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.
Frontloading Performance Engineering
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.
Process & Technology Innovation Partner
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.
New Product Development Process
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 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
Instrument Panel | Seat | Trims | | Glove Box | Air Vents | Consoles | HVAC | Headliners | Steering Controls
BIW | Bumpers | Doors and Closures | Mirrors | Spoilers | Fenders | Bonnet, Boot Lid, Tank Cover Module | Roof System | Grills | Pillars | Lighting | Lift Gates
Manual & Power Steering | | Suspension Analysis |
| Stability & NVH
Battery Capacity |Battery Calculation |Battery Management System
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
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:
- Design a product,
- Select the best technologies and processes for manufacturing it,
- Plan and design the factory that will produce the product, and
- Oversee the running, management, maintenance and improvement of the factory.
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.
- Plan and Define Program
- Product Design and Development Verification.
- Process Design and Development Verification.
- Product and Process Validation and Production Feedback.
- Launch, Assessment & Corrective Action
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. |
