20140128 cisec-continental-automotive-electronics-development-and-assurance
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Continental Corporation is a leading automotive supplier with sales of €32.7 billion in 2012 and operates in five divisions including chassis & safety and powertrain. The document outlines the product development process for automotive electronics, emphasizing custom parts, quality targets, validation processes, and project phases. It also details the manufacturing and testing requirements to ensure high-quality standards in automotive products.
20140128 cisec-continental-automotive-electronics-development-and-assurance
- 1. CISEC January 28th 2014 Electronics development and assurance Automotive Electronics Jean-Pierre Loncle www.continental-corporation.com Interior Division
- 2. Continental Corporation Overview 2012 Sales by division in % ContiTech 11% Chassis & Safety 21% › Since 1871 with headquarters in Hanover, Germany › Sales of €32.7 billion › 169,639 employees worldwide › 291 locations in 46 countries › One of the top 3 in the automotive supplier industry Tires 29% Powertrain 19% Interior 20% Status: December 31, 2012 BU Body & Security Public January 28, 2014 Continental Automotive GmbH 2
- 3. Continental Corporation Five Strong Divisions Chassis & Safety Powertrain Interior Tires ContiTech Vehicle Dynamics Engine Systems Instrumentation & Driver HMI PLT, Original Equipment Air Spring Systems Hydraulic Brake Systems Transmission Infotainment & Connectivity PLT, Repl. Business, EMEA Benecke-Kaliko Group Passive Safety & Sensorics Hybrid Electric Vehicle Body & Security PLT, Repl. Business, The Americas Compounding Technology Advanced Driver Assistance Systems (ADAS) Sensors & Actuators Commercial Vehicles & Aftermarket PLT, Repl. Business, Asia Pacific Conveyor Belt Group Commercial Vehicle Tires Elastomer Coatings Fuel Supply Two Wheel Tires Fluid Technology Power Transmission Group Vibration Control PLT – Passenger and Light Truck Tires BU Body & Security Public January 28, 2014 Continental Automotive GmbH 3
- 4. Business Unit Body & Security Product Overview (main products only) Pneumatic Seat System Seat Control Unit Intelligent Antenna Module Immobilizer Start-Stop Button Central Gateway Car Key/ID LED/Lighting and AFS Control Unit Central Body Control Module Window/Door and Sunroof Control Unit TPMS Sensor (valve mounted) RKE & PASE Control Module BU Body & Security Public eTIS Sensor (tire mounted) DC/DC Converter January 28, 2014 Continental Automotive GmbH 4
- 5. Automotive product development Automotive product constraints › Custom parts: most of the products are custom to fit OEMS specific requirements and EE architecture › High volume: Some parts are exceeding 1Mio Unit / year › Flexibility: Stick to customer needs › Logistics for purchased parts › Logistics for finished parts › Manufacturing volumes, real time adaptation (JIT policy) › Lifetime: standard is 15 years or 220 000 km › Management of part change notification, part termination notice › Quality target: Single digit ppm (part per million) for 0 km failure › Short response time for failure analysis: 30 days associated to a 8D documentation to identify root cause, corrective actions and prevent reoccurence › Automotive Environment requirements: Watertighness, Immunity to disturbances, Low EMC radiation level, Resistance to fluids, Low current consumption for Permanent Battery supplied parts (<1 mA)… BU Body & Security Public January 28, 2014 Continental Automotive GmbH 5
- 6. Automotive product development Project Cycle and Quality gates › G40 Target: Starts the detailed development › G50 Target: Product design is completed › G55 Target: Starts ordering of components and sourcing of production equipment › G60 Target: Starts set up of production line › G70 Target: Ready for PPAP › G80 Target: Starts series production › G90 Target: Series production running › Each Gate has to be released prior to enter in next project phase. BU Body & Security Public January 28, 2014 Continental Automotive GmbH 6
- 7. Automotive product quality development How to achieve Quality targets (pre development phase) › Upfront validation of new components, technologies and processes prior to Mass Production › › Motto: Never develop a novelty with the scope of an application project. Leading to: › › Base development for new technical solutions (eg: new custom component) Design Of Experiment (DOE) for Technology and process › Eg: DOE for pressfit technology › Eg: DOE for leadfree solder paste selection to cope with RoHS regulation BU Body & Security Public January 28, 2014 Continental Automotive GmbH 7
- 8. Automotive product quality development How to achieve Quality targets › To secure component quality and performances by achieving Automotive Electronics Council (AEC) Q100 (for Active components) Q200 (for Passive components) requirements. › By adding application oriented specific requirements: Or Specific Supplier Quality agreements › By continuously monitoring supplier / technology / component quality performances › Supplier Audit and 3 level of approvals: Supplier Approval, Component Approval, Manufacturing Approval BU Body & Security Public January 28, 2014 Continental Automotive GmbH 8
- 9. Automotive product quality development How to achieve Quality targets (Development and PV Phases) › › To successfully product DV (Design Validation) and PV (Product / Production Validation) on top of design verification Representative DV/PV tests (Environmental): Solid Tightness Liquid tightness Water test Salt spray Corrosive atmosphere Thermal shocks endurance test Thermal shocks pre-ageing test Warm storage Cold storage Climatic sequence Temperature range (steps) test Temperature range (steps) test Cold operation Cold and low pressure storage Withstand voltage test Insulation resistance test Check of saturation temperature Thermal cycling life test Constant humid heat life test Thermal life & combined road actuation endurance Free fall test Collision impact test Endurance to driving shocks test Falling tool shock test Curbstone shocks test Brackets and fasteners resistance test Terminal strength test Resonance-point detecting point Resonance-point oscillation test Random vibration endurance test BU Body & Security Public Standard reference IEC 60529 ISO/DIS 16750-4 IEC 60068-2-52 Kb IEC 60068-2-60 Ke IEC 60068-2-14 Na IEC 60068-2-14 Na IEC 60068-2-2 B IEC 60068-2-1 A IEC60068-2-38 Z/AD ISO/DIS 16750-4 ISO/DIS 16750-4 IEC 60068-2-1 A IEC 60068-2-40 Z/AM ISO/DIS 16750-2 ISO/DIS 16750-2 Specific Specific Specific Specific IEC 60068-2-32 Ed: Free-fall IEC 60068-2-27 Ea : Shock IEC 60068-2-27 Ea : Shock Specific IEC 60068-2-29 Eb: Bump Specific Specific Specific IEC 60068-2-6 Fc IEC 60068-2-64 Fh January 28, 2014 Continental Automotive GmbH 9
- 10. Automotive product quality development How to achieve Quality targets (Development and PV phases) › Representative DV/PV tests (Electrical & EMC): Resistance to pulse 1 bis Resistance to pulse 2a Resistance to pulse 3a Resistance to pulse 3b Resistance to pulse 5a or 5b Resistance to power supply micro-interruptions Resistance to starting profile Resistance to on-board power system voltage ripples Immunity to signal line transients Immunity to bulk current injection (BCI) Immunity to bulk current injection (BCI) Resistance of inductive load connected circuits Resistance to impulsive transient Immunity to radiated field Immunity to audio frequency magnetic field Resistance to electrostatic discharges, equipment not supplied Resistance to electrostatic discharges, equipment supplied Resistance to handy transmitters Standard reference ISO 7637-2 ISO 7637-2 ISO 7637-2 ISO 7637-2 ISO 7637-2 ISO16750-2 ISO16750-2 ISO16750-2 ISO 7637-3 ISO 11452-4 ISO 11452-4 Specific Specific ISO 11452-2 ISO 11452-8 IEC 61000-4-2 ISO 10605 ISO11452-9 Measurement of conducted transient emission ISO 7637-2 Measurement of audio frequency conducted emission Specific Measurement of radio frequency conducted emission CISPR 25 Measurement of radio frequency radiated emission CISPR 25 Measurement of magnetic field radiated emissions MIL-STD 461 E ISO16750-2 Resistance to power supply voltages Resistance to slow decrease and increase power of suply voltages Re-initialization test Resistance to non usual power supply voltages Resistance to ground and positive supply voltages short circuit Safety switch compatibility BU Body & Security Public ISO 16750-2. ISO16750-2 ISO16750-2 ISO16750-2 Specific January 28, 2014 Continental Automotive GmbH 10
- 11. Automotive product quality development How to achieve Quality targets (manufacturing phase) › Capability (Cpk) analysis › Test results drift analysis › Process step FPY analysis and improvement › Non conform parts analysis › Safe Launch plan › Products and component traceability › PPAP submission and customer audit BU Body & Security Public January 28, 2014 Continental Automotive GmbH 11
- 12. Automotive product quality development Supporting Tools › Design FMEA (Failure Mode Effect Analysis) › Process FMEA › Worst case analysises › FMEDA (Failure Mode Effects and Diagnosis Analysis), FTA (Fault Tree Analysis) for Safety relevant functions according ISO 26262 › Design Review › Change Management › Lessons Learnt › R&R (Repetability and reproductibility) Analysis BU Body & Security Public January 28, 2014 Continental Automotive GmbH 12
- 13. Thank you for your attention! BU Body & Security Public January 28, 2014 Continental Automotive GmbH 13