Optimizing automotive electrical distribution systems design and development by reducing design iterations

Abstract

The design and development (D&D) of electrical distribution systems (EDS) is a practice that has been performed in the automotive industry for more than 100 years. The amount of technology infusion in vehicles within this history impacts the design and development of electrical distribution systems in an exponential manner. The electrical architecture of a vehicle increases in complexity with every new product launched into the market. The number of interactions and interdependencies between design and development activities, and across functional groups, has been increasing as a consequence of the constant innovation in the vehicle electrical architecture. These interdependencies and interactions with design and development tasks and cross functional groups generate potential design iterations and rework loops that have direct impacts on the cost, scope and schedule of automotive projects. This research has a fundamental purpose, the review of the electrical distribution systems design and development process inside an automotive OEM through the use of (1) traditional and modern project management tools, (2) surveys and interviews inside the OEM EDS organization, and (3) a review of product development literature, in order to identify recommendations to reduce unplanned design iterations and rework generated by the nonlinear nature of automotive product development. While the analyses, summary and recommendations are specific to EDS product development, it is hoped that the use of both traditional and modern project management tools described in this thesis can serve as a model for those in other industries.