Auto Seat Design For Comfort And Speed To Market

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Auto seat design for comfort and speed to market ERL LLC January 27, 2011

description

Auto seat design uses old process that is slow and unreliable. Virtual seat design is available to update the industry for speed and driver comfort.

Transcript of Auto Seat Design For Comfort And Speed To Market

Page 1: Auto Seat Design For Comfort And Speed To Market

Auto seat design for comfort and speed to market

ERL LLCJanuary 27, 2011

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GM CEO Dan Akerson wants to speed up

vehicle development!

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Can vehicle development speed up using a classical

industrial design iteration process and

1960’s tool for seats?

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OEM’s Design

The Speed Dilemma!

Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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OEM’s Design

Production Car

The Speed Dilemma!

Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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OEM’s Design

Production Car

The Speed Dilemma!Suppliers

develop seat!

Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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January February March April

May June July August

September October November December

January February March April

May June July August

September October November December

Process requires 24+ months for seat supplier

to design & develop seat!

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Why does the Supplier, not the OEM, design the seat?

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Process has always lacked tools, and tools first developed in 1960s have been incorporated in industry standards and government regulations.

The Culture

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Today, OEM says, “Supplier, here’s design position, build a seat, we will

test it.”

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Interiors begin at OEM with design position and no

seat!

“Oscar” in Design Position

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What does Design Position definein the interior architecture for the seat?

‣ Seating Reference Point: Oscar’s “hip”

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What does Design Position definein the interior architecture for the seat?

‣ Seating Reference Point: Oscar’s “hip”

‣ Oscar’s Back Angle

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What does Design Position definein the interior architecture for the seat?

‣ Seating Reference Point: Oscar’s “hip”

‣ Oscar’s Back Angle

‣ Seat Travel (fore-aft, up-down, tilt)

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What does Design Position definein the interior architecture for the seat?

‣ Seating Reference Point: Oscar’s “hip”

‣ Oscar’s Back Angle

‣ Seat Travel (fore-aft, up-down, tilt)

‣ Controls position and travel

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What does Design Position definein the interior architecture for the seat?

‣ Seating Reference Point: Oscar’s “hip”

‣ Oscar’s Back Angle

‣ Seat Travel (fore-aft, up-down, tilt)

‣ Controls position and travel

‣ Head Restraint & vision “eyellipse”

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What does Design Position definein the interior architecture for the seat?

‣ Seating Reference Point: Oscar’s “hip”

‣ Oscar’s Back Angle

‣ Seat Travel (fore-aft, up-down, tilt)

‣ Controls position and travel

‣ Head Restraint & vision “eyellipse”

Where’s the seat?

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First prototype seat is built for design position represented by Oscar and

experience!

OEM Seat Supplier

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Supplier’s seat is installed in OEM’s “mule” and drivers

evaluate comfort!

OEM Seat Supplier

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Iterations begin!

First Iteratio

n

OEM & Supplier

H-pt Test

Driver Comfort Test

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Iterations continue until OEM’s requirements are

met!

5+ Iteratio

ns

OEM & Supplier

H-pt Test

Driver Comfort Test

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The Culture: iterative design process develops

seat!

Pro

ductio

n

Design Iteration

s

OEM Seat Supplier

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The Seat: To improve,consumer speaks but who

learns?

Pro

ductio

n

OEM Supplier

Sales VolumeJ. D. PowerConsumer Reports

Consumer

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Lessons Lost: Circular logic & lengthy manual process repeats

itself in Seats!

OEM Consumer

3+ Years

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Physical Iterations are:

Seat Design, world-wide, follows the same iterative

process.

Slow

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Physical Iterations are:

Seat Design, world-wide, follows the same iterative

process.

Slow

Expensive

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Physical Iterations are:

Seat Design, world-wide, follows the same iterative

process.

Slow

Expensive

Unreliable

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Physical Iterations are:

Seat Design, world-wide, follows the same iterative

process.

Slow

Expensive

Unreliable

Difficult for process to learn lessons

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Culture change is hard & painful!!!

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Culture change is hard & painful!!!

Change occurs when VALUE ($) > PAIN

($).

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Examples of Need to Change Process

Analysis shows process is unreliable for many drivers

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Can one seat comfortably fit all body sizes?

04/12/202333

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The process, worldwide, fails to meet 7.5 comfort score for small female

(SF) drivers.

06 B

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Fit

0

1

2

3

4

5

6

7

8

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10

Seating Comfort by Manufacturer

Total

SF

MM

LM

Ma

th S

ea

tin

g C

om

fort

Sco

re

SF

LM

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The process, in Europe, fails to meet 7.5 comfort score for small female

(SF) drivers.

06 B

MW

X3

07 B

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328

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07 A

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4

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Fit

0

1

2

3

4

5

6

7

8

9

10

Seating Comfort by Manufacturer

Total

SF

MM

LM

Ma

th S

ea

tin

g C

om

fort

Sco

re

Europe

SF

LM

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The process, in the US, fails to meet 7.5 comfort score for small female

(SF) drivers.

06 B

MW

X3

07 B

MW

328

xi

07 A

udi A

4

09 Fi

at 5

00

06 V

W P

assa

t

06 S

aab

9-5

06 C

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05 C

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07 H

onda

Fit

0

1

2

3

4

5

6

7

8

9

10

Seating Comfort by Manufacturer

Total

SF

MM

LM

Ma

th S

ea

tin

g C

om

fort

Sco

re

Europe

US

SF

LM

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The process, in Japan, struggles to stay above 7.5 score for SF & Large

Male drivers.

06 B

MW

X3

07 B

MW

328

xi

07 A

udi A

4

09 Fi

at 5

00

06 V

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06 S

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9-5

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Fit

0

1

2

3

4

5

6

7

8

9

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Seating Comfort by Manufacturer

Total

SF

MM

LM

Ma

th S

ea

tin

g C

om

fort

Sco

re

Europe

US Japan

SF

LM

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Production Seat: Can OEM know this before seat is

built?Driver says:

“cushion - a little long”

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ERL Patents: US #6,840,125, US#7,047,831, US#7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Driver says:

“cushion - a little long”

“head rest - a little hard to move, orientation bad”

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ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

Production Seat: Can OEM know this before seat is

built?

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Driver says:

“cushion - a little long”

“head rest - a little hard to move, orientation bad”

“too close to steering wheel”

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ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

Production Seat: Can OEM know this before seat is

built?

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Production Seat: Can OEM know this before seat is

built?Driver says:

“cushion - a little long”

“head rest - a little hard to move, orientation bad”

“too close to steering wheel”

“back rest lateral too low and are pushing my arms”

Driver Score 7.0/10.0

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ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Design Position Error:Seat height was too high for small females.

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ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

Original Design Position

Heel didn’t touch floor.

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In process, seat heightwas corrected but in development process,

seat length, head restraint and wings were not.

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ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

Production Vehicle

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Head restraints and frames can create discomfort for shorter

drivers (up to 60% female and 25% male drivers).

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Math comfort scores show inconsistency in cars

for small, average, and large drivers.

Range of Math Comfort ScoresTotal

VehicleSmall

FemaleAverage

Male Large Male

Ave. 8.7 6.9 9.0 8.0

Worst

Pontiac G6 7.7

Chrysler T&C 4.7

Pontiac G6 7.9

Toyota Prius 6.5

Best Cadillac CTS 9.3

BMW 5308.3

Cadillac CTS 9.7

Buick LaCrosse

8.9

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Math comfort scores show inconsistency in cars

for small, average, and large drivers.Range of Math Comfort Scores

Total Vehicle

Small Female

Average Male Large Male

Ave. 8.7 6.9 9.0 8.0

Worst

Pontiac G6 7.7

Chrysler T&C 4.7

Pontiac G6 7.9

Toyota Prius 6.5

Best Cadillac CTS 9.3

BMW 5308.3

Cadillac CTS 9.7

Buick LaCrosse

8.9Math scores accurately predict subjective scores with correlation of 0.8.

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The Goals: reduce cost and time & increase comfort for

all driversChange process to meet these goals with virtual seat design

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“I’d like to understand why {vehicle X} just feels so “totally right” the minute you slip into the seat, get feet on pedals, and grab the wheel.”

Bob Lutz – Retired Vice Chairman of General Motors

In 2003,

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Virtual seat design optimizes “totally right” for all drivers to shorten development time and reduce expenses for the manufacturer.

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In virtual seat design, OEM says, “Supplier, here

are the specs, build the seat!”

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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The seat is as essential as the steering wheel and needs to be an integral part of the data that define the interior of the car!

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Virtual seat design changes development

from iterations to specifications.

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

OEM

Pro

ductio

n

Supplier

Specifications

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One seat for all! Improve smallfemale “totally right” feeling by 58%.

Production Score = 4.8 ERL Virtual Score = 7.6

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Reality Check: does production miss“totally right” for small female driver?

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One seat for all! Improve large male “totally right” feeling by 20%.

Production Score = 7.4 ERL Virtual Score = 8.9

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Reality Check: does production miss“totally right” for large male driver?

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1. Population: Drivers

Seat design &development optimizes:

2. Seat: Biomechanics & Comfort

3. Ergonomics: Driving Task

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Population: Small drivers prefer aneutral posture but Vision is a problem.

Erect (E)

Neutral (N)

Slumped (S)

Small Female (5th %)

Vision

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Population: Medium drivers prefer a neutral posture but seat shape is a

problem.

Erect (E)

Neutral (N)

Slumped (S)

Small Female (5th %)

Vision

Medium Male (50th

%)

Controls Reach

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Population: Large drivers prefer a neutral posture but legroom is a

problem.

Erect (E)

Neutral (N)

Slumped (S)

Small Female (5th %)

Vision

Large Male (95th %)

Legroom

Medium Male (50th

%)

Controls Reach

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Oscar (SAE J826) represents one driver in the global

population.

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

Small Indian Woman

Large American Male

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The iterative seat design process struggles to optimize drivers’ needs in one seat for all drivers.

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Seat: 3 critical regions for drivers.

Head Restraint for Safety Regulations creates slumped posture.

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Seat: 3 critical regions for drivers.

Head Restraint for Safety Regulations creates slumped posture.Biteline pushes

driver into slumped posture.

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Seat: 3 critical regions for drivers.

Head Restraint for Safety Regulations creates slumped posture.Biteline pushes driver

into slumped posture.

Seat length for tall and short drivers.

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Chest

Lumbar

Buttocks

Thigh

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ERL Seat Design supports same four regions in every

driver’s body.

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

Load-Bearing Regions

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Seat Contact Regions

Top of Seatback

Bottom of Seatback

Head Restraint

End of Cushion

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ERL Seat Design contacts every

driver’s body in four sitting areas.

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

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Load-Bearing Region in Seat Seat Contact Region in Seat

Top of Seatback

Chest

Lumbar

Bottom of Seatback

Buttocks

Thigh

Head Restraint

End of Cushion

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ERL Seat: Same biomechanical

sitting objectives for all drivers.

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

Small Female

Large Male

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Ergonomics: Objective variables must

be designed “totally right” for all drivers.Large

Slumped Male

Head Restraint for 202a

Small Erect Female Large Slumped

Male

Track Angle & Seat

Position

ERL Patents: US #6,840,125, US #7,047,831, US #7,347,114, US #7,797,138, EU #1019693 & Patents Pending

Line of Sight

Right/Left Hand Reach Curves

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Virtual Design: calculate “totally right”

fit for all drivers in 142 controls variables!

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Controls Package Seat Driver & PassengersDesign Position & Track Material Properties (Stiffness) Population (Small to Large)

Seat Travel Windows Seat Shape: Centerline & Wings Joint Angles (Comfort)

Mirror & Headliner Adjustable Head Restraint & Lumbar

Seat Support (Biomechanics)

Accelerator Meat-to-Metal & Manufacturability Controls: Reach

Steering Wheel Frame: Size, Adjusters & Recliners Vision: Line of Sight

142 Variables 440 Variables 268 VariablesERL Patents: US #6,840,125, US#7,047,831, US#7,347,114, US# 7,797,138, EU #1019693 & Patents Pending

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Virtual Design: calculate “totally right”

fit for all drivers in 440 seat variables!

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Controls Package Seat Driver & PassengersDesign Position & Track Material Properties (Stiffness) Population (Small to Large)

Seat Travel Windows Seat Shape: Centerline & Wings Joint Angles (Comfort)

Mirror & Headliner Adjustable Head Restraint & Lumbar

Seat Support (Biomechanics)

Accelerator Meat-to-Metal & Manufacturability Controls: Reach

Steering Wheel Frame: Size, Adjusters & Recliners Vision: Line of Sight

142 Variables 440 Variables 268 VariablesERL Patents: US #6,840,125, US#7,047,831, US#7,347,114, US# 7,797,138, EU #1019693 & Patents Pending

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Virtual Design: calculate “totally right”

fit for all drivers in 268 driver variables!

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Controls Package Seat Driver & PassengersDesign Position & Track Material Properties (Stiffness) Population (Small to Large)

Seat Travel Windows Seat Shape: Centerline & Wings Joint Angles (Comfort)

Mirror & Headliner Adjustable Head Restraint & Lumbar

Seat Support (Biomechanics)

Accelerator Meat-to-Metal & Manufacturability Controls: Reach

Steering Wheel Frame: Size, Adjusters & Recliners Vision: Line of Sight

142 Variables 440 Variables 268 VariablesERL Patents: US #6,840,125, US#7,047,831, US#7,347,114, US# 7,797,138, EU #1019693 & Patents Pending

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Virtual Design mathematically fits 4744 dimensions for all drivers in 850

variables!

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Controls Package Seat Driver & PassengersDesign Position & Track Material Properties (Stiffness) Population (Small to Large)

Seat Travel Windows Seat Shape: Centerline & Wings Joint Angles (Comfort)

Mirror & Headliner Adjustable Head Restraint & Lumbar

Seat Support (Biomechanics)

Accelerator Meat-to-Metal & Manufacturability Controls: Reach

Steering Wheel Frame: Size, Adjusters & Recliners Vision: Line of Sight

142 Variables 440 Variables 268 VariablesERL Patents: US #6,840,125, US#7,047,831, US#7,347,114, US# 7,797,138, EU #1019693 & Patents Pending

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Since the iterative process works and is used by all manufacturers, why change?

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Value of Virtual Seat Design outweighs the cost of change!Months faster time-to-market.

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Value of Virtual Seat Design outweighs the cost of change!Months faster time-to-market.

Design one seat in each vehicle for all drivers to feel “totally right.”

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Value of Virtual Seat Design outweighs the cost of change!Months faster time-to-market.

Design one seat in each vehicle for all drivers to feel “totally right.”

Engineers and designers collaborate with objective and verifiable math data.

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Value of Virtual Seat Design outweighs the cost of change!Months faster time-to-market.

Design one seat in each vehicle for all drivers to feel “totally right.”

Engineers and designers collaborate with objective and verifiable math data.

Tools retain lessons learned for engineers and designers at OEM and Supplier.

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OEM’s CarSupplier’s Seat

ERL Patents: US #6,840,125, US#7,047,831, US#7,347,114, US# 7,797,138, EU #1019693 & Patents Pending

ERL’s Virtual Seat Design brings them together!

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Thanks for your time!

Comments & Inquiries [email protected]