Sukhena Technologies

ISO 9001 : 2015 Certified Company

AUTOMOTIVE ENGINEERING

Sukhena technologies follow JIT/LP ‘Just In Time and Lean Production’ philosophy in its expertise and solution offerings to its customers and it recognizes that effective product realization requires flexibility and leanness (i.e. Agility) across the whole process of ‘ design to manufacturing’, achieving this is the main challenges for any product developer (OEM’s) and service provider (Suppliers) in the new millennium. Sukhena extensively utilizes following enablers in its product development process.

Any product’s development and manufacturing cost is largely determined by decisions taken during the initial phase (stage) of the design. Early simulation can significantly guide conceptual design, even before detailed geometry is firmed. Efficient use of simulation tools at the concept level enables the right design options in order to balance key performance attributes and avoid extensive troubleshooting in the prototype phase.

Sukhena engineers are continuously involved in full-vehicle and subsystem development programs, and have gained vast experience with automotive development processes and practices. Through technology deployment programs, Sukhena enables customers to implement innovative processes and advance their capability& capacity to carefully balance functional vehicle performance requirements.

Served by techniques that feed forward, into the design stage, the relevant information about the potential downstream consequences of decisions made early on in the product’s design process. The downstream consequences include the product’s manufacture and its subsequent use by customers in the market place. Early design decisions therefore ripple throughout the whole business organization. Defining quality as meeting (and exceeding) the needs and expectations of customers gives us a way to start to address about the product’s design in relation to the customers perception.

Vehicle category

System and Subsystem Experience

2-Wheelers

ICE | BEV

3-Wheelers

ICE | BEV

Commercial Vehicles (LCV, HCV)

ICE | BEV

Passenger Cars

ICE | BEV

Off-highway |(Tractors, Excavators)

ICE | BEV

Vehicle Design - Overview

The very first stage of the vehicle production has to be design. Design can be considered as an activity to find the best (optimal) solution to an engineering problem within certain constraints. The whole process involving solution from conception to evaluation, including safety, comfort, aesthetics, ergonomics, manufacture and cost. Designing is an integrated, multi-stage operation, which must be flexible to allow modifications for specific problems and all requirements arise during whole process. One of the management technique used for design is IPPD (Integrated Product and Process Development). IPPD facilitates meeting cost and performance objectives from product concept through production, including field support.

There are 10 key tends of IPPD

  • customer focus,
  • concurrent development of products and processes,
  • early and continuous life cycle planning,
  • maximize flexibility for optimization and use of contractor unique approaches,
  • encourage robust design and improved process capability,
  • event-driven scheduling,
  • multidisciplinary teamwork,
  • empowerment,
  • seamless management tools,
  • proactive identification and management risk .

Vehicle Design

Customer Relevant Vehicle Characteristics

The task of the design team is usually split into three main aspects: 

exterior design, interior design, and color and trim design. Graphic design is also an aspect of automotive design; this is generally shared amongst the design team as the lead designer sees fit. The design focuses not only on the isolated outer shape of automobile parts, but concentrates on the combination of form and function, starting from the vehicle package.

The aesthetic value will need to correspond to ergonomic functionality and utility features as well. In particular, vehicular electronic components and parts will give more challenges to automotive designers who are required to update on the latest information and knowledge associated with emerging vehicular gadgetry, particularly mobile devices , like GPS navigation, satellite radio, HD radio, mobile TV, MP3 players, video playback, and smartphone interfaces, iOT. Though not all the new vehicular gadgets are to be designated as factory standard items, some of them may be integral to determining the future course of any specific vehicular models.

Vehicle Engineering

System and Subsystem Experience

Interiors & Seating
Instrument Panel | Seat | Trims | | Glove Box | Air Vents | Consoles | HVAC | Headliners | Steering Controls
Exteriors
BIW | Bumpers | Doors and Closures | Mirrors | Spoilers | Fenders | Bonnet, Boot Lid, Tank Cover Module | Roof System | Grills | Pillars | Lighting | Lift Gates
Steering | Suspension
Manual & Power Steering | | Suspension Analysis | | Stability & NVH
Battery System | Management
Battery Capacity |Battery Calculation |Battery Management System
Chassis | Axle | Brake
Ladder Type Chassis | Monocoque | | Power & Driven Axle | Disc & Drum Brake Packaging

Product Engineering

Heads-up

Some of the computer-aided design and development capabilities that Sukhena team has developed over a period of time,
  • Concept Development
  • Styling & Surfacing
  • Homologation & Compliance
  • Reverse engineering & Bench Marking,
  • BOM, Localization
  • Detail design & development
  • Packaging & System integration
  • Design DFMEA, Validation & Optimization
  • Manufacturing Process development
  • VAVE ideas, to help reduce cost
  • EV Module based design
  • Design Calculations
  • Proficient with Manufacturing support activity.
  • Design & Development of Jigs & Fixture and Equipment Tooling (GHE, GSE, PME & FME).
  • GD & T
  • Manufacturing & Structural Assembly Tools Design and Composite Tool design.
  • Prototyping & Manufacturing support.
  • Process Planning and Improvements. Process Flow PFMEA, Control Plan
  • Virtual manufacturing and Simulations.
  • Collaboration with testing labs facilities and Consultancy
  • Test Plan Development
  • Test Plan Checklist Creation
  • Jigs & Fixture Detailing & Designing & Validation
  • Prototype testing
  • Material Coupon Testing
  • Fatigue Testing
  • Strength and Stiffness Testing
  • 4-Post RLD Vibration
  • Corrosion Testing
  • NDT – Dye Penetration Test
  • Legacy data conversion
  • 2D & 3D Design, Detailing & Drafting
  • Product Packaging
  • BOM, Math Per VDP
  • Engineering Change Request
  • Design standardization
  • GD & T, Tolerance Stacking
  • VA &VE Studies
  • DFM, DFA
  • DFMEA
  • Engineering custom application development and maintenance.
  • Data integration services.
  • Reliability engineering.
  • Engineering data application support.
  • Component Level tool development Support
  • BIW Welding Fixture
  • Testing Fixtures
  • Die Designs, Sheet metal Forming
  • Injection Mould designs
  • Rapid Prototyping
  • Tooling Design
  • Forming Simulation
  • Vendor supply management

Design Verification (CAE) – Heads-up

Some of the computer-aided engineering analysis capabilities that Sukhena team has developed over a period of time,
  • BIW Global Bending and Torsional Stiffness analysis
  • Component Strength & Stiffness
  • Chassis static Abuse and Fatigue loads
  • BIW Dynamic Fatigue / Spot-weld Evaluation
  • Panel Abuse Cases – Oil Canning & Dent Resistance
  • Seating Specific Analysis
  • Closures Specific Analysis
  • Interior Specific analysis
  • Normal Modes Analysis
  • Component Modes Analysis
  • Modal Mapping
  • Panel Participation
  • Dynamic Stiffness / Point Mobility / NTF
  • Complete Vehicle Modal Performance
  • Model Integrity Checks
  • Front / Side / Rear Impact (Low & High Speed)
  • Roof Crush / Strength
  • Interior Head Impact
  • Occupant Protection / Seat-Seat Belt Pull
  • Pedestrian Protection
  • Low Speed Bumper
  • Specific Vehicle (Truck) cases
  • Topology Optimization
  • Topography Optimization
  • Attachment / Joining Methods
  • Single discipline or multi disciplinary
  • Optimization for Mass, Cost and Manufacturability
  • Optimization for Strength and Stiffness
  • Component/Part level
  • Sub-System level
  • Complete Vehicle level
  • Mold flow Modeling
  • CFD modeling
  • Full Vehicle Integration
  • Welds
  • Joints
  • Connections/bolt/clips/rivets
  • Adhesives
  • Metal Forming for die face design evaluation
  • Stamping Process, Strip layout
  • Single and Multi steps
  • Buckling, wrinkling, tearing, and other negatives
  • Spring back
  • Material Utilization

PRODUCTION ENGINEERING

Tooling Engineering

Sukhena Technologies brings stringent Automotive, Aerospace, General Engineering Rigor across its offerings to develop quality conscious, durable products. Keep pace with the global market by engaging us as your strategic partner. Manufacturing Industry is constantly working on building capabilities and optimizing existing resources. Manufacturing techniques evolve with newer technologies which in turn generate demand for high performance technologies. Demand for efficiency at every stage of the process, global clientele, product localization criteria imply conforming to myriad regulatory and process compliances.
Sukhena offers support as a strong associate and strategic partner in facing challenges and delivering reliable services through high business values..

FMEA

We perform Failure Mode Effect Analysis to determine and evaluate potential failure of a product or process and the consequences of the same. Extensive documentation processes are undertaken to record the actions to rectify or minimize the possibilities of potential failure. Sukhena Technologies offers FMEA for various levels of a product design and development cycle:

Concept Design

Detailed Design

Process Design

Other processes

Tool Design

Tool Design forms a significant process which enables realization of the product. Our wide gamut of tool design expertise helps support unique challenges addressed by the engineering services industry.

Jigs and Fixtures Design

Jigs and Fixtures design calls for a great deal of creativity and knowledge base in providing solutions to specific challenges depending on the requirements. Sukhena offer services in designing jigs and fixtures with feature based modelling, component libraries and design for assembly requirements.

We offer design services for

  • Machining Fixtures
  • Assembly Fixtures
  • Welding Fixtures
  • Checking Fixtures

Our services include

  • Creation of detailed 2D Drawings
  • Alignment with datasheet specifications
  • Preparation of process sheet
  • Preparation of Bill of Materials and Cost estimates
  • Compliance with Industry/Clients’ standards

STAMPING DIE DESIGN

We offer services for:

All types of Stamping Die design

Welding Fixtures

We offer services for

  • Process Planning
  • Design (Concept Design, 3D Finish, 2D Detailing, BOM)
  • Simulation
  • Documentation

Stamping Die Design

We offer services for

All types of Stamping Die design

  • Transfer
  • Tandem (or stage tool)
  • Progressive
TANDEM DIE - Draw
PART THICKNESS - 1.0mm
CONSTRUCTION TYPE - Steel Plate
TOOL SIZE - 850 X 750 X 500mm.

Manufacturing Engineering

From writing pen to the car you drive, nearly everything you use in your daily life is man-made, or ‘manufactured. At its most basic level, Manufacturing Engineering takes ideas from concept generation right through to working products. The reality is more complex, and much more interesting.

Manufacturing Engineers:

Manufacturing Engineers also get involved in supply chain management, logistics and distribution, quality management as well as environmental and life-cycle management. In short, Manufacturing Engineering is the branch of engineering that is concerned with understanding, analyzing and improving complex industrial, manufacturing and infrastructure systems.

The growing importance of Manufacturing Engineering

We live in an age of rapid innovation, complex technology and sustainability. Naturally, the job of a Manufacturing Engineer has become even more important. Organizations, both public and private, are crying out for Manufacturing Engineers because they have diverse analytical skills, especially skills in integrating technology with commercial and organizational solutions.

Highlights of Sukhena Consulting: Setting up of Green field Manufacturing Plants for production of Sheet Metal Bumper & Seating

Stamping Die Design

We offer services for

All types of Stamping Die design

  • Transfer
  • Tandem (or stage tool)
  • Progressive
TANDEM DIE - Draw
PART THICKNESS - 1.0mm
CONSTRUCTION TYPE - Steel Plate
TOOL SIZE - 850 X 750 X 500mm.