Case Study

Case Study

Overview
Designing rear seats for a ‘Welfare Vehicle’ enabling vehicle access for people using wheel chair
About the Client
The client is a leading Automotive Tier 1, offering products such as Automotive Suspension Springs, Automotive Seats, Precision Spring & Components, HDD suspensions and mechanical components.
 
Business & Technology Context
  • Currently around 10% of the total world's population, or roughly 650 million people, live with a disability
  • About 23% of these individuals need some sort of specialized assistance or equipment to travel outside the home
  • According to 2015 Open Doors Organization study, adults with disabilities spend $17.3 billion annually on their travel
The above mentioned statistics testifies the demand and the business potential for creating transportation related solutions for physical challenged passengers.
Our client, was looking to develop a rear seat in a “Welfare vehicle“ for an Automotive OEM. This requirement though had a limited market size, was executed by the client as a part of their social responsibility initiatives.
The key requirement was a seat layout such that it can provide space, as well as ease of access to vehicle for people using wheel chair. The rear seats should have the capability to effectively fold and tumble and make way for wheelchair docking as required. Taking into consideration the market constraints, the client wanted to execute the project at low cost with minimal design changes.
KPIT's Solution
The engineering design team at KPIT took these requirements to work on every aspect of product design life cycle such as concept seat design, layout & packaging studies, safety requirements, material selection, DFMEA and more. Detailed computer aided analysis on LS Dyna, Hypermesh & Hyperform was performed to ensure that the design meets the product and regulatory requirements. Final design drawings were released for design verification tooling and physical seat build.
After analysis of the physical test results, the design was improved and released for production.KPIT was involved in a range of activities across the development lifecycle that included:
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Scope of work for KPIT - High alignment with customer processes, practices, tools


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Scope of work for KPIT - High alignment with customer processes, practices, tools

Challenges faced & KPIT's approach
Seating mechanism design developed from scratch: Since these requirement was unique, specification of standard seating mechanism could not be used. A customized seating mechanism was developed from scratch by KPIT engineers.
Quick turnaround for CAE simulation request: Since the client had stringent deadline for executing the project, KPIT engineers performed initial simulations and adopted parallel design modification approach on basis of the simulation results to create multiple layout options for the client.
Understanding client's drawing requirements and standards: The client did not follow global design standards like ASME or ISO & had their own design standards. KPIT engineers prepared a guideline document as per the client's design requirements and used the same for reference.
Seat weight target: After KPIT delivered the seating layout to client, they came back with requirement of reducing the weight of the seating system, ensuring that it conforms to all the regulatory requirements and clears all the simulation tests. KPIT engineers redesigned around 20 components of the system, by reducing their weight & modifying the shape and reduced the weight of the system by 9.25% of the initial weight.
Success Benefits
Cost Optimization: Initially the client wanted to execute this project in Japan. This would have resulted in high investment cost for them. KPIT executed this project from India in a very cost effective manner, providing substantial saving to the client.
On Time Delivery: The client was hesitant in outsourcing the project to an Indian vendor, as the project had to be completed in a very stringent deadline of 6 months. KPIT convinced the client and successfully executed the project comprising of 321 tasks (drawings/models) with 98.1% On Time Delivery. This was achieved by adopting the best practices of ‘Indian Outsourcing Model’ like leveraging past experience to minimize the simulation and design efforts, working in shifts etc.
Extreme Quality Control: 100% reviewed artifacts, 100% defect free delivery
 
Tags: DFMEA, Computer Aided Analysis, LS Dyna, Hypermesh, Hyperform, Automotive Seats, Seat Design, Engineering Design, Welfare Vehicle, Seating System

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CIN: L72200PN1990PLC059594