AUTOMOTIVE Project Management for Automotive Engineers

AUTOMOTIVE
Project Management for Automotive Engineers
A Field Guide

Jon M. Quigley Roopa J. Shenoy

image courtesy of A2Mac1

Table of Contents
Preface.................................................................................................. 1 Chapter 1: Overview of Managing Automotive Projects ...................3
1.1 What is at Stake?...........................................................................................................3 1.2 Overview of Project Management Areas...................................................................4 1.3 Organizational Influences..........................................................................................14 1.4 Communication ..........................................................................................................20 1.5 Contract Types.............................................................................................................22
Chapter 2: Business Case and Product Development Models....... 25
2.1 Business Justification..................................................................................................25 2.2 Project Life Cycle.........................................................................................................29 2.3 Models of Development.............................................................................................33 2.4 Mix the Two: Business Case and Phases..................................................................35
Chapter 3: Vehicle Subsystem and Concept Generation .............. 37
3.1 Vehicle Concept Development and Selection.........................................................37 3.2 Requirements, Specifications, and Drawings.........................................................40 3.3 Requirements and Change Management ...............................................................43 3.4 Requirements Traceability Plan................................................................................46 3.5 Configuration Management Plan.............................................................................47 3.6 Technical Reviews.......................................................................................................48 3.7 OEM and Top-Tier Supplier Selection.....................................................................49
Chapter 4: Product Development................................................... 59
4.1 Project Schedule: Time Plan.......................................................................................59 4.2 Prototype Delivery and Risk ....................................................................................64 4.3 Virtual Testing and Prototype in Product Development.......................................66 4.4 Resources Allocation..................................................................................................70 4.5 Key Product Characteristics......................................................................................75
Chapter 5: Process Development.................................................... 79
5.1 Process Overview........................................................................................................79 5.2 Tier 1 Production Line and Prototypes....................................................................83 5.3 OEM Product Handling.............................................................................................84 5.4 Manufacturing Specific Deliverables.......................................................................86

Chapter 6: Product Life Cycle and Testing...................................... 95
6.1 Fundamentals..............................................................................................................95 6.2 Testing Process.............................................................................................................97 6.3 Agile Practices Applied to Conventional Projects................................................100 6.4 Communication during the Test Phases................................................................101 6.5 Verification vs. Validation Process..........................................................................104 6.6 Product Validation ...................................................................................................105 6.7 Product Verification and Features..........................................................................106 6.8 Process Verification...................................................................................................107 6.9 Verification through Simulation..............................................................................108 6.10 Continuous Conformance Testing........................................................................108 6.11 Different Test Modes...............................................................................................109
Chapter 7: Design to Ramp Up Production..................................... 111
7.1 Why is it Critical?...................................................................................................... 111 7.2 Activities Needed from Design Board to Production Floor................................ 114 7.3 Critical Activities to Support Ramp Up................................................................. 117 7.4 Transition from Project to Operations....................................................................120 7.5 Transition from Prototype to Production..............................................................125 7.6 Supply Chain Decisions...........................................................................................126 7.7 Environmental Impact..............................................................................................127
Chapter 8: Early Production...........................................................129
8.1 Tier 1 and Vehicle Operations.................................................................................129 8.2 Export Vehicles .........................................................................................................132 8.3 Prediction of Product Production Quality (OEM and Tier 1).............................133 8.4 Impact of Customization..........................................................................................134 8.5 Statistical Process Control for Tier 1 and OEM.....................................................135 8.6 OEM Sampling Strategies (Inspections)................................................................135 8.7 Missing Hardware Strategy.....................................................................................136 8.8 Labels, Certifications, and Manuals.......................................................................136 8.9 Post-Vehicle Launch Activities................................................................................137 8.10 Vehicle and Part Field Failure Recovery..............................................................137 8.11 Transition from Project to Customer Service Group..........................................138
Chapter 9: Project Closure and Something More.......................... 141
9.1 End of the Game........................................................................................................141 9.2 Lessons Learned........................................................................................................142 9.3 Knowledge Management.........................................................................................145 9.4 Something More........................................................................................................147

Chapter 10: Closing Remarks......................................................... 155
10.1 Prioritize and Plan..................................................................................................155 10.2 Use Fact-Based Metrics..........................................................................................156 10.3 Review of Chapters.................................................................................................157
Index..................................................................................................161 List of Abbreviations.........................................................................00 About the Authors............................................................................00