Overview on the main project steps

The main phases of the project are shown in the following image, which is quite similar to all other projects in any vehicle manufacturing company.

It has to be mentioned that clearly the overall phases are similar, but the detail of the planning and phases are vary in each company and there is specific “Vehicle Development methodology” in each company. In this project the PSA development methodology was used, which could not be explained here due to confidentiality constraint.

Exterior styling is one of the key elements of the vehicle success in the target markets.

In order to put vehicle on the market as quick as possible and to achieve the targeted investment efficiency, it was decided to carryover all the front part of the 206 Hatch, including the rear doors. The decision was also made based on the fact of P206 current style success in the market and appreciation by the customers.

The styling of “Peugeot 206 Sedan” was conducted with maximum utilizing of the virtual technology, via implementation of following steps:

  1. Creation of renderings and selection process of them to agree on the fundamentals of vehicle image.
  2. Creation of 3D CAS surface in the virtual environment and review that by virtual reality to advise required modification.
  3. Input from engineering feasibility to the style and implement required modifications.
  4. Milling the physical model directly from CAS data for final validation of the model.
  5. Fine tune the model where necessary and update the virtual data accordingly.
  6. Provide “A” quality surface.

Design and Development:


There is a methodology for design and development the vehicle, which is called “V matrix”, like many other car manufacturers, this methodology was also utilized in P206 sedan project.

Following image shows the concept of this methodology in a global view:


 The left hand and middle part of this matrix is covering the design and development activities and the right hand is allocated to validation activities.

Product definition/ Vehicle target setting:
At early stage of design and development, the product definition and features were described.

The vehicle targets were also established by using the input from 3 following sources:

  • Customer wants
  • Legislations must
  • Company wants

The vehicle targets were established in following categories: (In the items, where impacted by the area of changes)

  • Crash & Safety
  • Fatigue
  • Aerodynamic & Thermodynamic
  • Road behavior / Ride & Handling
  • NVH (Noise Vibration Harshness)
  • Squeak & Rattle
  • Longitudinal performance
  • Water & Dust intrusion/ Tightness
  • Corrosion resistance



Systems/ Sub systems/ Parts Design:

With an overlap with styling activities the design were started. The main steps of design and development could be summarized in the following steps:
  • Definition of vehicle design architecture. (In this case architecture of rear end of the car)
  • Concept design of systems and parts.
  • Detail design. (Creation of 3D models and 2D drawings)

CAE simulation and Analysis:

Reliability of the CAE models was a strong point of the project. This strength was a good tool to reduce the time and budget of the project.

The later conducted tests proved the accuracy of the simulations.
Wide diversity of the CAE simulations were conducted in the project, which some of them shown in the following image:

Prototype build/ Test, validation and homologation:


This is the right hand of the “V” matrix and third phase of the project shown in the plan.

Numbers of prototype parts were made by supplier and utilized for sub system and system validations,   in line with the advised specifications by designers.

A vehicle prototype plan was also established and prototype vehicles were built accordingly to support test and validation plan.


Also a number of pre-series cars were allocated to validation and homologation plan. The homologation was managed to apply for European countries certification in addition to all local regulation in each market.

Tooling supply and industrialization:


The design of the tooling and production line were started at earliest possible time to have the real meaning of concurrent engineering to agree of design modification at early stage and reduce the cost of physical modifications on the tooling and equipments.

As some of the tooling had been ordered to abroad, so a robust management was necessary to have all the tooling on time in factory or suppliers site for home line try out.

Construction and commercialization of a new body shop, with following specification was a part of project:
  • Automation rate: 85%
  • Mix production P206 hatch back & Sedan
  • Automatic switching between Hatch back and sedan
  • Robots:   55    Specific for Sedan variant         180    Common with hatch back

Quality loops:


A strong part of the used methodology was in the area of product quality management.

3 off line and 2 online pre- production phases were established and the quality targets for each stage were defined and agreed.

During production of each stage the achievement of the quality targets were monitored and after root cause analysis of defects, the feed backs were given to related area. (Design, parts quality, suppliers, production lines….)

Movement to the next phase of pre-production was only possible if the target was achieved.