UMTRI Project

Dimensional Validation & Functional Build Analysis for Exterior Lamp Assemblies

Sponsor: Visteon
Investigator: Patrick Hammett
08/01/2006 - 03/31/2007

Recently, the development of 3D non-contact large data measurement systems as a viable technology option has further enhanced functional build strategies. This technology allows manufacturers to support numerous functional build type-activities such as virtually re-aligning parts to different datum schemes, performing virtual assemblies from components, evaluating tolerance and nominal stack conditions, and creating a functional master “average part” for future production monitoring. For many vehicle components, these 3D non-contact systems are capable of meeting Gage R&R requirements and provide both a comprehensive part assessment (e.g., full surface profile) as well as a subset of discrete point measurement outputs to assess process stability and capability. Although functional build strategies represent a recognized, effective process for many automotive body manufacturers, they are less common with the exterior components that fit to them. Thus, fundamentally changing the traditional dimensional validation systems used for body exterior parts would represent a significant challenge. Part validation and approval processes like PPAP are in-grained within the vehicle development process for NA manufacturers. The purpose of this project is to evaluate the feasibility of modifying traditional dimensional quality evaluation business processes toward a new system that effectively incorporates functional build concepts and potentially 3D non-contact measurement systems. The part focus of the project will be on exterior lamp assembly systems, though the business process to be developed is expected to generalize across other exterior component systems.