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The current and future greatness challenge for the car and light truck manufacturer is to develop less costly, weight efficient vehicles within shorter lead times. Based upon these circumstances, the technique of “systems design”, “systems integration” and “total interior systems integration” will be discussed in detail. Component integration and systems integration has been taking place in automotive interior design for sometime. However, total systems integration is relatively new. A potential area for interior systems integration application is in side impact “upgrade”. For added side impact protection the door structure and impact beam can be upgraded, a side air bag utilized, door/sill interlock, crushable arm rest, etc. Individually, each of these systems could meet the new side impact requirements; however, at a cost, weight and quality penalty. Utilizing two or more of these systems in combination could lead to an optimum solution (total systems integration).

One of the major steps that can be taken to reduce vehicle leadtime is optimal body engineering. To understand this process, a short history of vehicle body development will be presented plus examples of three active programs that highlight the use of aluminum, plastics and steel concentrating on weight and cost reduction. In addition, two areas of potential design and development leadtime reduction will be investigated. First, the potential of drastically reducing the “concept” decision leadtime…this can be done with the aid of a new computer program. Secondly, the need for excellent communication between the car companies, their contract design services and the “blackbox/graybox” suppliers.

Automotive Body Engineering has been one of the most important disciplines in automotive engineering during the past 100 years. A brief historical review will take place highlighting the major automotive trends which have challenged the expertise of the body engineer, including the major contributions of the body engineering profession that brought comfort, convenience and safety to the modern automobile. Finally, the current challenges to body engineering will be discussed. These include the need to drastically reduce program leadtime and control both engineering and product costs. The two areas in which the above stated challenges can be met are as follows: First, the technologies and materials being applied to new vehicle bodies will be discussed. Highlighted, will be the effect upon cost and leadtime reduction. Secondly, the component design process will no longer start with a clean sheet for a new design.