About the Client

A global automotive OEM manufacturing vehicles with diverse styles and complex geometries. The client required a precise and coordinated approach to ensure dimensional accuracy and structural integrity across Body-in-White (BIW) assembly operations.

The Challenge

Managing BIW components across multiple models and variants demands accurate CAD, coordinated weld planning, and robust quality control. The client faced challenges due to:

• Complex data files and variant configurations
• High volume of CAD parts requiring fitment validation
• Coordination of digital math data with weld planning workflows
• Lack of streamlined systems for ensuring consistent model updates across global teams

The Solution

We delivered an integrated digital process to manage BIW design-to-build accuracy, from CAD coordination to measurement strategy planning.

Key solution components included:

• Centralized coordination of CAD math data across all BIW components
• Fit-and-finish validation ensuring proper clamping, alignment, and weld sequencing
• Support for weld process planning directly linked to math models
• Development of Measurement Point Strategy to ensure accuracy across build stages
• Real-time validation of model and variant updates to minimize errors and rework

The Impact

The solution ensured consistent product quality and manufacturing efficiency across BIW operations:

• Reduced dimensional variation across styles and variants
• Improved weld process consistency through data-driven planning
• Enhanced final appearance and craftsmanship via validated fit-and-finish
• Streamlined data handling and file management for complex CAD assemblies
• Higher first-time-right build quality, minimizing in-process distortion