Remarkable story of an automobile company drastically improving new product development.
In the highly competitive landscape of automobile manufacturing, increasing plant production while keeping engineering and design costs in check is a paramount challenge. This challenge becomes even more critical for companies specializing in the production of CNG and electric buses, which are in high demand from various government agencies. Winning government contracts hinges on meeting technical standards and offering the lowest price bids.
Moreover, the complexity is compounded by the fact that different government bodies have unique requirements for these buses. To accommodate these diverse needs, a bus manufacturer often creates multiple design variants of the same bus. This can lead to a scenario where out of, say, five hundred buses, there could be fifty different versions.
Each of these versions demands the attention of a team of experts, including engineers and designers. These teams must also ensure that the sourcing team can seamlessly find the right parts for these different bus variants. This complexity adds layers to an already intricate problem, making it imperative for companies to strategize, to meet industry standards.
Amidst these multifaceted challenges, the quest to establish an efficient process that addresses these design & engineering intricacies and maximizes efficiency took centre stage. This is precisely what the leading bus manufacturer in the country sought when they engaged Brain Wave Consulting (BWC Labs).
The client struggled with consistently delayed deliveries, affecting their ability to meet their manufacturing targets.
A lack of visibility into the status of product development projects created significant operational blind spots, making it difficult to track progress and allocate resources effectively.
The manufacturer faced recurrent product defects, tarnishing their reputation and incurring costs for rectification.
Heavy penalties were incurred due to faulty and incorrect parts in the final products, impacting the bottom line and eroding customer trust.
Lack of process and communication was resulting in ground level errors resulting in frequent arguments and conflicts between the teams.
The absence of a robust design and engineering change management process resulted in changes happening without proper coordination and awareness, leading to chaos in the product development cycle.
A non-standard part numbering system gave rise to duplicate parts, causing confusion and inefficiency.
Lack of parts documentation process and coordination between engineering and R&D resulted in different versions of The Engineering Bill of Materials (EBOM) and Manufacturing Bill of Materials (MBOM), adding further complexity to critical documentation.
BWC experts meticulously crafted a standardized product design change management process, mapping business processes and creating dedicated workflows to inject much-needed standardization into a once-chaotic landscape.
To minimize irregular design changes, BWC Labs defined a team, in collaboration with client-appointed group leaders, to initiate and approve changes, preventing impulsive alterations and ensuring adherence to a well-structured change management process.
A standard part numbering system was introduced to eliminate duplicate parts, meticulously monitoring design information’s creation, flow, and evolution to blend previously inconsistent segments.
Synchronizing Product Lifecycle Management (PLM) with Enterprise Resource Planning (ERP) ensured continuity from Engineering to Manufacturing, creating a seamless digital thread. EBOM and MBOM continuity provided a smooth transition and accurate products without redundancy.
| Digit Position | Identification |
|---|---|
| 1st Digit | Product Category |
| 2nd Digit | Vehicle Type |
| 3rd & 4th Digit | Component Category / Sub Assembly |
| 5th, 6th, & 7th Digit | Serial Number |
| 8th & 9th Digit | Process / Component Stage |
| 10th Digit | ‘M’: ZMFG / ‘B’: ZROH / ‘O’: Drawing Spec. |
In addition to these solutions, BWC aided the client in cloud deployment and data migration while addressing other related engineering and design challenges.
The solution provided by BWC Labs was not only unique and effective but also user-friendly, successfully eliminating preexisting problems. This wave of change resulted in transformative outcomes:
Accurate parts, lean inventory, reduction in product defects, and improved product release cycle. These were some of the outcomes of the custom solution provided by BWC using 3DEXPERIENCE.
BWC Labs Consulting’s solution tackled the intricate layers of complexity in the client’s inbound logistics. Seamlessly integrating GPS tracking, live cargo updates, and consolidated shipment monitoring, it granted unparalleled control and transparency. As a result, the client’s production line flowed seamlessly, disruptions minimized, on-time deliveries became standard, and their reputation for reliability soared.
Partner with seasoned experts to accelerate your digital transformation and engineering workflows across industries with cutting-edge solutions.
We provide custom software development, cloud solutions, IT infrastructure setup, system integration, and ongoing tech support.
It depends on the scope. Small projects may take 2–4 weeks, while larger systems can take 2–3 months or more.
Yes, we offer maintenance and support packages to keep your system secure, updated, and running smoothly.
Absolutely. Every solution we deliver is tailored specifically to each client’s business goals and operations.
We’ve worked with clients in retail, healthcare, logistics, finance, and more.
Simply contact us through our website or email, and we’ll schedule a free consultation to understand your needs.
At BWC Labs, our mission is to empower businesses with cutting-edge technology solutions. We believe in the transformative power of innovation and are committed to helping our clients achieve their goals.
