新整车项目设计验证的试验和开发.ppt

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* 新整车项目设计验证的试验和开发 New Car Program Test & Development for Design Validation * 2300年前秦朝制造 Engineered by Qin Dynasty, 2,300 years ago. * 2300年前秦朝制造 Engineered by Qin Dynasty, 2,300 years ago. Performance : 4 Hp Acceleration : Ride comfort : Handling : Durability : 2300 Years? * 试验和开发的介绍 Introduction Test & Development What it mean Design Validation? What it mean ; 什么是设计验证？ Design Validation? 什么是产品验证？ Production Validation? 整车试验开发：M11案例研究 Vehicle Test & Development ; M11 Case study. 试验技术中心试验开发流程的提升 CTTC T&D Process Improvement 试验开发项目管理 T&D Program management 操稳开发 R&H Development 整车可靠性项目 Vehicle Durability program 闭环系统和ESO Closed loop system & ESO 结论 Conclusion * 什么是设计验证？ What it mean Design Validation? 设计验证 Design Validation 设计验证是一个新车为了达到目标值，设计、开发和验证的过程，包括：功能、性能、可靠性和生产制造能力。 Design Validation is a process whereby the new car is designed, developed and validated for achieving Target, including function, performance, durability and production build ability 通过试制样车的制造（装配）、开发和试验完成的。 This is done through build, development and testing of prototype vehicles. 制造： 供应商和试制车间 Build : Suppliers & Prototype build shop 试验：试验开发部门（可靠性、主观评价、气候性试验） Testing : T&D dept ( Durability, Appraisal, Climatic test…) 开发：试验开发部门（NVH、操稳、白车身结构） Development : T&D dept ( NVH, R&H, BIW structure…) 装配、试验开发完成并实现目标值，然后图纸完结，最终大批量生产批准（工程完结） After Build, Test & Development completed and achieve Target, then Drawing will be signed-off, and finally approved for Mass production. ( Engineering Sign-off) * 试制样车的试验和开发 Prototype Test & Development PH 1 : 第一阶段试制样件 1st Proto Samples 车身和底盘结构开发Conduct body & Chassis structure test 基本装配、功能、碰撞 Basic fitness, function, Crash test 界定主要问题 Major problems definition PH 2 : 第二阶段整改后试制样件 2nd Improved Samples 开发 和 调教 Development and tuning 试验样件版本归类 Test sample library 3循环开发过程 3 loop development process OTS1 : 车身和底盘次要部分冻结 Body & Chassis minor freezing OTS2 : 设计验证的代表性样件Representative Parts for design validation 应完成最终调教和优化 Final tuning & Refinement should be completed ESO 的80%可靠性试验里程 80% durability test mileages for ESO 第一轮，第一台样车 PH 1 PH 2 OTS1 车身和底盘主体冻结 Body & Chassis Major Freezing 车身和底盘次要部分冻结 Body & Chassis Minor Freezing 工程 总结Engineering Sign-Off OTS 第一台样车 OTS2 * 试制样车的试验和开发 Prototype Test & Development Powertrain Development Platform Development New Car development Engine Dyno test Vehicle Test Mule car Prototype Pilot Karry Rely Chery Riich Powertrain > Platform > Upper Body Development Q21, 22, S16, S18 A13, A21, M11, M16 B12 B13 B21 B23 * 什么是产品验证？ What it mean Production Validation? 产品验证 Production Validation 产品生产验证的过程。 The Process whereby the product is validated for production. 通过产品零部件的提供，装配计划、制造和小批量车的验证试验完成的。 This is done through the production component sourcing, assembly plan, build, and validation testing of pilot vehicles. 部件质量：供应商 Parts Quality : Suppliers 装配质量： 生产制造部门 Assembly quality : Manufacturing Dept 功能和可靠性试验将会确认小批量产品车是否具有ESO目标值同样的水平。 Function & Durability testing to confirm whether the Pilot production vehicle has same level of ESO target. * P9 P1 P2 P3 P4 P8 质量门和时间节点 Gateways and Milestones P0 Prototype PH1 test Pilot小批量 竞争车型 试验开发计划 Prototype PH2 test OTS1 test OTS2 test P7 P6 P5 Product Development stage 产品开发阶段 Concept Planning stage 概念计划阶段 Prod Validation 产品验证阶段 Concept Drawing Prototype Drawing Production Drawing Concept CAE CAE- Test correlation Mule car SOP Design Validation At P5 Prod Validation * 试验开发介绍 Introduction Test & Development What it mean Design Validation? 什么含义 ：What it mean ; 设计验证？ Design Validation? 产品验证？ Production Validation? 整车试验开发：M11案例研究 Vehicle Test & Development ; M11 Case study. 试验技术中心试验开发流程的提升 CTTC T&D Process Improvement 试验开发项目管理 T&D Program management 操稳开发 R&H Development 整车可靠性项目 Vehicle Durability program 闭环系统和ESO Closed loop system & ESO 结论 Conclusion * CTTC新整车项目的试验开发 New Car Test & Develop by CTTC Nice Looking Car Mid Size but Luxury feel How to Develop? How to Tune? M11案例学习 M11 Case study * M11开发目标 M11 Development Target Development target (Example) 开发目标 （示例） M11 驾驶舒适 comfortable Drive 经济 Economy 安全 Safety R 在同等级车里最好表现 Best in Class 4 star 4星级 怎样开发M11? How to develop M11? 操控性和稳定性平衡，安全感觉 Balanced Ride & Handling, & Safety Feel 实现 性能和燃油经济性的最优化 Performance & Fuel Economy Optimization 车内环境舒适 Comfortable Interior environment NVH水平可以接受，平顺的声音品质Acceptable NVH level, Smooth Sound Quality 很好的可靠性质量 Good Durability Quality * M11 操稳 Benchmarking 和目标值设定 M11目标值 ：高于平均值Higher than average Values * Electric/EMC 电器 Crash 碰撞 Cooling 冷却系 Heat Damage 温度场 Economy 经济性 Performance 性能 R&H 操稳 NVH Appraisal 主观评价 Climatic Test 气候性试验 HVAC Brake 制动 Durability 可靠性 Driveability 驾驶性 Emission 排放 M11试验和开发 M11 Test & Development Function Technology Improvement * Current Process　目前的流程 CCPMS – New Process 新流程 　CR summary system 　定义试验开发流程 Defined T&D Process 　试验开发计划 Test & Development planning 　TR summary system 　闭环系统 Closed Loop system 　R&H, NVH, Durability, Veh. T&D process 　整车品质关注 Vehicle Attribute Focus 　试制阶段工程总结流程 Prototype ESO Process 　目标设定流程 Targets setting Process 　试验车辆管理方法 Test Vehicle Management system M11试验和开发 M11 Test & Development * M11试验开发结果M11 Test & Development results 出色的现代感造型Excellent Modern Styling 安全驾驶感觉 Safe Driving feel 乘坐舒适Comfortable Ride 易控制 Easy of Controls 性能和经济性的最优化Optimized Perf & Economy 可靠性质量高 High Durability Quality 碰撞5星 5 star Crash Level Medium size Passenger car, But High performance, Luxury car 中型乘用车但是高性能，豪华车 * What it mean Design Validation? 什么含义 ：What it mean ; 设计验证？ Design Validation? 产品验证？ Production Validation? 整车试验开发：M11案例研究 Vehicle Test & Development ; M11 Case study. 试验技术中心试验开发流程的提升 CTTC T&D Process Improvement 试验开发项目管理 T&D Program management 操稳开发 R&H Development 整车可靠性项目 Vehicle Durability program 闭环系统和ESO Closed loop system & ESO 结论 Conclusion 试验开发介绍 Introduction Test & Development * CTTC 试验开发项目管理 CTTC T&D program Improvement 2006 2007 2008 2009 2010 2011 Team Structure set-up. Engineer Training Car Program T&D process in CTTC Quality gate system Function Test Administration Component Brake PE NVH HVAC/Cooling Material Crash Durability S-Car AM Car B-car T-Car Climatic test R&H Prototype stage Concept stage Pilot Benchmark Styling Proto DRW Proto Proto PH1,2 Production Drawing Proto OTS PH1,2 Pilot DVP PVP SOP P5 T&D should be integrated with Chery R&D process T&D Process to be agreed by PM team Co-work with PM, CAE, Design, Prototype build shop, etc. T&D Program to be managed by T&D Manager. Strong Car program team operation Full responsibility from P0 to P9 * 阶段 市场分析 竞争对手评估 产品规划 供应商选择 项目组成立 活动 竞品分析 概念选择 QFD 造型方案 工程规划 生产制造可行性 销售预测 成本目标 性能和重量分析 造型冻结 整车参数固定 目标固定 试验开发计划固定 财务分析 营业目标固定 设计分析和模拟 发动机试制试验（如果合适） ) Mule test 生产制造规划 详细的成本 分阶段设计和模具释放 试制第一、二阶段材料和零部件试制试验 生产模具 Install & comm. Facilities OTS 一、二阶段设计验证完成 工程总结 外协件的质量开发 质量验证和工艺验证 装配工艺 外协件批准认可 认证 上坡 小批量试装 生产Prod. Sign-off Fleet operation 产品策略和规划阶段 概念评估阶段 概念开发阶段 产品设计和开发阶段 设计验证和产品准备 预生产阶段 上坡阶段 奇瑞节点 P1 P0 项目启动 SOP 项目批准 项目工程启动 工程规划认可 产品设计验证完成 采购认可 P2 P3 P4 P5 战略回顾 概念选择 设计释放 产品释放 项目批准 小批量完成 零部件和材料认可 投产 P9 P8 P7 P6 新车型开发流程 New Car Development Process – Overview 项目回顾 * 整车项目举例 Example of Car Program 新开发整车项目的定义 New Car Development Program definition VTS 主要部分Major 附属部分Minor 系统应用System Application Face lift 外部车身 Body Exterior New Modify C/O Rad. Grill 内部车身 Body Interior New Modify C/O C/O 底板 Under floor New, Modify Modify, C/O C/O C/O 悬架 Suspension New, C/O Modify, C/O C/O C/O 转向 Steering New, C/O C/O C/O, (or RHD) C/O 制动 Brake New, C/O C/O C/O C/O 动力总成 Powertrain New, C/O Modify, C/O New C/O 空调采暖通风 HVAC New C/O C/O C/O 电器 Electrical New Modify, C/O C/O C/O * 整车项目举例 Example of New Car Program Test Procedures Total Benchmark Prototype Inspection & Static Meas’t 13 - 13 Whole Vehicle Appraisal 1 1 1 Durability 13 - 4 Climatic Test 4 4 2 Body & Trim, Hardware 25 3 22 R&H – Susp, Steering, Tire 40 11 22 Brake system 22 13 16 Powertrain 14 6 14 HVAC & Cooling, Fuel System 26 6 17 NVH 63 15 65 Total 221 59 176 试验项目 Test Procedures ( JC22 T&D Plan issue 3# ) 根据VTS Based on VTS 新开发是那些？ What are the new? 目标水平 Target level 高于目标？ Higher Target? 仅仅调校？ Just Tuning? 试验轮次 Test iteration? 试验、开发和验证？ Test & Development, and Validation? 仅验证？ Only Validation? * 换发动机项目举例 Example of New Eng. Application 试验项目的确定 Test items decision 发动机性能和经济性，驾驶性，排放：电喷标定 Engine performance & Economy, Driveability, Emission : EMS calibration NVH : 通过噪声 Pass-by noise : 动力总成相关的车内噪声 Interior Noise – Powertrain related : 发动机悬置的调校 Engine mounts tuning : 怠速抖动 Idle shake : 进排气系统的NVH优化 Intake, exaust NVH refinement - Transmission shiftability, Clutch function test 空调冷却系、温度场试验 HVAC & Cooling, Heat damage test, 操稳、制动验证主观评价 R&H, Brake subjective evaluation for Validation 高速、动力总成可靠性 High speed, Powertrain durability 综合可靠性- 验证 General Durability – for Validation * 整车项目举例 Example of Car Program 试验开发周期和车的数量 T&D lead time & No. of cars Major BM Mule ProtoPH1,2 OTS Pilot T&D Lead time 4 M 3~6 M 6 M 6 M 4 M No. of Cars 2~5 3~5 ~40 ~40 ~30 Minor BM Mule ProtoPH1,2 OTS Pilot T&D Lead time 1 M - 3 M 3 M 2 M No. of Cars 2~3 - ~10 ~10 ~10 Face Lift BM Mule ProtoPH1,2 OTS Pilot T&D Lead time - - - 3 M 1 M No. of Cars - - - ~2 ~5 * 试验开发主计划 Master T&D Plan * 试验和开发的介绍 Introduction Test & Development 什么含义 ：What it mean ; 设计验证？ Design Validation? 产品验证？ Production Validation? 整车试验开发：M11案例研究 Vehicle Test & Development ; M11 Case study. 试验技术中心试验开发流程的提升 CTTC T&D Process Improvement 试验开发项目管理 T&D Program management 操稳开发 R&H Development 整车可靠性项目 Vehicle Durability program 闭环系统和ESO Closed loop system & ESO 结论 Conclusion * 操稳试验和开发 R&H Test & Development 调查技术能力 Investigate technology available 驾驶竞争车型 Drive competitor vehicles 市场分析 Market analysis 整车DNA提案 Veh DNA proposal 竞争车型 Benchmark competitor vehicles 检验概念车的模拟模型 Prove concept vehicle simulation models 整车和子系统的模拟 Full vehicle and sub-system simulation 目标书的输入Target book input 子系统目标Sub-system targets 零部件技术规格 Component specifications Program Definition & Concept Development Program Start Program Definition Market Analysis Competitor Analysis Benchmarking Concept Definition Target setting Attribute Dev VTS Benchmark Vehicles Technology Requirements Master timing Plan Benchmark Data Concept Performance Target Book * 我们的产品的特点是什么？What’s our Product Characters 特性 Character 舒适性 Comfort 转向 Steering 操控 Handling 基本 –平衡 Balanced 可接受 Acceptable 可接受 Acceptable 可接受 Acceptable 一级 ; 乘坐舒适性 Level I – Ride 柔软 Soft 轻 Light 好 Good 二级 ; 操控性 Level II – Handling 硬 Hard 比基本型重 Heavier than Base 更精准 More Precise 三级 ; 运动 Level III – Sporty 平稳的乘坐舒适性Flat ride 接近中性转向 Near Neutral steer 快速反应 Quick response 四级 ; 豪华 Level IV – Luxury 高减震 Highly Damped 预见性 Predictable 非常安全的感觉 Very safe feel R&H Characteristic study 操稳 * 操稳开发流程 R&H Development Process ADAMS建模检验目标的可完成性。 ADAMS modelling to prove target achievable mule车和子系统的功能性试验 Mule vehicle and/or sub-system functional tests 样件 Mock-up parts 软模 Soft tooling 原型车功能确认 Prototype functional confirmation 对“主观”参数的调校 Iterative tuning of “subjective” parameters 更新模型 Update model 工程总结 Engineering sign off 确认制造质量 Confirmation of build quality 客观测量 Objective measures against targets 解决公差问题 Tolerance issues solved Pre-press preparation Product Development & Sign-off R&H Development Mule Car PH1 Tuning Prototypes Target setting Sub-system Specification Hard point setting Target Book Production Specification PH2 Tuning OTS cars Engineering Sign-off PH1 Demonstration * 操稳开发过程 R&H Development process 操稳开发流程 – 时间表 R&H Development Process – Timing Chart 操稳开发流程 – 节点和职责 R&H Development Process – Milestone & Responsibility 操稳试验项目 R&H Test procedures 操稳目标值设定的项目 R&H Target setting items 操稳目标值数据 R&H Target data 试制样车的制造要求 Prototype Build requirements 调校件清单 Tuning Parts list 操稳技师数据库 R&H Technical data base 一级 – 主观数据 Level 1 – Subjective data 二级 – 客观数据 Level 2 – Objective data 三级 – K&C矩阵 Level 3 – KnC Matrix R&H Development Process * What it mean Design Validation? 什么含义 ：What it mean ; 设计验证？ Design Validation? 产品验证？ Production Validation? 整车试验开发：M11案例研究 Vehicle Test & Development ; M11 Case study. 试验技术中心试验开发流程的提升 CTTC T&D Process Improvement 试验开发项目管理 T&D Program management 操稳开发 R&H Development 整车可靠性项目 Vehicle Durability program 闭环系统和ESO Closed loop system & ESO 结论 Conclusion 试验和开发的介绍 Introduction Test & Development * 车身、底盘可靠性 Body & Chassis Durability 整车综合可靠性 Whole Vehicle General Durability 高环可靠性 High speed Durability 动力总成可靠性 Powertrain Durability 出租车可靠性 Taxi Durability SUV越野路可靠性 Off-road durability : 耐腐蚀可靠性 Corrosion 车队可靠性试验 Fleet operation 可靠性试验标准 Durability test procedures * 可靠性试验标准 Durability test procedures 顾客驾驶里程16万公里 Customer’s Driving mileages : up to 160,000Km Body & Chassis structural Durability : ~ 1600~2000公里车身、底盘结构可靠性 General Dura -All Vehicle system, Parts : 40K 4万公里综合可靠性-考核整车各系统和零部件 发动机10万公里可靠性 Engine Durability : 100K Fleet test : 50~100K 车队试验 ~ 1 : 1 ~ 5 : 1 ~ 100 : 1 ~ 2 : 1 ~ : 1 * 综合可靠性项目 Integrated Durability Program 可靠性目标 为了使消费者满意设计 Design Durability Target For CS 试验场试验 Proving ground test 材料 试验 信息 Material Test Information 疲劳分析 Fatigue Analysis 可靠性 寿命预估 Durability Life Prediction 用户使用Customers Usage - 市场抱怨 Field claim - 担保成本 Warranty Cost 设计 Design 样件制造 Parts Build 原型车制造 Prototype Vehicle build 应力分析疲劳模型 Stress Analysis Fatigue Modelling 道路载荷数据信息 Road Load Data Information 台架试验 Rig Test * 实验室试验 Lab test 零部件试验Component level tests 座椅，车门内外饰 Seats, Door trim 控制臂，弹簧 Control arm, Spring Cassette, Lamps, etc 系统和模块试验 System & Module tests Suspension module IP & Console Body Structure & openings Vehicle Lab test Tire coupled Simulator Multi Channel MTS Engine/Powertrain dyno Engine, Transmission 试验场，室内实验室和消费者驾驶环境联系起来 Correlate with PG & Lab, and Customers Driving environments 试验场试验 Veh Test 试验场试验 Proving Ground tests 车身和底盘结构 Body &Chassis structure 高速可靠性 High speed Durability 动力总成可靠性 Powertrain Durability 整车综合可靠性 Whole Vehicle General Durability 越野路 Off-road Durability 腐蚀试验 Corrosion 普通路试验 Public road test 车队试验 Fleet test 10K, 50K 100K including Hot/Cold climatic, 可靠性试验- 零部件、系统和整车 Dura Test – Comp/ Sys/ Veh * 概念：整车可靠性项目 Concept : Vehicle Durability program 开发阶段 验证阶段 进一步提升 New Powertrain 新动力总成 UnderBody & Chassis Structure车身底部和底盘结构 Whole Vehicle 整车 Comp PH1 OTS1 Mule PH1 Ots1 PH 2 OTS 2 Pilot Corrosion 腐蚀试验 OTS 2 Pilot Proto eng. Pilot Eng. Production Eng. * Body 车身 Chassis 底盘 Powertrain 动力总成 Trim 内外饰 PH1,2 OTS1,2 No of Proto 试制车的数量 New New New New 12~15 New New C/O New . P1 10~11 New Modify C/O Modify S1,G2,H1 . 7~8 Modify C/O C/O Modify S1,G1 G2, 4 Modify C/O New C/O S1,G1, 12 Modify C/O C/O C/O G1. G2. 3 C/O C/O New C/O 10 S 1 : Structure durability 1 car S1指1台结构验证可靠性车 G3 : General Durability 3 cars G3指3台综合可靠性车 H1 : High speed durability 1 car H1指1台高环可靠性车 P2 : Powertrain durability 2 cars P2指2台动力总成可靠性车 需要可靠性车辆的数量 No. of Durability Vehicle required * P6 P7 可靠性关闭率的目标 Durability Closed ratio target P9 P1 P2 P3 P4 P8 P0 P5 Product Development stage Concept Planning stage Product Validation stage 在P5点时可靠性的目标 Durability Targets at P5 1、2类严重问题无开口项 No major Open critical items : “1 & 2” 所有评分高于6分 All rating would be above 关闭率应大于80% Closed ratio should be more than 80% 在P8点时可靠性的目标 Durability Target at P8(Before SOP) 所有严重问题都已关闭。 All critical items should be closed. 所有评分高于6分（根据车的水平而定） All rating would be above (Depends on Car level) 关闭率达到100% （待定） Closed ratio should be (100)% : 无开口项 No open items. * 什么含义 ：What it mean ; 设计验证？ Design Validation? 产品验证？ Production Validation? 整车试验开发：M11案例研究 Vehicle Test & Development ; M11 Case study. 试验技术中心试验开发流程的提升 CTTC T&D Process Improvement 试验开发项目管理 T&D Program management 操稳开发 R&H Development 整车可靠性项目 Vehicle Durability program 闭环系统和ESO Closed loop system & ESO 结论 Conclusion 试验和开发的介绍 Introduction Test & Development * Design Review 重新设计 Test Concern Report试验故障反馈单 TR/CR Summary Retest 重新验证 Risk Analysis风险分析 Risk Analysis风险分析 Open开口 Close关闭 Resolve 解决 如果未达到目标值 If below target 目标值与试验结果对比 Target vs Results comparison 严重问题确认 Critical Items Selection R1; 可行的改进样件 Improved sample available. If above / meet target 如果接近或达到目标值 R2 ; 重新搭载试验开始 Re-test start R3 ; 重新搭载试验结束. Re-test completed 闭环系统 Closed Loop System * 可靠性CR流程 Durability CR Process Concern Report Symptom Investigation Actions taken CR Summary Total issued CR Critical items Open Status DRM : Corrective action R1, R2, R3 R1. : Design improved sample Retest for Validation Analysis : meet Target? Drawing release CR Summary Corrective action R1,R2,R3 Resolved Status Open again If Yes, If No, * No of Problems　 问题缺陷的数量 PH 1,2 Prototype SOP Close Ratio 关闭率 (%) OTS 1,2 Prototype Pilot ~ 80 % 100 % Future 将来 关闭率管理的目标 Closed ratio management target P5 P3 P4 P8 * Comp/System DVP Engineering sign-off at P5 Vehicle T&D Plan NVH Appraisal Component test R&H Durability - Body Brake Climatic test - Trim PE Electric/EMC - Chassis HVAC Crash Material test Appraisal Customer base Subjective evaluation TR Summary Engineering Target vs Development results CR Summary Failures customer desire to repair P5 : ESO Report Target vs Test results Concerns & Action plan DRM Report to PM/Top management Target : Level 1, Level 2 T&D Summary Plan 计划 Do 实施 Check检查 Action整改 P5 P1 P2 P3 P4 All Planned test completed No major open issues. * 什么含义 ：What it mean ; 设计验证？ Design Validation? 产品验证？ Production Validation? 整车试验开发：M11案例研究 Vehicle Test & Development ; M11 Case study. 试验技术中心试验开发流程的提升 CTTC T&D Process Improvement 试验开发项目管理 T&D Program management 操稳开发 R&H Development 整车可靠性项目 Vehicle Durability program 闭环系统和ESO Closed loop system & ESO 结论 Conclusion 试验和开发的介绍 Introduction Test & Development * 试验开发项目管理的原理 Principles for T&D Management Prototype Validation Pilot Validation Mule Car Development Benchmark & Target setting 技术能力 Technical Capability 对目标的责任感 Target Ownership 团队工作Team Work 清晰的目标定义 Clear Targets definition 责任感 Ownership and Responsibilities 清晰的节点和质量门制度 Clear Milestones and Quality gate system 理解全体团队成员 Understanding all team members 设计/CAE/试验开发团队良好的接口 Good interfaces with the Design / CAE / T&D team 高超的功能开发的技术能力 High Technical skills for Function Develop 高水平的流程管理体系 High Level Process Management system * 整车品质和系统关系 Veh attribute and System relationship * 试验开发项目管理的原理 Principles for T&D Management Prototype Validation Pilot Validation Mule Car Development Benchmark & Target setting 技术能力 Technical Capability 对目标的责任感 Target Ownership 团队工作Team Work 清晰的目标定义 Clear Targets definition 责任感 Ownership and Responsibilities 清晰的节点和质量门制度 Clear Milestones and Quality gate system 理解全体团队成员 Understanding all team members 设计/CAE/试验开发团队良好的接口 Good interfaces with the Design / CAE / T&D team 高超的功能开发的技术能力 High Technical skills for Function Develop 高水平的流程管理体系 High Level Process Management system * 高水平的流程管理体系 High Level Process Management system 整车总结 Whole Vehicle Development Process　 工程结构的提升Engineering Structure improvement　 资源管理的制度 Resource management system　 High Quality, Low Cost Car. Customer Satisfaction 高质量的功能开发技术 High Quality Function development Technology 技术发展的研发 R&D for Technology Development 充足的试验设设备和仪器 Adequate Test Equipments and Facilities 工程师的培训 Engineers Training　 技术能力 Technical Capability + * 试验开发项目管理的原理 Principles for T&D Management Prototype Validation Pilot Validation Mule Car Development Benchmark & Target setting 技术能力 Technical Capability 对目标的责任感 Target Ownership 团队工作Team Work 清晰的目标定义 Clear Targets definition 责任感 Ownership and Responsibilities 清晰的节点和质量门制度 Clear Milestones and Quality gate system 理解全体团队成员 Understanding all team members 设计/CAE/试验开发团队良好的接口 Good interfaces with the Design / CAE / T&D team 高超的功能开发的技术能力 High Technical skills for Function Develop 高水平的流程管理体系 High Level Process Management system * 基于目标值的运行体系 Target Based Operation System Customer desire Benchmarking Chery Brand Appraisal Image ride Define New Vehicle characteristics Engineering Target setting Engineering sign-off Test & Development Measurement Design Quality Parts Quality Assembly Quality Field Claim Analysis Market Investigation Confirmation Target Achievement Feasibility Study SOP Design Validation * CTTC的角色和运行 CTTC’s roll and Operation 设计质量 Design Quality 样件质量 Parts Quality 装配质量Assembly Quality 通过试验和开发工作来提升设计质量、 样件质量和装配质量 To Improve Design Quality, Parts Quality, and Assembly Quality through Test & Development 试验开发质量 T&D Quality 试验计划，试验，数据分析和整改 Test Planning, Testing, Data Analysis and Improvement. * Thanks. Any Questions? * Hello, every one. I’m very happy to have a discussion meeting with you today. From now on, I’d like to Introduce the New vehicle test & Development process for Design validation. * OK, I’d like to discuss Mainly three topics about Test & Development. Firstly the meaning of Design validation and Production validation. Secondly, I will explain the Vehicle test & Development experience based on M11 car program. And I’d like to explain CTTC’s Test & Development improvement activities. Finally we can make a conclusion. * What it mean Design validation. Many of Automotive company have their own definition, but generally we can say, “ Design Validation is……….” “This is done through…….…” "Build will be carried out by Suppliers and Prototype build shop. Testing is done by Test group including Material test, Component test, Lab test, and Proving ground tests. Development is done by NVH team, R&H team, Powertrain team, and others. And After Build, Test & Development activities are completed successfully and all the Targets were achieved, Engineering sign-off will be made by Top management. * This chart shows the example of Prototype Development process. PH1 might be a Body & Chassis structural test period, and Crash tests, BIW tests, and Body & Chassis structural durability test should be carried out. During PH2 stage, all of Checklist type tests and Development tests should be carried out. OTS1 stage, PH1 tests to be repeated to confirm whether the all of Body and Chassis structural concerns issued from PH1 testing are solved or not. OTS2 stage might be a refinement stage and all the Validation tests should be completed and finally Engineering sign-off to be done. I think this process is very similar with Current Chery Car program development process. * Recently world leading Automotive company have different process. Firstly Powertrain and Platform development are completed and then several kinds of Car models are developed. It was well known that if we normalize the platform, total cost & timing required for New car development will be significantly reduced. It is a good news that AERI already start to review this new concept and also Test team already start to review this process. I think We need to improve Chery’s Engineering development process as soon as possible to improve our product quality and also to reduce resources and costs. * Production validation. “The process whereby the…… “This is done through….. “Supplier will have a responsibility for the Parts quality. “And Manufacturing should improve the assembly quality. And Function quality monitoring and Durability tests to be repeated again to confirm that the Pilot vehicles have same level of ESO targets. * This chart shows total New car program development process. I think Design Validation should be completed at P5, And Production validation should be completed P8, before SOP. In case of our quality gate, these sign-off requirements should be defined more in detail. * Secondly, I’d like to explain M11 Test and development experience. * When M11 test team review the M11 styling model, M11 team started to discuss How to tune this Nice looking, mid size family car. * Program manager give us the general target, Comfortable drive, Best in class fuel economy and at least 4 star Crash target. And CTTC vehicle development team to consider the vehicle function target. “Balanced R&H “P&E optimization “Comfortable interior environment, “Acceptable NVH level, smooth sound quality, “ High quality of durability. * We run many of benchmarking tests and finally we decided the engineering targets. * During Prototype test period, M11 test team had carried out Test & Development work for Design improvement based on the test plan. Through M11 development, many engineers were trained and we can improve out test capabilities, too. * And also Test team and Design team, PM team had lots of discussion, How to improve the Team work, how to solve the problems, and finally we can improve many kinds of T&D Process. Now we still try to improve, so called CCPMS, “CTTC Car Program Management System” internally. * Finally we complete the M11 development work successfully. I heard that A3 is now very popular in the market. * OK, From now on, I’d like to explain more details about the Test and development activities for Design validation. Firstly T&D Program management. * As I explained just before, CTTC is trying to improve the New car Test & Development process to contribute more on Design validation work. CTTC’s process should be integrated with Chery R&D process, and CTTC’s T&D Process should be agreed by Program managers. And CTTC internally, we are trying to build strong car program team to give more effort to improve the Performance or to carry out the problems solving work more closely with design team. * This shows current Chery quality gate system. From last year, CTTC try to understand Chery quality gate system And based on this system CTTC try to establish more detail Test & Development process. And we found there were lots of items to be improved regarding Responsibility, Targets, milestones, etc. * This chart shows example of new car program scale ability. If Program team release the VTS for the new car development, CTTC Test engineer will define what are the new parts, What kinds of tests are required. * After reviewing the VTS, we define T&D work scope. CTTC Vehicle test team have a capability to run 220 vehicle test items including Baseline test, Development test, Validation and also homologation test. After reviewing VTS, and depends on Target level, T&D procedures for development, for Validation will be decided and to be proposed to program team and Designer. * For example, If we have New engine application program to Current platform without Upper body change, Test & Development items to be as follows: Vehicle performance & Economy improvement test Engine related NVH Development tests Transmission driveability improvement HVAC & Cooling tests and Heat damage tests should be run. R&H, Brake evaluation just for confirmation Engine durability And General durability for Validation can be carried out. * Depends on Car program scale, for example, Major car program, minor car program or just face lift program, we can judge the development lead time, Test procedures, No. of prototypes needed and Test budget. * Finally T&D Timing plan to be proposed to Program team. In this T&D Plan,, I assume total 40 months From feasibility study to SOP if under floor, upper body are new and Powertrain is carried over. If New engine is installed on new car program, maybe total development period will be more than 40 months. If just modified platform to be used, total development timing might be shortened. Based on this T&D Plan, CTTC T&D Mangement work will be carried out. * Now I’d like to introduce another example, R&H development process. * If new car program is proposed by Program management team, Chassis designer, CAE engineer and R&H engineer should make a CHASSIS DEVELOPMENT PLAN. This team will define the character of new car through Competitor analysis and market analysis, Then carry out benchmarking test and finally target to be proposed to Program manager. Maybe we can call this stage “ Concept development stage” Also this stage, Concept drawing might be released and initial CAE work to be started. * In case of R&H character, Once CTTC proposed 5 types of Characteristics. Base model is Balanced R&H Level 1 is more ride comfort car Level 2 is Handling, or fun to drive car, Level 3 is Sporty car Level 4 is Luxury car In terms of Handling, Comfort and steering, we can choose the character based on Styling, Engine power, Vehicle cost, Susp design, etc. * During Production development stage, R&H Development work through mule car testing, iterative Prototype tuning tests to be carried out, and all R&H Development work to be completed at the P5 point Then engineering sign-off to be made by Program manager. * Based on the Vehicle development process, Our R&H team produced Detail R&H Development process including Planning, Milestone & Responsibility, Procedures and Data analysis process. This sheet shows Timing plan for R&H development. This sheet define R&H related activities from P0 to P9, and shows Deliverables at each quality gate. This shows What test should be done at each stage, Benchmarking, Mule car, Prototype and Pilot stage. This is test items for Target setting. This is so called Target book. All of benchmarking data to be recorded in this sheet. This shows prototype vehicle & Component build requirements. This is Tuning parts list. In case of R&H test data, All the data to be recorded during whole New car development period based on this format. Level 1 Subjective evaluation results. Level2, Objective data. Level3, K&C data, I hope we can improve more after discussion with CAE and Chassis design engineer together and then this new process can be implemented to new car program. * Next, I’d like to explain Durability program. * Normally durability test require long period of timing and Test costs are pretty high. It means we should have very accurate Durability test procedures for System and/or Vehicle validation. Most of Automotive engineering center have similar durability test procedures. Accelerated Body & Chassis structural durability test General durability for whole vehicle validation Engine durability test program Corrosion test, Fleet test, etc. * And normally all kinds of durability test procedures are correlated to 160,000Km Customer driving mileages. * Recently Durability test can not be done by Vehicle on-road test due to reduced program timing. So we should consider so called Integrated durability test program. It means, CAE FATIGUE ANALYSIS, Rig and Bench test in the Lab, Proving ground test should be correlated each other. Component, System and Vehicle Durability development should be done through CAE Analysis and Rig test in advance, and finally whole Vehicle durability test should be carried out for final design validation. * This shows Correlation between Customer’s driving environment, Component, Module or Vehicle system lab test and Proving ground test. * This chart shows Durability test program operation concept. CTTC durability team are now considering 3 iteration durability test operation. Iteration 1 will be problems finding and Design improvement stage Iteration 2 will be design validation stage And Iteration 3 will be a production quality validation stage. * This chart shows Durability plan for the new Car program. Depends of the New car program scale, We can define what test should be carried out and How many iteration to be required, Then Durability test timing plan, No. of test vehicle will be decided. * It shows Durability Target at P5, and before SOP timing. Recently, Chery durability committee had started to discuss how to improve durability quality of Chery Product. And CTTC durability test team is going to propose the Durability target. Before SOP, all Critical items should be closed. Maybe there must be lots of discussions how to achieve this target. * OK, Now I will explain about the Closed loop system and Engineering sign-off * This chart shows Problems solving process. Principle is very simple. If problems or Concerns are issued through testing, Concerns will be reported to related Designers, And all the concerns should be discussed with related Engineers and Improvement plan should be decided Then re-test should be carried out for confirmation. After re-test, and if meet target, open items will be closed. * This chart shows the process how to close the concerns issued from Durability test. If test engineer find out the problem, this problems will be reported to related engineers and listed up on the CR summary, And through Design review meeting, Test engineer and Designer should make improvement plan. R1 date should be proposed by Designer, R2 and R3 date should be proposed by Durability test engineer. And if improved sample is available, Same test should be repeated to confirm the problems is solved or not. If problems occurred again, then 2nd design improvement to be carried out. * I think durability quality of our product is not good and many of our customers are complain about this. How to improve the Quality ? If designers provide high quality prototype drawing, and if Supplier to provide good quality prototype parts based on Prototype drawing, And if Prototype build quality is improved more from the early prototype stage, Then CTTC can start durability test from the early prototype stage, It means CTTC can find out the concerns more early, and Designers can have enough time to improve the drawing, And if CTTC run confirmation tests exactly, then our product quality should be improved. * Actually Closed loop system is very complicated for engineering sign-off. Early stage we establish the engineering target. Then We establish the test & Development plan. Many kinds of test and development work should be carried out through Material, Component and Vehicle testing. And all the test results and Improvement activities should be documented through reporting system, At P5 point, All the test should be completed and all target should be met. And finally Engineering sign-off will be made by top management. * OK, Conclusion * CTTC is now trying to establish the New car program Test & Development process based on Three principles. First one is Team work. * This figure shows the relation ship of Vehicle attribute and vehicle system. We can say all of vehicle attribute are integrated with every system of the vehicle. It means Designers, CAE engineers and test engineers should understand each other to achieve balanced Target for the WHOLE vehicle attribute. Team play, communication, sharing the technology and information, these kinds of things are very important for Vehicle development. * Second one is Technical capability improvement. * Most of working level engineers in Chery are very young and we need to improve their engineering capability as quickly as possible through training. An also we need to improve process management system simultaneously. And both Function technology and Process management should be combined together, then we can produce High quality Low cost car to our customers. * Third, Target ownership * Before we start the new car program, related engineers should define the New car’s character and engineering target. The target should meet both customer desire and Chery brand values. Based on the fixed target, all of related engineers and team should try their best to achieve the target. After we achieve the Design quality target, Parts quality target and assembly quality target, then our new vehicle can be introduced to market. We should continuously investigate any field claims or Customer complaints, and we can improve more and more for Customer satisfaction. * I think Test & Development work is one of important task to improve Vehicle quality, like CAE, DESIGN, Prototype build, Quality Control, etc. Currently CTTC is trying to establish the new improved T&D process including T&D Planning, Test technology, Development capability and analysis capability. I hope this CTTC’s T&D activities will contribute more to improve Product quality and also do more contribute to your design validation work.