Transportation & Mobility INTRODUCTION:

State of the
Industry

CHAPTER 1:
Escaping the Silos

CHAPTER 2:
Total Quality
in Motion

CHAPTER 3:
Experience
Total Quality,
Not Manage It

FIND THE BEST BALANCE

BETWEEN QUALITY, Virtually optimize
development

REGULATIONS & COST

With digital continuity, you can best experience
total quality management

1
I N T R O D UC T I O N
INTRODUCTION:
State of the

STATE
Industry

CHAPTER 1:
Escaping the Silos

OF THE CHAPTER 2:
Total Quality
in Motion

INDUSTRY
CHAPTER 3:
Experience
Total Quality,
Not Manage It

Q uality, regulations and cost (QRC) drive many of the

important decisions in your business. From crash testing,
to recyclability, recalls and now, autonomous vehicles, further
Virtually optimize
development

complexity beckons for manufacturers like you. Across the

globe, governments are becoming stricter than ever on safety,
emissions and recyclability. Not complying can result in very
harsh penalties. Additionally, cities are simply banning — or will
soon ban — vehicles that do not meet their own standards.

2
 INTRODUCTION:
Under upcoming EU Whilst industry players are working hard to ensure that
State of the
strong negotiation and collaboration with regulators will drive
regulations, vehicles that emit innovation, quality and customer satisfaction, what exactly Industry
1 gram of CO2 over the limit gives them the confidence to deliver on what regulators
allow them to do? Even if you are able to comply with the
will cost about €400 million regulations, what ultimately enables you to retain loyal CHAPTER 1:
to an OEM. Can you risk this? customers and appeal to new ones? Escaping the Silos

The requirements in these regulations are driving the entire CHAPTER 2:

cross-discipline value chain to ensure that products are ready Total Quality
for homologation in each regional market in time, safely and in Motion
competitively. So, while companies desire to adapt to market
changes and provide modularization that matches local
CHAPTER 3:
preferences, QRC adds complexity to this process. But, with
Experience
today's technology, flexible and smart production enables
the delivery of customized products with accelerated time-to-
Total Quality,
Not Manage It
market and competitive prices.

On the back of pressing environmental,

economic and social concerns, governments Virtually optimize
are taking the lead on QRC, not consumer development
preference. While sustainability and pollution
control are now non-negotiable, consumer
preferences across the globe continue to shift
with the times and trends.

3
 INTRODUCTION:
State of the
Industry

CHAPTER 1:
Escaping the Silos

CHAPTER 2:
Total Quality
in Motion

CHAPTER 3:
Experience
Global demands are different depending on a country's That approach offers some level of quality management, but Total Quality,
level of development and its cultural preferences, giving it is clearly insufficient to meet the demands of the future Not Manage It
rise to complexity for global companies. The internet is with confidence — it is not total quality management.
driving Industry 4.0 (which is revolutionizing mobility and
the services that support it) with new regional regulations, It is imperative that vehicle innovators achieve this to satisfy
Virtually optimize
demand for ever-higher vehicle quality and streamlined customers’ expectations and companies should be able to
operations that can increase the capacity to deliver innovative provide this level of customization across all their products,
development
products, control costs and maximize profits. not just a select few. There’s the added expectation that these
manufacturers will be agile and flexible enough to incorporate
So while, on the one hand, regulators are presenting the latest technologies into existing highly proliferated
challenges of their own, car manufacturers are also pressured product line-ups, as well as offer new products at a pace that
to appeal to their global customers’ diverse wants and needs. mirrors the best pure-play technology companies.
To address this, car manufacturers usually employ siloed
solutions to attempt to solve challenges along the value chain. As we will see, what is needed is a single, end-to-end solution
that gives vehicle innovators the confidence to find the best
balance in QRC and deliver vehicles that turn customers into
brand loyalists.
4
 INTRODUCTION:
State of the
Industry

CHAPTER 1:
Escaping the Silos

CHAPTER 1
CHAPTER 2:
Total Quality

ESCAPING
in Motion

A lthough ensuring quality certainly

comes at a cost, falling short on
quality can have catastrophic effects on
CHAPTER 3:
Experience
Total Quality,

THE SILOS
the bottom line. The cost of a failed or Not Manage It
recalled product can put a company’s
financial position at risk.
Virtually optimize
development

5
 INTRODUCTION:
State of the
Industry

CHAPTER 1:
Escaping the Silos

CHAPTER 2:
Total Quality
in Motion

CHAPTER 3:
Experience
Total Quality,
Not Manage It

Recently, 53.1 million vehicles Despite efforts by some organizations to embed quality
into their processes, the information and data required for
were recalled in the US, resulting effective quality management is still locked in silos. Virtually optimize
in US$22.1 billion in claims and development
warranty accruals by automakers Early in development, teams are faced with a lack of
information needed to plan for success because information
and suppliers.1
is disparate and the critical teams in the enterprise are not
communicating effectively with each other. Later on, teams
struggle with late or incorrect data leading to poor decisions
and wasted effort. Quality issues are often discovered during
the launch process, and compliance is routinely treated as a
reporting function toward the end of product development
that leaves companies simply hoping that no violations are
discovered.

6
Silos, the obstacle to total quality INTRODUCTION:

Often, issues are found by customers after a product has State of the
been introduced to the market. These quality delivery failures Industry
lead to an increase in rework, prolonged time-to-market and
poor customer satisfaction. Furthermore, all of these issues
increase development and material costs and negatively CHAPTER 1:
impact sales and brand value. Escaping the Silos

Automotive and mobility OEMs and their suppliers cite CHAPTER 2:

a myriad of quality challenges as a result of operating in Total Quality

silos. These include: in Motion
• Lack of systematic problem-solving approaches result
in continually repeating the same quality issues. CHAPTER 3:
• No standard quality metrics to apply to customer- Experience
specific requirements because these often fall outside Total Quality,
the scope of quality standards defined by third-party Not Manage It
certification bodies (e.g. ISO/TS 16949, ISO 9001,
ISO 14001, etc.).
• Insufficient flexibility in their Quality Management
System (QMS) to accommodate customer-specific Virtually optimize
requirements. development
• Methods and tools that do not support embedding
quality into design and current processes per
established best practices like Design in Quality,
Design for Manufacturability and Design for Six Sigma.
• Loss of know-how, teachers and mentors due to a
large number of retiring workers over the next five to
eight years.
• Inability to effectively feed warranty and recall
information back into processes in order to improve
future product quality and reduce costs.
7
 INTRODUCTION:
State of the
Industry

CHAPTER 1:
Escaping the Silos

CHAPTER 2:
Total Quality
Designer Supplier Manufacturer Consumer in Motion

CHAPTER 3:
Experience
Total Quality,
Not Manage It

Virtually optimize
One Single Regulations Compliance, Rules, Process KPI Performance development
Source of Truth Regulations,
Guidelines

True digital continuity begins with a single source of truth that That way, regulations and compliance issues — besides a
keeps all stakeholders in sync, from end to end. myriad of design and safety considerations — are transparent
across the entire value chain, giving every stakeholder the
ability to ensure quality at every point and meet KPIs.

8
Perhaps most troubling is that fact that many of these quality issues are repeat problems that occurred INTRODUCTION:

in previous projects and programs and, although they already have been investigated and corrected, have State of the
occurred again. In fact, one study found that 80 percent of issues encountered are repeat problems with Industry
known solutions.2

CHAPTER 1:
Escaping the Silos

Manufacturer
Final Tests / Consumer CHAPTER 2:

Traceability Adverse Events / Total Quality

PL VOC in Motion
CT

AN
A
CHAPTER 3:
Experience
Total Quality,
Not Manage It

K
EC

D
O
CH
Virtually optimize
development
Designer
Supplier Work Instructions
Material / Process Quality Specifications
Performance

The ability to plan, do, check and act across the entire value chain from conceptualization to post-sale ensures
the continuous and authentic experience of quality that vehicle innovators want.

9
For years now, companies have been implementing QMSs One main reason is that the vast majority of quality and INTRODUCTION:

and processes as a structured way of delivering a better compliance practices today are primarily reactive to issues State of the
product by documenting information such as procedures, in the product development process. In most organizations, Industry
work instructions, policies and forms that enable those tasked quality management is a separate function that establishes
with quality execution to systematically meet a company’s processes for planning and assurance, control and
quality requirements and goals. As a part of this effort, improvement. And, although the creation and execution of CHAPTER 1:
many manufacturers have focused on tools for quality issue a closed loop process has improved overall quality, it has Escaping the Silos
prevention, such as Quality Functional Deployment (QFD) and provided only incremental gains and still often relies on the
Failure Mode and Effect Analysis (FMEA). end customer to report issues. This is unsustainable. CHAPTER 2:
Total Quality
But, if these tools are designed to predict and prevent quality Quality management must become a pervasive, holistic, in Motion
issues up front, and processes are in place to manage the enterprise-wide endeavor — it needs to be become total.
closure of quality and compliance issues when they are found, Teams need to come together on a single innovation
CHAPTER 3:
why do companies still struggle with quality issues? platform to predict, manage and meet the challenges of new
Experience
product development projects that allows manufacturers to
design in quality and compliance from the start.
Total Quality,
Not Manage It

Virtually optimize
development

10
 INTRODUCTION:
State of the
Industry

C H AP T E R 2

TOTAL
CHAPTER 1:
Escaping the Silos

CHAPTER 2:

QUALITY
Total Quality
in Motion

CHAPTER 3:
Experience

IN MOTION
Total Quality,
Not Manage It

Virtually optimize
development

H ow can vehicle innovators be better prepared to respond to

trends as well as changing regulations and standards? It’s a
question of the processes and the chosen platform. The answer lies
with the one that better enables manufacturers to validate QRC
priorities and respond to global opportunities.

11
 INTRODUCTION:
State of the
Industry

CHAPTER 1:
Escaping the Silos

CHAPTER 2:
Total Quality
in Motion

CHAPTER 3:
Experience
Total Quality,
Not Manage It

Today, €1 billion is spent by OEMs on testing, When you do this, quality transforms from a burden into an
simulation and physical prototyping. What if there advantage; improved quality, increased compliance and less
Virtually optimize
was a way to digitalize the entire process for a rework ensures companies can become and remain quality
development
leaders. When you can protect your product investments and
fraction of the cost and enjoy a new level of ROI?
market access, you can turn customers into advocates.
Testing on physical prototypes simply takes too long,
which would put manufacturers out of the market. To stay Car manufacturers have many experts that are
competitive and provide vehicles with the right quality level working in silos, with efficient processes and
in respect of regulations, they need to rely heavily on digital best-of-class tools in dedicated areas. What they
solutions like virtual simulation. True end-to-end digital need now is to be able to connect all of that.
continuity is the necessary transformation that needs to take
place to improve margins and protect revenues by preventing
issues rather than reacting to them.

12
 INTRODUCTION:
The automotive industry’s response to
State of the
IATF 16949 ISO/TS 16949 is a technical Industry
specification for automotive sector QMSs and
it has become one of the most widely used
international standards in the automotive CHAPTER 1:
industry. It harmonizes the different Escaping the Silos
assessment and certification systems in the
global automotive supply chain. CHAPTER 2:
Total Quality
On October 3, 2016, IATF 16949-2016 was in Motion
published by the International Automotive
Task Force (IATF) and it supersedes and CHAPTER 3:
replaces ISO/TS 16949. It defines the Experience
requirements of a quality management Total Quality,
system for organizations in the automotive Not Manage It
industry. A certified management system in
accordance with IATF 16949 is a ticket to
new markets and customers. Virtually optimize
development

13
Total Quality Management seamlessly Total Quality Management (TQM) provides a strategic and INTRODUCTION:

embeds quality into every process systematic set of principles that allow manufacturers to State of the
There’s no doubt that production complexity and the ever take a process-centered approach to quality that focuses Industry
growing amount of data that comes with it poses real on customers. The TQM approach is best driven by a
challenges for automotive manufacturers and suppliers when platform that enables digital continuity to connect all quality
it comes to effective quality management. contributors across the value chain — within the organization CHAPTER 1:
as well as with partners and suppliers — in a way that Escaping the Silos
transparently embeds quality into every process
and action. CHAPTER 2:
Requirements
Product Total Quality
Design
CAD Design in Motion
Risk Management
& Dependability
Manufacturing Post Market
V&V End of Life CHAPTER 3:
Go To Market Management Planning/
Management Experience
Total Quality,
Not Manage It
Design Design Design
simulation simulation simulation

Definition/ Virtually optimize

Concept Development Qualification Launch Post-Launch End-of-Life
Planning
development
Document Control Quality Control Change Control Registration Inspection

Manufacturing
Regulatory
Material
Management
Traceability The total quality experience gives vehicle innovators
the confidence that their entire value chain is geared to
Requirement meet QRC considerations.
14
 INTRODUCTION:
When an innovation platform supports the practice of TQM, Digital continuity ensures that different
every stakeholder in the product development process is State of the
parties can work with shared knowledge at Industry
connected. This environment enables fact-based decision-
their fingertips, and that digital data and
making and communication, while allowing teams to
predict, manage and meet the challenges of new product information is unique, authoritative and
development projects transparently. This also seamlessly consistent throughout the product lifecycle. CHAPTER 1:
embeds quality every step of the way. Escaping the Silos
Take the Advanced Product Quality Planning (APQP)
framework, for example. Whilst it is pervasive in the
CHAPTER 2:
automotive industry, the question remains whether
Total Quality
manufacturers are getting the best results from this in Motion
framework. It should provide a flow of information throughout
the organization as well as up and down the supply chain,
CHAPTER 3:
thereby driving quality into the whole process. However,
in reality, there is a huge amount of administration and Experience
paperwork required to correctly manage the process. The Total Quality,
problem lies in the numerous documents involved — typically Not Manage It
spreadsheets and project files stored on each user’s hard drive.
The inability to communicate effectively means all involved
parties cannot work in a truly collaborative way. Only by
Virtually optimize
switching to a central TQM platform can manufacturers and
development
suppliers track, re-use and leverage existing data.

Quality management doesn’t stop there. When developing a

new vehicle, manufacturers can either begin from scratch or
recycle data from their previous projects. Considering their
typically large product portfolio, it makes business sense to
reuse 3D models of parts in new designs. This enables them
to considerably cut costs reduce market delivery time and
appeal to customers that value vehicle reliability but also want
high quality at an attractive price point.

15
Are you thinking about turning mass customization INTRODUCTION:

into a market advantage? State of the

Industry
Imagine having the ability to confidently release many
dozens of customized designs per week and call upon
hundreds of thousands of production parts in your CHAPTER 1:
database to customize many more. Escaping the Silos

The ability to reuse parts from a continuously CHAPTER 2:

optimized product data management (PDM) database Total Quality
is key to bringing compliant, high-quality vehicles to in Motion
market quickly. With the right platform, you can.
CHAPTER 3:
Instinctively, we all know a higher quality product is a better
Experience
product; it not only brings customers back repeatedly, but
also turns them into a company’s best spokespeople in
Total Quality,
Not Manage It
the marketplace. Studies show that a 5 percent increase in
customer loyalty can increase profits by 25 to 50 percent.3
You retain your customers by keeping them happy, and gain
new customers through the power of grassroots, word-of- Virtually optimize
mouth advertising from happy customers — this comes easy development
when you have high-quality products. The question is: How?

16
 INTRODUCTION:
State of the
Industry

CHAPTER 3

EXPERIENCE
CHAPTER 1:
Escaping the Silos

CHAPTER 2:

TOTAL QUALITY,
Total Quality
in Motion

CHAPTER 3:
Experience

NOT MANAGE IT
Total Quality,
Not Manage It

Virtually optimize
development

H ow can vehicle innovators be better prepared to respond to

trends as well as changing regulations and standards? It’s a
question for the processes and the chosen platform. The answer
lies with the one that better enables manufacturers to validate
QRC priorities and respond to global opportunities.

17
 INTRODUCTION:
State of the
Industry

CHAPTER 1:
Escaping the Silos

CHAPTER 2:
Total Quality
in Motion

CHAPTER 3:
Experience
Total Quality,
Not Manage It

embeds efficient and effective quality management into all of

We can monitor the overall quality of a vehicle Virtually optimize
an organization's processes and decisions, besides providing
from ideation to manufacture in real time and development
the means for opening the aperture for predictive analysis
deliver products at a fast pace with zero defects.” across the entire quality management landscape.

- Dr. N. SARAVANAN When assessing the cost to obtain quality (CTOB) — the
Senior vice president and head of R&D, balance point between cost of investment in quality (CIQ)
Ashok Leyland and cost of defect (CNQ) — shifting to a TQM approach on an
innovation platform allows your company to find and monitor
In today’s markets, being innovative in product development this balance point. When vehicle innovators find this balance,
isn’t enough. Control is a critical part of any process. TQM they can become and remain quality leaders that can protect
with a platform that provides digital continuity establishes their product investments and market access. This is an
the framework for control, automation and visibility that experience to revel in.
18
 INTRODUCTION:
The platform that enables TQM
State of the
The 3DEXPERIENCE® platform uniquely provides the
Industry
applications, collaborative processes and single data source to
embed quality throughout the product development process.
The platform enables digital continuity, which is the ability to
control and have visibility to ensure quality challenges are not CHAPTER 1:

only met, but transformed into advantages. Escaping the Silos

The 3DEXPERIENCE platform allows contributors across the CHAPTER 2:

extended enterprise to anticipate and mitigate errors, rather Total Quality
than react to them, creating a learning organization that in Motion
doesn’t repeat quality issues. This delivers an authentic TQM
experience. CHAPTER 3:
Experience
Positioning the gearbox and battery Total Quality,
pack in the car’s very limited space could Not Manage It
not have been done in time and with this
quality without the applications of the
3DEXPERIENCE platform.” Virtually optimize
development
- Helmut KASTLER,
Head of mechanical and electrical
engineering, Kreisel Electric

19
 INTRODUCTION:
The platform supports Design Failure Mode and Effect
State of the
Analysis (DFMEA), Process Failure Mode Effects Analysis
Industry
(PFMEA) and Corrective and Preventive Action (CAPA)
processes to proactively identify and resolve quality issues.
Then, the platform enables you to virtually validate and
CHAPTER 1:
certify designs, thus reducing the dependency on physical
Escaping the Silos
validation. Traceability from initial requirements to product
delivery ensures consistency and completeness of all tests and
verifications. CHAPTER 2:
Total Quality
The 3DEXPERIENCE platform help in Motion
us ensure compliance because we have
all the documents secured in CHAPTER 3:

one place.” Experience

Total Quality,
Not Manage It
- Hugues LE CARDINAL,
Head of airworthiness, AeroMobil

By automating the prototype testing process with virtual Virtually optimize

simulation, we are able to help customers reduce 10 percent development
of their annual costs. When testing, simulation and
prototyping can cost up to €1 billion for some manufacturers,
that 10 percent saving constitutes €100 million in ROI
through Dassault Systèmes’ virtual simulation capability.

20
 INTRODUCTION:
State of the
Industry
The 3DEXPERIENCE platform offers the following • Complaints, deviations and
capabilities to ensure that TQM is embedded from non-conformance management
end to end: Customer complaints and non-conformances CHAPTER 1:
• A Lean approach are managed and directly linked to the Escaping the Silos
Digitalized Lean practices offer intuitive tools product definitions, reusing past experiences
that leverage Lean methodologies to reduce or either for efficient resolution or to enrich the CHAPTER 2:
eliminate non-value added work and ensure know-how database. Total Quality
efficient processes. • Audits for compliance in Motion
• Project management methodology A fully traced process — from ideation to
Quality methods are governed as projects go-to-market — with audit and inspections CHAPTER 3:

with automated and event-driven tasks, tools allows for continual and seamless Experience
change orders and actions, and a model-based compliance with regulations and internal Total Quality,
requirements. Not Manage It
enterprise approach for requirements and
functions. • Analysis and reporting
• Risk-based thinking Organizations can reveal and analyze
As part of quality management (e.g. ISO9001/ multi-source, heterogeneous, structured Virtually optimize
EN9100/AS9100) risks are managed, and unstructured quality and compliance development
controlled and synchronized with controlling data to improve quality processes and gain
tasks throughout all design, manufacturing competitive advantage. With digital analysis,
and services processes. Fully embedded future quality issues can be predicted and
tools, such as FMEA and FTA, link directly to prevented before they reveal themselves.
designs, product definitions and process flows.
All quality decisions are based on risk thinking.

21
 INTRODUCTION:
State of the
Industry

VIRTUALLY
CHAPTER 1:
Escaping the Silos

OPTIMIZE
CHAPTER 2:
Total Quality
in Motion

CHAPTER 3:

DEVELOPMENT
Experience
Total Quality,
Not Manage It

Virtually optimize

H ow can vehicle innovators be better prepared to respond to trends as well

as changing regulations and standards? It’s a question for the processes
and the chosen platform. The answer lies with the one that better enables
development

manufacturers to validate QRC priorities and respond to global opportunities.

22
 INTRODUCTION:
With the emergence of driver-assisted State of the
and autonomous vehicles, validation Industry
requirements are increasing beyond
what is practical with physical tests. CHAPTER 1:
Escaping the Silos
As new business is won, and successfully completed, critical
success factors need to be captured for re-use in a systematic
CHAPTER 2:
process to fortify your expertise and knowledge base. Then, it
Total Quality
needs to be updated with real data when projects are selected
in Motion
and parts are produced.

Dassault Systèmes delivers the best of 3D modeling and CHAPTER 3:

simulation technologies on a single platform. Use the Experience
platform’s integrated, automated solutions to: Total Quality,
• Synchronize and enhance multi-disciplinary design, Not Manage It
engineering and production collaboration.
• Implement governance to integrate distributed programs
for global synergies.
Virtually optimize
• Transform engineering processes with holistic systems
engineering development and performance.
development
• Accelerate requirements fulfillment and regional reporting
• Perform virtual testing to increase product performance
and safety.
• Maintain traceability from ideas and requirements
throughout the product lifecycle.

23
Surpass requirements, manage costs and ensure success INTRODUCTION:

©2018 Dassault Systèmes. All rights reserved. 3DEXPERIENCE®, the Compass icon, the 3DS logo, CATIA, SOLIDWORKS, ENOVIA, DELMIA, SIMULIA, GEOVIA, EXALEAD, 3D VIA, BIOVIA, NETVIBES, IFWE and 3DEXCITE are commercial trademarks or registered trademarks of
Dassault Systèmes, a French "société européenne" (Versailles Commercial Register # B 322 306 440), or its subsidiaries in the United States and/or other countries. All other trademarks are owned by their respective owners. Use of any Dassault Systèmes or its subsidiaries
Today's most promising and innovative opportunities aren't State of the
always aligned with your resources and priorities. They may Industry
also include complex global and local requirements that
stretch your enterprise capabilities beyond their current
limits. CHAPTER 1:
Escaping the Silos
The 3DEXPERIENCE platform enables your teams to
accomplish this with industry-proven tools and processes. CHAPTER 2:
You can analyze opportunities, win optimal new business, Total Quality
then design, engineer, validate, manufacture and deliver on in Motion
target to your customers’ satisfaction.
CHAPTER 3:
Explore your options at 3DS.com/transportation
Experience
Total Quality,
Not Manage It

Virtually optimize
development

Our 3DEXPERIENCE® platform powers our brand applications, serving 12 industries, and provides a rich portfolio
of industry solution experiences.
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