Author - Mr. Jagdish Jadhav, Tata Motors Ltd, India 1, (*) Co-authors - Mr. Kunal Gaikwad, Tata Motors Ltd, India 1, Mr. Sandeep Nevase, Tata Motors Ltd, India.1 KEYWORDS – Light weighting, BIW Analysis, Automotive benchmarking, PMXU study, VAVE Objective: Automotive benchmarking is a crucial aspect in-order to innovate, enhance and evolve by physical and digital analysis of competitor’s vehicles to understand their functionality, design and packaging. This data is useful to perform VAVE and optimize the part to achieve weight and cost reduction. Body-in-white (BIW) viz. Vehicle’s welded steel structure is a vital part and has high potential for light weighting as it contributes to nearly 40% of vehicle’s kerb weight. The main objective is to know the recent trends and technologies by doing benchmarking and deep analysis of competitor’s BIW to achieve significant light weighting targets. Methodology: The methodology below aims to describe the approach adopted to deeply analyze the BIW and achieve significant light weighting targets. We have adopted a 12 step detailed approach towards BIW teardown and analysis comprising of: 1. Torsion and Bending testing of BIW to analyze the stiffness value. 2. 3D scanning of BIW interior and exterior. 3. Dismantling BIW Panels wise. 4. Identifying weld spot strategy used by competitors. 5. Analyze sealant strategy used by competitors. 6. 3D scanning of BIW panels. 7. CAD Conversion of 3D scan data. 8. Material analysis to identify the material composition and grades. 9. Measure BIW panel stiffness. 10. Identify grommets and melt sheet strategy used by competitors. 11. Structured VAVE Approach. 12. PMXU strategy. Results: Development of competency for BIW analysis with a structured approach. Understanding competitor’s platform strategy in BIW design. Evolution of a Novel process in Level Next benchmarking complying with industry 4.0. Achieve weight and cost reduction targets. Achieved reduction in carbon footprints. Benchmark Database creation for future projects. Limitations of this study: Since this was the Level Next approach we had limitations to generate a CT scan inspection of the BIW before physical teardown. The CT scan technology would have helped us for better visualization of internal panels of BIW. What does the paper offer that is new in the field including in comparison to other work by the authors? The structured approach to bring accurate digital validation of competitor’s welded steel structure i.e. BIW is novel in its sense. For any OEM they have design data of their own product but there is no way to get competition design data on which we can perform certain objective level analysis which is comparable with OEM’s product design. The structured step by step process developed by the team will ensure capturing of competition data systematically and then would be converted into the digital form to perform the objective level analysis. Conclusions: By developing our systematic process of BIW level teardown and benchmarking we have brought the benchmarking to whole new level by developing this capability as a way of life, we could understand the competition strategy over a period of time and at the same time can build our strategy for our future products. This process will be the continuous practice so as to capture the technological advancements in terms of Material Science, Manufacturing process and light- weighing strategy.
Mr. JAGDISH JADHAV, Deputy General Manager, Tata Motors Passenger Vehicles Ltd.