E-2-Design Phase

According to the input from Planning Phase, we had an initial idea and relevant information. This phase we are going to define the design of the final product, sub-assembly, and individual component. the method of assembling each component to sub-assembly and final product.

According to the information above, the final product could be:

  • A big box has at least 2 space inside which could accommodate a 4 people family and the luggage of the family.
  • People inside shall be able to see the outside environment, it shall equip with transparent material.
  • The box shall also have space that could accommodate necessary equipment/systems to drive the box to move.
  • The box shall equip with the system to control while the box moving at a very speed.
  • There are hundreds more of the requirement description for this final product…etc.

According to information above, the final product is a sedan.

Following activities and documents shall be carried out in this phase.

  • Design/drawings (including component, subassembly and final assembly)
    The design of each component to assemble the final product, and the assessment/simulation/verification of the design shall be defined as well. It includes from a screw to logo, seat, and bumper …etc. It could be defined by the automotive companies and development partners.
  • Bill of Materials (BOM)
    The list contents all components required to assemble the final product, it could include component name/raw material/color/no./qty….etc.
  • Functional Description
    Provide the introduction and background to the finished product: sedan, and sub-assembly including brake sub-assembly for control the speed, fuel pump sub-assembly to transport fuel from tank to engine, and light sub-assembly to provide illumination…etcThe functional description shall also explain how the finished device or combination product functions from a user interface perspective and describe the mechanical features that enable those functions. 
  • Assembly Guidance
    Introduce the assembly planning and development of final assembly equipment and subassembly concepts. It including the assembly of component to sub-assembly to final product.
  • Test Plan
    The protocol/methods/acceptance criteria…etc. shall be defined. It includes endurance/aging test of component and sub-assembly, 4 major test for the final product provided by Euro NCAP…etc.
  • Industrial Design Description
    Define the industrial design of the finished device or combination product based on the customer / development partner requirements. Ex. Michelin/Bridgestone could provide the common tire design as a suggestion to automotive company for wheel frame design, Aerodynamic labs provide the suggestion to automotive company for outer profile design, Brose/Bosch/Continental provide suggestions to automotive company for sub-assembly design…etc.
  • FMEA (Failure mode and effects analysis)
    This assessment is performed at an early stage to identify component functions, potential failures, hazardous situations, and to provide controls to mitigate potential failures to get a robust product design. The assessment shall also include selection of suitable materials and possible hazardous situations related to chemical and physical properties of the material. Additionally, possible risks with handling of the sub-assemblies shall also be included in the risk assessment of the design.
  • Hazard identification checklist (HIC)
    It is intended to identify product characteristics that could affect safety and potential hazards that may occur during the lifetime of the product. The product characteristics and hazards shall be identified from the perspective of the use of the final combination product but only hazards related to the functionality and production of the sub-assemblies shall be further evaluated in the PRA Matrix (FRA0429) (identified hazards that shall be communicated with the customer shall be transferred to RMR).

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