle)
    • Light weight solutions
    • Bi-injected solutions for noise performance
    • Ambient light integration and homologation

Scope Of Work :

Rear Floor revisions to accommodate and repositioned 12V Battery into spare wheel area. Development of new 12V Battery sheet metal mounting structural Brackets in spare wheel

Inputs Received :

Metal Leaf Spring CAD Data, Environmental Data, Load requirements and OEM Requirements

Solutions Delivered :

  • Material selection
  • Deviation Variability Analysis
  • CAD Modelling
  • GD&T drawing creation
  • Fulfil OEM Requirements
  • Process Feasibility
  • Tool Feasibility Design
  • Prototype Build Support

 DVP and DFMEA report

FE Analysis done :

  • Stiffness Analysis
  • Strength Analysis
  • Durability
  • Material Grade and Thickness optimization
  • Rear Safety Crash

Inputs

  • Floor mounting points
  • Seat environment
  • H Point, Mannequin details
  • Torso and cushion angle

Challenges

  • 2nd row with track
  • Double Dump
  • Packaging

Cost / Weight reduction

Solutions delivered

  • Design data
  • Trench positioning
  • Trench profile
  • Hog-ring window position and shapes
  • Manufacturing Drawings
  • Stack up analysis Report

DV Test, DFAM report