AC-DC - Automotive Chassis Development for 5-day Cars
Overview
Background & policy context:
To date, a clear hierarchic structure dominates automotive manufacturing assuring a 100% delivery of components and systems just in time and just in sequence.
However, new challenges emerge, such as:
- a steep increase in modularisation and interdisciplinary technologies;
- market pressure for variability and flexibility to customers;
- cost pressure demanding a reduction of stocks on the supply side;
- a highly flexible mastering of global production and delivery, which will mean a rapid development of an efficient 'networked' production scheme.
This called for a determined step forward in motor vehicle technology combined with a dynamic planning process involving the full supply chain. In order to break with the traditional hierarchic manufacturing, revolutionary concurrent elements were introduced that reduce stocks and allow last minute configuration of new products in higher variations and quality and at lower costs.
Objectives:
The prime objective of AC-DC was to develop a concept that radically enhances automotive
manufacturing in order to achieve the high level of responsiveness required for a 5-day car process, according to customer specifications, with the development and introduction of individual and highly reactive planning loops in the supply chain.
The efficiency of this future system was validated realistically by considering the emerging step-change in component technology (technology convergence of 'Mechatronics' for customer neutral modules of high parameterisation).
Methodology:
Coordinated by Continental Automotive Systems (Dr. Wolfgang Menzel -Vice President Logistics Automotive) the consortium of major European car manufacturers, suppliers, research institutions, and academia addressed a vehicle system that promises maximum impact and reward regarding the transferability to other parts of the vehicle and that could be achieved within the four years duration of the project.
From a technical point of view, the developed highly mechatronic automotive chassis modules support a late customisation of order-neutral modules towards costumer-specific requirements. Derived from this novel automotive chassis technology there is plenty of potential for even new drive-trains, electrical propulsion, and new wheel systems. The technologies tackled by AC-DC enhanced existing safety functions and increase driving comfort options. Technical progress in intelligent software and sensor-actuator technology combined in customer-neutral mechatronic chassis modules pave the way to the next generation of automotive chassis, which needs to be taken into account by new automotive production processes.
Furthermore, AC-DC developed the requisite 'dynamic supply chain collaboration concept' that promotes the conventional automotive terms of delivery to a highly reactive 5-day-capable' system that cuts down inventories in the supply network. Importantly, AC-DC maintained a 100% guarantee of delivery as an uncompromised constraint. Leaving hierarchic production concepts behind by building on multiple planning loops the dynamic supply network management is an ideal test case for the integration of both the requisite high-tech module technology and the appropriate process configuration features.
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