About the Client

A premium European OEM in the passenger car luxury segment. The client required a multi-party engineering partnership to support the design, validation, and launch of a technologically advanced, high-finish door trim panel under a simultaneous engineering model.

The Challenge

The project involved close coordination between three stakeholders – the OEM, a global part supplier, and AllyGrow — across multiple geographies and languages. The client expected concept-to-launch support for a complex door panel integrating premium materials and next-gen features.

Key challenges included:

• Managing cross-functional teams across client, supplier, and offshore locations
• Meeting aggressive timelines under simultaneous engineering constraints
• Ensuring manufacturability and design integration of premium finishes
• Addressing regulatory and packaging challenges early in development

The Solution

We executed the program through a hybrid delivery model combining onsite, near-site, and offshore teams.

Key solution components included:

• Concept development and feasibility studies
• Master section and assembly sequence definition
• RPS (Reference Point System) definition and regulatory compliance checks
• Detailed engineering design considering DFM and DFA principles
• Material-specific engineering for leather wrapping, sew lines, and premium insert integration (wood, chrome, aluminum, painted parts)
• Close coordination with supplier tooling teams for manufacturability alignment

The Impact

The collaborative engineering effort delivered a high-precision, premium-quality door trim panel within a compressed timeline:

• Successfully launched the product through multi-location design coordination
• Improved manufacturability through early-stage DFM/DFA validation
• Achieved design excellence with seamless integration of luxury finishes
• Enabled supplier readiness by aligning engineering output to tool shop constraints
• Strengthened client relationship through flexible execution and delivery ownership