Body engineering for production

The body engineering responsibilities are to simulate the styling model and overall requirements laid down by the management in terms of drawings and specification. The engineering structures are designed for production, at a given date, at the lowest possible tooling cost and to a high standard of quality and reliability.
As competition between the major car manufacturers increases, so does the need for lighter and more effective body structures. Until recently the choice of section, size and metal gauges was based upon previous experience. However, methods have now been evolved which allow engineers to solve problems with complicated geometry on a graphical display computer which can be constructed to resemble a body shape (Figure 1.26). The stiffness and stress can then be computed from its geometry, and calculations made of the load bearing of the structures using finite-element methods (Figure 1.27).
With the final specifications approved, the new car is ready for production. At this stage an initial batch of cars is built (a pilot run) to ensure that the plant facilities and the workforce are ready for the start of full production. When the production line begins to turn out the brand new model, every stage of production is carefully scrutinized to ensure quality in all the vehicles to be built.