Case Histories

 

 

Project recovery
The case of a high volume OEM powertrain project that needed help
 

The Challenge.

  

A road car OEM was to introduce a new Diesel engine as well as a new transmission on an all new platform.

The engine supplier had run into delays which jeopardized the test work being done at the transmission supplier.

Significant incentives from the supplier meant that the cost to the company of not meeting the timing goals ran into many millions.

Our challenge was to work with the suppliers to recover a key part of the the project and ensure that the transmission supplier had representative engines and mule cars to complete their development and test work with.
 
The Solution
  
Based on site with the transmission supplier, a strategic plan was drawn up with the following steps.
 
  • Define the key goals and deliverables.
  • Define the inhibitors.
  • Draw up a plan for each inhibitor and execute.
  • Monitor and report progress.

As the engine supplier was not able to support fully the testing needs of the transmission supplier, various alternatives were implemented to allow representative testing to continue using custom engineered solutions and parts from other engine manufacturers.

Monitors were put on the test cells to allow preemptive servicing and repairs to remove unnecessary down time.

Many issues in the supply chain hinged on corporate politics and so new links were formed and communications opened up to free things up.
  The Result  
Test hours completed went from a monthly average of 40 hours with two cells running to over 1000 hours with four cells running. The systems and procedures set in place allowed a smooth hand over and the product has now been launched.

 

 

Show Vehicle
A TV program with a tight budget and and even tighter time scale want an impossible vehicle, so we make it.
 

The Challenge.

  

A TV company were making a new game show where contestants had to drive a double ended vehicle using team work and skill.

Our challenge was to design and build the vehicle in five weeks using minimal resources.
 
The Solution
  
A plan was created where we would take on the following activities.
 
  • Work with producer and director to create workable specification.
  • Rigs to test and evaluate initial concepts.
  • Safety certification process.
  • Design and build vehicle.
  • On set support including late change engineering.
  • Team management of customer selected suppliers and contractors.

 
  The Result  
The vehicle was completed on time and the series successfully filmed.

 

 

Powertrain Development
From defining user requirements, through design and development to delivery.
 

The Challenge.

  

A vehicle manufacturer was to introduce a new powertrain that will surpass all competition whilst maintaining independence from other powertrain suppliers.

Our challenge was to manage the powertrain control system and facilitate early test work.
 
The Solution
  
We took an active role in the customers powertrain development team and provided the following services.
 
  • Define system specification, key goals and deliverables.
  • Identify and manage suppliers.
  • Facilitate test buck cylinder heads to evaluate key concepts.
  • Organize testing and evaluation sessions.
  The Result  
The first mule engine produced so much torque that the dyno coolant boiled! New emissions and performance levels were achieved.