Integrated build: a new approach to building automotive bodies

Richard J. Gerth and Jay Baron

International Journal of Automotive Technology and Management, 2003, vol. 3, issue 3/4, 185-201

Abstract: This paper introduces three auto body build concepts: net build (NB), functional build (FB) and integrated build (IB). Most manufacturers design and validate their vehicle launches using the NB concept. This concept is shown to be expensive, time consuming and not effective value added. Functional build has found growing acceptance as being preferable over NB. FB has tended to find the greatest acceptance as a die buyoff procedure for individual parts based on subassembly quality. Aspects of FB are shown in a case study where the manufacturer claimed to use FB for die development, but critical elements were omitted and opportunities lost. The integrated build (IB) process is an extension of the FB approach. It is a more inclusive process that considers the entire vehicle and requires closer coordination with product design. Aspects of IB are also shown in two case studies. In the first, IB concepts were included in the design process, which enabled the company to implement an effective material introduction strategy. The second is a comparison of the product development timelines of two companies and shows how IB concepts can shorten lead and production ramp time.

Keywords: net build; functional build; integrated build; tooling validation; die design; automotive body development; process capability; lean product development. (search for similar items in EconPapers)
Date: 2003
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