The integrated bracket is a plastic part that packages functional components such as the ADAS (Advanced Driver Assistance System) camera, rain light sensor, and the mounting provisions of the auto-dimming IRVM (Inner Rear View Mirror). This part is fixed on the windshield of an automobile using double-sided adhesive tapes and glue. ADAS, rain light sensors, and auto-dimming IRVM play an important part in the safety of the driver and everyone present in the automobile. This makes proper functioning of the integrated bracket very integral to occupant safety.
Prior to this work, the following literature; Integrated Bracket for Rain Light Sensor/ADAS/Auto-Dimming IRVM with provision of mounting for Aesthetic Cover [1] outlines the design considerations and advantages of mounting several components on the same bracket. It follows the theme where the authors first define the components packaged on the integrated bracket and then the advantages of packaging multiple components on a single bracket. However, it fails to showcase the development phase of the part.
In this paper, the authors take the readers through a set of issues faced in the development phase of integrated bracket. The development phase is the phase when tooled-up parts arrive at the manufacturing plant and get assembled on the vehicle. During this phase, issues at the part level and assembly level are addressed by respective engineering teams. The issue resolution comprises three main parts: root cause analysis, immediate corrective action, and permanent corrective action. Root cause analysis is where the cause is identified. Immediate corrective action is a temporary solution to the problem that can be implemented on day one without any lead time. Permanent corrective action is the final stage of issue resolution where the improved parts start arriving at the manufacturing plant after tool modification.