Automotive OEM Research Articles

Electric Vehicle Import/Export Flows in Maritime Ports: Are Local Stakeholders Monitoring their Arrival?

Within the global climate change risk mitigation frame, automotive OEMs are progressively replacing ICE-powered cars with electric vehicles in their model ranges. This strategic move is deeply impacting every level of their supply chains, including maritime ports. To shed some light, in the absence of relevant academic literature, on how closely local stakeholders are monitoring this evolution, multiple port authorities’ and logistic service providers’ institutional websites, as well as auto industry-related web sources, have been browsed (Q4 2023), looking for comments on the arrival of electric vehicles in North American and European auto ports. Study shows that contexts differ from one region to another, even from one port/one stakeholder group to another, leading to various attitudes ranging from spontaneous early movers to hyper-cautious followers.

Testing scenario for comparison of real-time locating system in automotive manufacturing

Manufacturing plants are pursuing a more profound knowledge of movement within the plant, including processes, products, and people. Varied methods are used today to track machines, parts, and bins, including computer vision, Bluetooth, Radio-Frequency Identification (RFID), Wi-Fi, 5G, and Ultra-wideband. Prior studies have examined the capabilities of these systems in the laboratory, and limited studies have analyzed performance in the real world. This work describes the testing methodology to be used in the first study that examines the performance of multiple commercial Ultra-wideband systems within the same environment that closely simulates a real-world automotive production facility to understand the capabilities of modern system performance in a series of functional tests. This work details the tests developed and limited results in cooperation with a large automotive OEM to go beyond the specifications available from each commercial vendor. Future work will expand upon the resulting data output and compare additional types of motion-tracking systems, such as computer vision.

Innovative approach to develop a thermal management system for a battery electric vehicle

Nowadays all the automotive OEMs were investing huge amount of dollars to develop an innovative technology to handle the thermal management system of their battery electric vehicle (BEV) and hybrid electric vehicle (HEV) . Lots of techniques were used to develop this thermal management system (TMS) by investing huge amount of man hours . In this paper an innovative is handled to understand the available available possible ways to achieve a cost optimized TMS for a HEV and BEV. This is a very basic, but efficient methodology which leads to provide an enhanced system to balance the cost and achieve the customer requirements. The pugh DFSS methodology is used to compare,analyze and evaluate using the simulation techniques. Going forward this proven solution can be implemented in the real time vehicles.

Product-service systems in large automotive OEMs: characterising the decision-making process when developing and introducing vehicle sharing/pooling schemes

AbstractAutomotive OEM introduced Product-Service Systems in the past 20 years, challenging their traditional business model. A qualitative study was developed to characterise the decision-making process across 6 case studies, and similar patterns across different enabled the identification of lessons learned and possible future implications. All PSS initiatives were introduced following an Agile/Lean experimental approach, but the opportunistic nature of trials casts doubts in future validity. New testing methods that generate more robust conclusions need to be developed.

BASF launched the GLASS tool to calculate CO2 and cost simulations for automotive OEM

BASF launched the GLASS tool to calculate CO2 and cost simulations for automotive OEM

Applying a System of Systems Perspective to Hyundai‐Kia's Virtual Tire Development

ABSTRACTSystems engineering has become important in almost every complex product manufacturing industry, especially automotive. Emerging trends like vehicle electrification and autonomous driving now pose a system of systems (SoS) engineering challenge to automotive OEMs. This paper presents a proof‐of‐concept (PoC) that applies a top‐down SoS perspective to Hyundai‐Kia Motor Corporation's (HKMC) virtual product development process to develop a performance‐critical component of the vehicle, the tire. The PoC demonstrates using the Arcadia MBSE method to develop a consistent, layered, vehicle architecture model starting from the SoS operational context down to the lowest level of system decomposition in the physical architecture thereby capturing top‐down knowledge traceability Using the concept of functional chains, several vehicle performance views are captured that serve as the basis for architecture verification orchestration across engineering domains using a cross‐domain orchestration platform thereby validating key vehicle/tire performance metrics that influence the tire design parameters. Preliminary results of the study show that applying a method‐based modeling approach could provide several benefits to HKMC's current product development approach such as reduced time to model, SoS knowledge capture and reusability, parameter/requirement traceability, early performance verification, and effective systems engineering collaboration between the OEM, tire design supplier, and tire manufacturers.

Testing the S-Curve Theory in OEM for Lean Operations: A Study on Organizational Transformation in the VUCA World

As the world is becoming more VUCA, only a few studies focus on exploring the plant performance and mapping its pattern in real time. The existing study shows that plant performance can be linked to an S-curve theory. This is mainly due to market turbulence, demand for continuous improvement, and the introduction of emerging technologies. Taking this idea, in this article, we focus on testing the S-curve in the lean deployment of an OEM. The study proposes integrating lean tools with decision-making techniques to achieve productivity benefits. The proposed method uses VSM to portray the changeover activities and standardize them using the SMED technique to reduce the changeover time alongside other continuous improvement suggestions. This provides real-time active solutions for decision making, prediction, and planning of resources. It also assists the industrial units in getting better insights into their productivity improvization and market evaluation trends. The study proposed an IoT-driven ecosystem for effective decision making in the OEM environment. Finally, the study is tested in an automotive OEM that has reduced changeover time by > 75% and an overall productivity increase of 27.31%. Such an ecosystem contributes to organizational transformation and promotes innovation in OEM.

Optimal Capacity Allocation to an Automotive OEM Facing Service-dependent Demand and Market Exit Risk

Optimal Capacity Allocation to an Automotive OEM Facing Service-dependent Demand and Market Exit Risk

Systems engineering in automotive product development: A guide to initiate organisational transformation

Systems Engineering (SE) is an engineering method that has rarely been applied in Automotive Product Development, despite its noticeable positive effects in other engineering fields. With increasing interests, firms and scholars have started to discover its impact in the segment, however internal hurdles appear when it comes to implementation practices at organisations across the industry. This paper presents a comprehensive guideline, results and good practices on the SE implementation, developed in Formula SAE (FSAE), which is a relevant model environment of automotive industry. The impact of applying SE show project results improvement in cost, time and quality aspects, although, the maturity of SE should be assessed at the system of systems level. Outcomes gained from FSAE have been validated by in-depth interviews with SE experts, engineers and managers affiliated at technical development departments of 4 different automotive OEMs. These practitioners provide evaluated practices as employee involvement, applying learning by doing, and playing with architectures relevant and feasible in industrial setting, however emphasized expected impeding factors as sluggishness and general resistance to organisational changes.

Solvent Borne Paints for Automotive OEM

Solvent Borne Paints for Automotive OEM

Applying a System of Systems Perspective to Hyundai‐Kia's Virtual Tire Development

AbstractSystems engineering has become important in almost every complex product manufacturing industry, especially automotive. Emerging trends like vehicle electrification and autonomous driving now pose a System of Systems (SoS) engineering challenge to automotive OEMs. This paper presents a proof‐of‐concept (PoC) that applies a top‐down SoS perspective to Hyundai‐Kia Motor Corporation's (HKMC) virtual product development process to develop a performance‐critical component of the vehicle, the tire. The PoC demonstrates using the Arcadia MBSE method to develop a consistent, layered, vehicle architecture model starting from the SoS operational context down to the lowest level of system decomposition in the physical architecture thereby capturing top‐down knowledge traceability. Using the concept of functional chains, several vehicle performance views are captured that serve as the basis for architecture verification orchestration across engineering domains using a cross‐domain orchestration platform thereby validating key vehicle/tire performance metrics that influence the tire design parameters. Preliminary results of the study show that applying a method‐based modeling approach could provide several benefits to HKMC's current product development approach such as reduced time to model, SoS knowledge capture and reusability, parameter/requirement traceability, early performance verification, and effective systems engineering collaboration between the OEM, tire design supplier and tire manufacturers.

WORKING AGILE TO SPEED UP RESEARCH WITH INDUSTRY: FIVE INDEPENDENCE PRINCIPLES

AbstractOne of the obstacles to the ability of research to make an impact on industry resides on the research process itself. Today, there is a need to accelerate the means for research to support industrial transformation. At the same time, there is the need to maintain scientific rigorousness, which often requires time. To solve this trade-off, this paper evaluates existing research approaches through the lenses of agile development. The analysis is based on a simulation of research process architectures, and on observations made over several research projects with industry. The results of this analysis highlight five light-but-sufficient rules of research project behavior to keep momentum, motivation and trust when doing research with industry. The paper demonstrates the use of these five rules in a “research sprint” conducted iwith two automotive OEMs.

ELIX Polymers receive approval from premium Automotive OEM for anti-squeak materials

On June 20, 2023, ELIX Polymers announced it had developed a range of speciality grades of ABS and PC/ABS to reduce the squeaking and rattling sounds that are generated by plastic parts making contact with other plastic parts, leather, PVC-foil or other products.

Frequency-dependent automotive suspension damping systems: State of the art review

Configuration of a passive suspension of a passenger vehicle most often requires a compromise between its handling, road-holding, and ride (passenger) comfort. Nowadays, car manufacturers (automotive OEMs) are forced to develop ways for enhancing the functionality of shock absorbers and yet keeping their costs low. The use of so-called frequency-dependent (FD) valves in hydraulic passive suspension dampers, which allow the damping force to vary with the frequency of the excitation (or its change rate), is a satisfactory solution to the problem by means of adaptive passive valves. In this study, the effectiveness of the FD technology in passenger vehicles is demonstrated on the basis of a quarter-car simulation model. This is followed by a comprehensive review of several FD type valve structures currently offered by various automotive damper suppliers. Their advantages as well as potential drawbacks are shown and hydraulic circuits are formulated for each of the considered designs. Exemplary characteristics of a FD shock absorber obtained from own measurements are shown, too. The results of subjective qualitative evaluation of analyzed cases are presented and appropriate directions for further development steps are proposed. Finally, simulation results of functional model of FD shock absorber are presented.

A Method for Managing Software Assets in the Automotive Industry (Focusing on the Case of Hyundai Motor Company and Parts Makers)

We propose a method for managing software assets in the automotive industry to enhance software competitiveness and to reduce development costs. The ownership of software assets in the automotive industry is held by automotive parts companies, making it challenging to exchange these technologies. Moreover, the criteria for determining software assets are often unclear, resulting in difficulties in integrating automotive software and implementing over-the-air updates. To address these issues, we suggest breaking down black-boxed software assets into tradable components, valuating them, and introducing the concept of exchanging software technology assets. Additionally, we provide a structured approach for recycling used software assets and establish a software asset management system for registration and tracking. Our proposed approach can help traditional automotive OEMs narrow the technology gap with automakers such as Tesla and improve their software competitiveness in the automotive industry. This paper contributes to the advancement of software asset management practices in the automotive industry, and provides insights into the integration of automotive software and over-the-air updates.

Methodology for Certification-Compliant Effect-Chain Modeling

The success of engineering complex technical systems is determined by meeting customer requirements and institutional regulations. One example relevant to the automobile industry is the United Nations Economic Commission of Europe (UN ECE), which specifies the homologation of automobile series and requires proof of traceability. The required traceability can be achieved by modeling system artifacts and their relations in a consistent, seamless model—an effect-chain model. Currently, no in-depth methodology exists to support engineers in developing certification-compliant effect-chain models. For this purpose, a new methodology for certification-compliant effect-chain modeling was developed, which includes extensions of an existing method, suitable models, and tools to support engineers in the modeling process. For evaluation purposes, applicability is proven based on the experience of more than 300 workshops at an automotive OEM and an automotive supplier. The following case example is chosen to demonstrate applicability: the development of a window lifter that has to meet the demands of UN ECE Regulations R156 and R21. Results indicate multiple benefits in supporting engineers with the certification-compliant modeling of effect chains. Three benefits are goal-oriented modeling to reduce the necessary modeling capacity, increasing model quality by applying information quality criteria, and the potential to reduce costs through automatable effect-chain analyses for technical changes. Further, companies in the automotive and other industries will benefit from increased modeling capabilities that can be used for architecture modeling and to comply with other regulations such as ASPICE or ISO 26262.

Relations of Digital Twin Fidelity and Benefits: A Design-to-Value Approach

Digital Twin (DT) is an important concept in research and practice. Its relevance spans across all product life cycle phases, including design, prototyping, manufacturing, service, and disposal. Despite its attention, practical examples of DTs in product design and manufacturing are scarce. One of the reasons for this is little understanding of the benefits. Organizations face problems in predicting whether applying DTs will achieve benefits. However, realistic benefit expectations and a qualitative understanding of the evolution of benefits are essential for successfully applying DTs. Fidelity is thereby a crucial factor influencing costs and savings potential. Consequently, the Digital Twin Benefit Curves (DT-BC) were developed using Design Science Research while drawing on existing literature. Results were evaluated in a focus group with 5 DT experts from 3 different aerospace and automotive OEMs and 1 university, along with additional interviews. The developed curves serve as a reference for managerial decisions concerning DT design and application. Additionally, they strengthen the understanding of DT benefits and prevent stakeholders from developing false expectations that lead to acceptance issues. By doing so, DT-BCs facilitate Digital Transformation. The results provide a novel approach to make DT benefit evolution clear and tangible by visualizing its relation to fidelity.

How automotive OEMs can lever platform-based ecosystems through the strategic use of boundary resources

How automotive OEMs can lever platform-based ecosystems through the strategic use of boundary resources

How automotive OEMs can lever platform-based ecosystems through the strategic use of boundary resources

How automotive OEMs can lever platform-based ecosystems through the strategic use of boundary resources

Remanufacturing Process Optimization - Introducing Dynamic New Part Infill to Increase the Utilization Rate of Remanufactured Components for Multi-Variant Cores

Climate change, resource scarcity, and the current energy crisis demand fundamental change to overcome future problems. The Circular Economy represents a sustainable process transformation by closing value chain loops. Remanufacturing is one method that extends the life cycle of materials by returning worn-out products (cores) to the manufacturer to produce like-new remanufactured products. In detail, cores are disassembled into core components, which are inspected, sorted out, cleaned, remanufactured, and reassembled into a remanufactured product. The challenge is that multiple components in different conditions must be combined into one remanufactured product because only a certain quantity of core components can be used for remanufacturing due to quality criteria (yield rates). The cores’ uncertain quantity and different yield rates of core components limit the maximum amount of remanufactured products, and the component with the lowest quantity acts as the bottleneck. In other words, although the rest of the parts have been remanufactured through costly and time-consuming processes, they remain unused, and the output of newly remanufactured products is obstructed. Such inefficiencies must be reduced to increase efficiency and create a sustainable process. This paper proposes a problem formulation and a concept that optimizes the utilization of remanufactured components in remanufacturing processes by modifying the bills of material of remanufactured products. The concept implements a dynamic infill of new parts, applying a dynamic mixture of new and remanufactured components to increase the number of remanufactured products while following technical and process restrictions (e.g., production and material planning, quality requirements). The utilization problem is identified as a combinatorial optimization problem and translated into a general multidimensional knapsack problem. The resulting knapsack problem is optimized with a meta-heuristic to find a satisfying solution for the utilization of remanufactured components. Following the case study methodology, the concept is developed, tested, and validated with an automotive OEM.