Lear Tackles The Safety Responsibilities of Modular Systems Integration
7 February 2000
Lear Corporation Leads the Way in Tackling The Safety Responsibilities of Modular Systems Integration
TROY, Mich., Feb. 7 -- In the era of modularity, the key to
earning and successfully executing the safety responsibilities of a Tier One
automotive interior systems integrator is having innovative technology and
comprehensive capabilities, said Lear Corporation Vice President
of Advanced Engineering and Validation Ash Galbreath. His remarks were part
of today's proceedings at the Society of Plastics Engineers' 1st Annual
Plastics in Automotive Safety Conference and underscored how Lear's
capabilities and expertise earned it key systems integrator responsibilities
with some of the world's largest automakers.
(Photo: http://www.newscom.com/cgi-bin/prnh/20000207/DEM017 )
In his speech titled "Modular Assembly: Safety Responsibilities of a Tier
One Interior Systems Integrator," Galbreath discussed integration trends and
identified the major driving forces for interior modules. "Cost reduction is
by far the most significant factor driving interior module integration," he
said. "The synergies that can be created through modular systems integration
require a high level of technical expertise and an intimate understanding of
how to optimize each system to maximize the benefits of integrating the entire
interior."
He also cited other driving forces: reduction of complexity/concentration
on core competency, product/process improvements, quality improvement, full
utilization of supplier's knowledge and the automaker's lack of resources. Of
lesser importance were inventory reduction, consolidation of supplier base,
shorter product development lead time and delegation of warranty/liability.
"In the early 1990s, when the automakers turned to Lear for the production
of seat modules, the cost savings were significant," Galbreath said. "As more
and more responsibilities were transferred to us -- such as purchasing,
assembly, logistics and engineering -- we were able to make greater
contributions in terms of efficiencies and quality improvement.
"Today Lear has become the acknowledged expert in consumer trends in
automotive interiors, thanks to a well-developed market research function that
helps us to determine consumer needs, wants and ergonomics," he said. "We now
do more than just produce to a customer's drawing -- we are part of the team
that helps to design and develop the vehicle. And because of our broad
expertise, we can offer tremendous synergies when we are given systems
integrator responsibilities."
Through its patented People-Vehicle-Interface Methodology(TM) -- or PVI
Method(TM), for short, Lear leverages its innovative technology and
comprehensive capabilities to meet critical safety responsibilities. The
first pillar of PVI, Consumer Research, determines consumer safety needs,
wants and ergonomics. Then Industrial Design & Visualization creates
harmonious conceptual interior solutions integrating consumer data and the
vehicle's brand image. Engineering, PVI's third pillar, develops and
integrates unique safety products, which are then turned over to Technical
Analysis, which provides analytical assessment, reducing cycle time and cost.
The PVI Method's Manufacturing Process Development, the fifth pillar,
develops innovative process technologies and improves cost of existing
products. The final PVI pillar, Validation, assesses conformance to physical
durability and customer safety requirements.
"We offer our customers an array of sophisticated safety system validation
capabilities, as well as product life simulation and NVH capabilities,"
Galbreath said. "We made these investments in technologies to ensure that we
have a full range of safety-related services and products to meet our
customer's systems integration requirements and provide added value."
In 1999, Lear completed a $40-million expansion to its World Headquarters
and Technology Center complex in Southfield, Michigan, as part of its
continuing commitment to providing its customers with state-of-the-art
services and innovative products. Lear's Safety Systems Validation
capabilities include a Hyge sled lab, crash dummy calibration lab, head impact
lab, side impact sled and static airbag deployment lab.
Lear also has the capabilities for testing cyclic durability for all
interior mechanisms, robot-based seat durability, environmental performance
and structural strength. Noise, vibration and harshness capabilities include
vibration durability road simulation, sound quality, modal analysis and
dynamic comfort evaluation. Materials testing also is handled on-site.
Sophisticated acoustics validation is available through materials testing
of acoustical properties, sound absorption and damping; component testing;
vehicles testing on smooth and rough dyno surfaces; vehicle program
benchmarking, noise path analysis, NVH improvement, and weight reduction; and
customized, full-vehicle diagnostic programs.
Lear has an extensive line of innovative safety products designed to meet
the complete scope of customer needs. Lear's Pro tec(TM) Occupant Protection
Systems line includes products in such areas as advanced restraints, child
safety, head impact protection, energy management, post-crash care, occupant
sensing, vehicle telematics, cargo retention, whiplash protection and
motorsports.
"The interior systems integrator's safety responsibilities are to generate
modular assembly synergies as well as providing system expertise, total system
validation capabilities, and regulatory understanding and monitoring,"
Galbreath said.
"The resulting safety benefits from modular assembly include opportunities
for improved performance, cost and weight reduction for safety systems,
complete system certification before shipments which can reduce warranty
exposure, and system validation prior to complete vehicle validation," he
added. "The bottom line is a win-win-win situation for the automaker, the
supplier/integrator and consumers."
Lear's Galbreath also is participating in a panel discussion on "Global
Harmonization of Automotive Safety Issues." He called for test procedure
harmonization, as well as test procedure and performance standard
harmonization. "Harmonization in both areas would positively impact on Lear's
ability to meet customer and consumer expectation and offer cost reduction
opportunities," Galbreath said.
But, he cautioned that, "there may be regulatory aspects that should be
different in different regions because of unique cost or vehicle use
considerations." He cited as examples economic limitations in developing
countries or a unique driving environment, such as Europe where driving speeds
on the Autobahn are, on average, faster than in the U.S.
Galbreath has more than 15 years of automotive research and development
experience. As Vice President -- Advanced Engineering and Validation for
Lear, he is responsible for advanced product, technology and material
development, total automotive interior validation testing, and analysis for
Lear's worldwide advanced engineering operations.
Lear Corporation, a Fortune 200 company headquartered in Southfield,
Michigan, USA, is the one of the world's largest automotive suppliers, with
1999 anticipated sales of more than $12 billion. The company's world-class
products are designed, engineered and manufactured by more than 120,000
employees in over 300 facilities located in 33 countries. Information about
Lear and its products is available on the Internet at http://www.lear.com