The quality of suspension systems is fundamental to the automotive industry. Components ranging from coil springs to stabilizer bars and torsion bars play an essential role in vehicle comfort, performance and safety.
But how can we guarantee optimum quality in such a complex and varied field? The challenge is not limited to production; it extends to the potential risks that can arise during manufacturing.
This paper explores the mechanisms and tools that enable engineers to navigate this complex environment to ensure quality control that meets the industry's high standards.
The importance of automotive suspension systems
Driving comfort
One of the primary roles of suspension systems is to enhance driving comfort. A good suspension system attenuates vibrations and shocks. This is not just a question of comfort, but also of safety.
A more stable ride means better maneuverability, which is essential in an emergency.
Vehicle performance
Suspension has a direct impact on vehicle performance. A well-designed suspension contributes to better grip on the road. This optimum grip is crucial to steering precision and braking efficiency.
In short, it makes the vehicle more responsive and maneuverable.
Component longevity
A high-performance suspension system offers many advantages:
- Reduced wear: A good suspension system minimizes the impact on other vehicle components.
- Fuel savings: Better grip and balance mean more efficient use of fuel.
- Maintenance costs: Parts last longer, reducing long-term maintenance costs.
"My manager referred me to Skill Software to benefit from their expertise, as they were already in place at other sites in our company."Loic DENNETIÈRE, Quality Engineer at SOGEFI SUSPENSION
Synergy with driver assistance systems (ASR, ESP, ABS)
In the modern automotive world, driving aids such as ASR (Anti-Slip Regulation), ESP (Electronic Stability Program) and ABS (Anti-lock Braking System) are omnipresent. These systems work in close collaboration with the suspension.
The mechanisms behind synergy
First and foremost, good suspension ensures optimum tire grip. Only with this grip can the ASR effectively prevent wheel spin. Secondly, suspension plays a decisive role in vehicle balance. Without this balance, even a state-of-the-art ESP would struggle to stabilize the car in the event of a bang or a slide. Thirdly, ABS works by reducing braking pressure on a wheel if it starts to lock. However, it is the suspension that ensures that the wheel remains in constant contact with the road, enabling the ABS to function properly.
Implications for safety and comfort
This synergy between suspensions and driving aids has direct repercussions on two crucial aspects: safety and comfort.
- Safety: A quality suspension system acts as a force multiplier for the driving assistants. For example, a good suspension system enables the ESP to react more effectively in the event of loss of control, thereby reducing the risk of an accident.
- Comfort: Beyond safety, good suspension also makes driving more comfortable. When coupled with systems like ASR, it reduces vibrations and jolts, creating a more pleasant driving experience.
"Skill FMEA Pro is our quality management tool of choice when setting up new manufacturing lines."Loic DENNETIÈRE, Quality Engineer at SOGEFI SUSPENSION
Managing quality in suspension system production
Risk analysis in manufacturing
- Materials: Choosing the right materials is fundamental. The wrong choice can lead to unexpected failures.
- Calibration: Dimensions must be strictly controlled to avoid any imbalance in the system.
- Assembly: An error at this stage can make the final product dangerous.
"As Quality Engineer, I'm responsible for the efficient implementation of new production lines at our plant in Romania."Loic DENNETIÈRE, Quality Engineer at SOGEFI SUSPENSION
From paper documentation to digitalization
Digital transformation is revolutionizing the way quality is managed in production. Whereas documentation used to be largely paper-based, things have changed radically.
- Accessibility: Digital systems provide instant access to drawings, standards and procedures, speeding up the verification process.
- Traceability: With digitization, every component can be tracked in real time, from manufacture to installation.
- Updating: Software enables real-time updates, ensuring that all teams are working with the most up-to-date information.
The transition from paper to digital is not just a technological upgrade; it's a complete overhaul of the quality management system. It requires adaptation, but the benefits are undeniable in terms of accuracy, speed and, ultimately, quality.
These two components, risk analysis and digitization, are pillars in the quest for superior quality in suspension systems. Each element responds to specific challenges and provides tangible solutions.
"We already had several production lines in place. The objective was to identify all possible failure modes for each line."
Loic DENNETIÈRE, Quality Engineer at SOGEFI SUSPENSION
The impact of a complete software solution in quality management
In the industrial world, process efficiency is a priority. Quality management is no exception. To achieve this, specialized software such as Skill FMEA Pro is essential. This software solution enables more precise, flexible and proactive risk management, while ensuring continuous quality improvement.
Skill FMEA Pro offers a range of features specifically designed for the automotive suspension sector. These include :
- Risk analysis: Enables the identification and assessment of risks associated with potential defects in each suspension component.
- Traceability: Provides rigorous tracking of modifications and adjustments during the manufacturing process.
- Data integration: Facilitates the aggregation of various sources of information for better decision-making.
- Report automation: Generates detailed reports in real time, making it easy to monitor quality-related KPIs.
- Interoperability: Easily integrates with other corporate information systems for a coherent ecosystem.
"Using Skill FMEA Pro has given us a more precise view of manufacturing lines, and has been much appreciated during customer audits."
Loic DENNETIÈRE, Quality Engineer at SOGEFI SUSPENSION
Control and optimization: the road to excellence in the manufacture of automotive suspension systems
The world of automotive suspension manufacturing is a competitive and complex battlefield, where the stakes go beyond simple production. It's not just a question of creating components that improve vehicle comfort and performance, but also of integrating these systems harmoniously with driver assistance technologies such as ASR, ESP and ABS. In this context, quality is king, and managing it requires meticulous attention at every stage of the manufacturing process.
Risk analysis cannot be neglected, especially with the variety of materials and processes involved. This is all the more crucial today, when digitization is transforming the way these systems are designed, monitored and updated. Software solutions have become essential to ensure proactive, cutting-edge risk management, thereby guaranteeing optimum quality.
"The contact and proximity with the trainer, as well as the ergonomics of the software, are the qualities I appreciate most in the solution offered by Skill Software."
Loic DENNETIÈRE, Quality Engineer at SOGEFI SUSPENSION
This overview underlines the importance of having a comprehensive, integrated strategy for the manufacture of suspension systems. It must include proven risk analysis methodologies, a well-orchestrated transition to digitization and, ideally, the adoption of specialized software solutions for optimal quality management.
If you're looking for true excellence in suspension system quality management, look no further.
Contact us today to find out how we can help you achieve your performance and quality objectives.
