Browse Topic: Supply chain management
The automotive industry is facing unprecedented pressure to reduce costs without compromising on quality and performance, particularly in the design and manufacturing. This paper provides a technical review of the multifaceted challenges involved in achieving cost efficiency while maintaining financial viability, functional integrity, and market competitiveness. Financial viability stands as a primary obstacle in cost reduction projects. The demand for innovative products needs to be balanced with the need for affordable materials while maintaining structural integrity. Suppliers’ cost structures, raw material fluctuations, and production volumes must be considered on the way to obtain optimal costs. Functional aspects lead to another layer of complexity, once changes in design or materials should not compromise safety, durability, or performance. Rigorous testing and simulation tools are indispensable to validate changes in the manufacturing process. Marketing considerations are also
Design validation plays a crucial role in the overall cost and time allocation for product development. This is especially evident in high-value manufacturing sectors like commercial vehicle electric drive systems or e-axles, where the expenses related to sample procurement, testing complexity, and diverse requirements are significant. Validation methodologies are continuously evolving to encompass new technologies, yet they must be rigorously evaluated to identify potential efficiencies and enhance the overall value of validation tests. Simulation tools have made substantial advancements and are now widely utilized in the development phase. The integration of simulation-based or simulation-supported validation processes can streamline testing timelines and sample quantities, all the while upholding quality standards and minimizing risks when compared to traditional methods. This study examines various scenarios where the implementation of advanced techniques has led to a reduction in
In today's world, the electric vehicle (EV) industry is experiencing a remarkable boom with increasing global demand. With it, comes the surging and unprecedented need for EV batteries. Recycling these batteries has become of crucial importance, as it not only plays a vital role in ensuring the security of the battery supply chain but also serves as a key measure for reducing greenhouse gas emissions. However, there are still several issues that remain unresolved in this domain. Unsettled Issues Regarding Electric Vehicle Battery Recycling delves deep into these issues, thoroughly exploring the current state of the industry and potential solutions to drive sustainable EV battery recycling. By addressing these challenges, we can strive towards a more sustainable future in the EV sector. Click here to access the full SAE EDGETM Research Report portfolio
LIDAR-based autonomous mobile robots (AMRs) are gradually being used for gas detection in industries. They detect tiny changes in the composition of the environment in indoor areas that is too risky for humans, making it ideal for the detection of gases. This current work focusses on the basic aspect of gas detection and avoiding unwanted accidents in industrial sectors by using an AMR with LIDAR sensor capable of autonomous navigation and MQ2 a gas detection sensor for identifying the leakages including toxic and explosive gases, and can alert the necessary personnel in real-time by using simultaneous localization and mapping (SLAM) algorithm and gas distribution mapping (GDM). GDM in accordance with SLAM algorithm directs the robot towards the leakage point immediately thereby avoiding accidents. Raspberry Pi 4 is used for efficient data processing and hardware part accomplished with PGM45775 DC motor for movements with 2D LIDAR allowing 360° mapping. The adoption of LIDAR-based AMRs
Heavy-duty vehicles, particularly those towing higher weights, require a continuous/secondary braking system. While conventional vehicles employ Retarder or Engine brake systems, electric vehicles utilize recuperation for continuous braking. In a state where HV Battery is at 100% of SOC, recuperated energy from vehicle operation is passed on to HPR and it converts electrical energy into waste heat energy. This study focuses on identification of routes which are critical for High Power Brake Resistors (HPRs), by analyzing the elevation data of existing charging stations, the route’s slope distribution, and the vehicle’s battery SOC. This research ultimately suggests a method to identify HPR critical vehicle operational routes which can be useful for energy efficient route planning algorithms, leading to significant cost savings for customers and contributing to environmental sustainability
This SAE Aerospace Standard (AS) identifies the requirements for mitigating Counterfeit EEE parts in the Authorized Distribution Channel. If an organization is not performing Authorized Distribution but acting as another seller (such as an Authorized Reseller, Broker, or Independent Distributor), then only 3.3.1 applies
Chinese battery manufacturer CATL (Contemporary Amperex Technology Co. Ltd.) completed the launch of its TECTRANS battery system for the commercial transport sector at IAA Transportation, which took place in September in Hanover, Germany. CATL added its heavy-duty truck and bus/coach battery ranges to the light-truck range that the company launched in China in July 2024. For heavy-duty trucks, CATL offers two alternatives: the TECTRANS - T Superfast Charging Edition and the TECTRANS - T Long Life Edition. As the name suggests, the Superfast Charging Edition is designed to offer rapid charging capability for operators needing to recharge during a duty cycle. CATL quotes a 4C peak charging rate, which would permit a charge to 70% in 15 minutes
A new aviation supply chain integrity coalition has offered 13 recommended actions to prevent the circulation of non-serialized aircraft parts throughout the global aviation industry. Embry-Riddle Aeronautical University, Daytona Beach, FL In the summer of 2023, a receiving clerk in the procurement department of TAP Air Portugal, a Lisbon-based airline, made a curious discovery: A $65 engine part that should have appeared brand-new showed signs of significant wear. The clerk checked the documentation from the London-based parts supplier and noticed that the submitted documentation was also suspicious. Using his safety training, the employee immediately reported the anomaly to TAP Air Portugal management, which raised the issue with the jet engine's manufacturer. Little did the procurement clerk know at the time, but this escalation led to one of the biggest investigations in the history of the aviation supply chain, as reported by Reuters and the British Broadcasting Corporation in
At the Reuters Automotive USA 2024 conference in Detroit, SAE Media spoke with Stuart Taylor, chief product officer of Envorso, a consultancy with a mission to help OEMs and Tier 1 suppliers write better software. Companies have been plagued with issues around software written both in-house and via outside contractors
R-1234yf is used in almost every new car sold in the U.S., but the EU is discussing a ban and the industry is investigating alternatives like CO2 and propane. According to its manufacturer, Chemours, use of R-1234yf has grown so much since the refrigerant replaced the long-established R-134a that it's now used in 95% of new cars sold in the U.S. An estimated 220 million cars on global roads are also using it. The problem with R-134a, which came in cars and trucks in the 1990s, is that it's a gas with “a global warming potential (GWP) that is 1,430 times that of CO2,” according to the EPA. Since 2017, EU legislation has banned the use of any refrigerant in new vehicles with a GWP higher than 150. That rule doomed R-134a but opened the door for R-1234yf, which has a GWP of only four. The EU is currently revisiting R-1234yf emissions rules and may ban the substance in a few years. In the U.S., the EPA stands by its use
Automotive electrical and electronics manufacturer MTA attended IAA Transportation for the first time, demonstrating its new range of wireless communication technologies for the truck industry. Earlier this year, the company acquired Calearo Antenne S.p.A, a company with a long history of producing antennas, amplifiers and cables. MTA global sales director Davide Bonelli explained to Truck & Off-Highway Engineering how that acquisition complements its business. “From a more strategic point of view, we see the world of antennas as complementary to what MTA does,” he said. “Often MTA products have an antenna as an interface, so this is one reason why we have done the deal. There are also a lot of synergies from an engineering standpoint. Historically, MTA is a company that uses many mechanical parts - plastics, metals - which we are very strong with so we can share them. And there are also some competences from Calearo Antenne that can be transferred to us
Sometimes, I cringe; sometimes, I just listen and wonder. These past few months have given us all a lot to think about in the automotive space, and it's clear now that the coming years will keep the foot down on the accelerator when it comes to the dramatic changes we've experienced this past decade. One thing that stood out to me in various recent conversations is that there's a widening gulf opening between Chinese automakers and the rest of the world. This isn't exactly news, and this column isn't meant to monger any fears. It's just a bit of off-the-cuff reporting that sheds a bit of light on the level of the challenges we face. As you can read in Chris Clonts' excellent report further in this issue about the warning that Voltaiq's CEO gave at The Battery Show this October, the U.S. is in serious danger of falling well behind Chinese competitors in the EV battery race (Michael Robinette tackles similar ground through a tariff lens in this month's Supplier Eye). But that message was
Continuing a common theme among some presenters at The Battery Show North America, the CEO and founder of Pure Lithium, which is betting on lithium vanadium, framed the company's efforts as a way to end China's dominance in the battery market. “The U.S. is facing an existential crisis, and that is the extinction of the U.S. automotive industry,” Emilie Bodoin said. “But unlike the dinosaurs, we can see this comet coming. We're literally in a cold war with China over supply chain
As I write this version of the Supplier Eye column, 2024 has been a critical year for our industry. No matter if you are a supplier, OEM or some other position in the ecosystem, this year has set us up for feast or famine through this decade. Let's explore why this year will go down in the record books as a pivotal one. Editorial timing dictates that this is submitted just before the U.S. elections. While you will read this with the election in the rearview mirror, all indications are for an extremely close political outcome, though the ensuing weeks will be the final arbiter. The outcome nonetheless will impact our industry for years
This specification covers metric aircraft quality spacers for use as positioners for tubes, flat washers for use as load spreaders, galling protection of adjacent surfaces and or material compatibility, and key or tab washers for use as locks for bolts, nuts, and screws
ABSTRACT Automatic guided vehicles (AGV) have made big inroads in the automation of assembly plants and warehouse operations. There are thousands of AGV units in operation at OEM supplier and service facilities worldwide in virtually every major manufacturing and distribution sector. Although today’s AGV systems can be reconfigured and adapted to meet changes in operation and need, their adaptability is often limited because of inadequacies in current systems. This paper describes a wireless navigated (WN) omni-directional (OD) autonomous guided vehicle (AGV) that incorporates three technical innovations that address the shortfalls. The AGV features consist of: 1) A newly developed integrated wireless navigation technology to allow rapid rerouting of navigation pathways; 2) Omnidirectional wheels to move independently in different directions; 3) Modular space frame construction to conveniently resize and reshape the AGV platform. It includes an overview of the AGVs technical features
ABSTRACT Product Development (PD) remains a highly uncertain process for both commercial and DoD programs. The presence of multiple stakeholders (e.g., DoD and allied agencies, soldiers/users, PEO, contractors, manufacturing, service, logistics) with varying requirements, preferences, constraints, and evolving priorities make this particularly challenging for the DoD. These risks are well recognized by agencies, and it is widely understood that acquisition is about risk management and not certainties. However, almost all the DoD acquisition processes still require critical reviews, and most importantly, structured decision support for the fuzzy front-end of the acquisition process. What is lacking, are effective decision support tools that explicitly recognize the sequential milestone structure embedded with multi-stakeholder decision making in all acquisition programs. We describe the Resilient Program Management & Development (RPMD) framework to support complex decision making with
ABSTRACT In order to assess a design from a supportability perspective early in a technology’s prototyping phase, TARDEC’s Systems Engineering Directorate has established a Design for Supportability (DfS) competency. This competency, under the SE umbrella, encompasses the relationship between Design for Reliability (DfR), Design for Maintainability (DfM), and Design for Logistics (DfL). The combination of DfR, DfM and DfL form a trifecta of knowledge that determines whether a developing technology will: 1) perform its intended function for the complete duration of the mission it’s designed for; 2) be designed in a way to be fixable in a reasonable amount of time using standard tools; 3) be designed to have replaceable parts as accessible as possible; 4) not increase the logistics burden for our men and women in uniform
ABSTRACT To support customers during product development, General Dynamics Land Systems (GDLS) utilizes a set of Operations Research/Decision Support processes and tools to facilitate all levels of decision-making aimed at achieving a balanced system design. GDLS employs a rigorous Structured Decision (SD) process that allows for large, highly complex or strategic decisions to be made at the system-of-systems, system, and/or subsystem level. Powerful, robust tools -the Advanced Collaborative System Optimization Modeler (ACSOM) and Logical Decisions for Windows (LDW) - are used to make relatively quick assessments and provide recommendations. The latest ACSOM algorithms have increased the response time for trade study analysis by over 2,000 times and future versions will incorporate logistics analysis helping to reduce vehicle Life Cycle Cost
ABSTRACT The DoD Digital Engineering Strategy [1] released in June 2018 outlined the DoD’s strategic goals which “promote the use of digital artifacts as a technical means of communication across a diverse set of stakeholders” In addition to build, test, field and sustainment of defense systems, emphasis was placed on the acquisition and procurement of systems and the importance of digital engineering. This was further reinforced in the Feb 2022 release of the Engineering of Defense Systems Guidebook [2] which contains Digital Engineering sections in each chapter. The norm for Systems Engineering has become Model-Based Systems Engineering (MBSE) in which models are used at all phases of development. To complete the digital thread from concept to disposal, models will be required for the acquisition phase. This paper will describe Model-Based Acquisition (MBAcq), and how it can be used to increase clarity compliance and understanding in Capability Systems and Software Acquisition for
ABSTRACT Power and energy demands on military vehicles and other large systems have been increasing significantly and modifications to these power systems are being explored on several programs. A key decision in a new power system is determining whether to use “high voltage” or “low voltage” for distribution throughout the vehicle. This decision has far reaching consequences throughout the vehicle and needs to be made after careful consideration. This paper addresses key trade-off criteria for consideration when comparing high voltage and low voltage vehicle architectures and then addresses a few other considerations for this type of decision
ABSTRACT Acquisition programs typically develop a set of system requirements early in their lifecycle, which then become the standard against which future designs are evaluated. It is critical that these requirements be set at appropriate levels. Requirement sets that are not simultaneously achievable are a relatively common problem in military acquisition programs and often are not recognized until significant investment has already been made – sometimes even leading to program cancellation. The Advanced Requirements Integration & Exploration System (ARIES) is designed to aid program stakeholders in understanding the requirements trade space for a system and facilitate the identification of an achievable set of requirements. This paper presents the ARIES methodology, describes the analytic capability, and discusses its application. Citation: A.I. Dessanti, D.J. Anderson, S.M. Henry, A.J. Pierson, R.S. Agusti, M.A. Zabat, “Advanced Requirements Integration & Exploration System (ARIES
ABSTRACT Leveraging an open standard may still not achieve the desired interoperability between systems. Addressing “lessons learned” from past implementations of open standards for various Department of Defense (DoD) acquisition programs is critical for future success. This paper discusses past issues which range from insufficient technical detail, when and how to apply a given specification, verification of an implementation’s compliance, to inconsistent and imprecise contractual language. This paper illustrates how the Vehicular Integration for C4ISR/EW Interoperability (VICTORY) initiative addresses these challenges to enable interoperability on Army ground vehicles, as well as facilitate rapid technology insertion and incorporation of new capabilities. VICTORY represents a leap ahead in solving interoperability challenges and defining open standards
ABSTRACT The military has a need to source propulsion systems that have enhanced efficiencies, lower noise signatures, and improved lifetimes over existing power systems. This is true for energy storage systems on unmanned ground vehicles and for manned vehicles (i.e., Auxiliary Power Units). Fuel cells have the promise to achieve all of these goals. However, to be truly effective, these advanced systems should integrate seamlessly with the current supplies of energy storage (batteries) and energy sources (logistics fuel). The largest fuel cell development hurdle to date has been the ability to handle sulfur concentrations present in logistics fuel. Secondly, the reformer must be capable of several thousands of hours of operation utilizing logistics fuels without loss of performance due to sulfur or carbon deposition. Advancements in several key technologies have the potential to allow development of a logistics fueled solid oxide fuel cell with similar size, weight, and power
ABSTRACT An increasing pace of technology advancements and recent heavy investment by potential adversaries has eroded the Army’s overmatch and spurred significant changes to the modernization enterprise. Commercial ground vehicle industry solutions are not directly applicable to Army acquisitions because of volume, usage and life cycle requirement differences. In order to meet increasingly aggressive schedule goals while ensuring high quality materiel, the Army acquisition and test and evaluation communities need to retain flexibility and continue to pursue novel analytic methods. Fully utilizing test and field data and incorporating advanced techniques, such as, big data analytics and machine learning can lead to smarter, more rapid acquisition and a better overall product for the Soldier. Logistics data collections during operationally relevant events that were originally intended for the development of condition based maintenance procedures in particular have been shown to provide
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