1. Advancements in Powertrain Test Environment
DELIVERING Productivity THROUGH STRATEGIC CHOICE OF TEST ENVIRONMENT
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Dr. Philip Lawson 30 Nov 2017 – AVL Product Development in Motion

2. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Outline
Motivations
Brief history of Powertrain Testing at JLR
Why?
Increasing Productivity through Shift & Expand
What?
Key enablers to deliver Shift & Expand strategies
How?

3. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Background & Motivation
Jaguar Land Rover Retail Sales Volumes by FY
Jaguar E-Pace
Jaguar F-Pace
Land Rover Discovery
Range Rover Velar

4. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Background & Motivation
Since 2011:
Doubled internal Engine Test activity
Tripled internal Chassis-Dyno Test activity
15x increase in outsourced test activity
Testing Effectiveness Four Levers
Internal capacity increase largely due to Testfield Efficiency Projects
“Holistic Powertrain Development & Test Productivity Optimisation at Jaguar Land Rover” J. Houldcroft et. al. 5th International Symposium on Development Methodology, 2013

5. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Background & Motivation – SAE 2016-01-0982
In fact, in 2015 my team got together with AVL’s Efficiency Team to look at the methodology lever of Test Field Efficiency in further detail.
Together, we explored very interesting topics which included ensuring that the capability of a test installation meets customer expectations. In other words, a systematic process to ensure that the statistically evaluated capability of the test installation is compatible with the quality and timing requirements of the test customer.
Throughout this project

6. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Background & Motivation
Testing Effectiveness Four Levers
New Testing Effort
Reuse Data
New Technologies
Efficiency Gains
Effectiveness Shift & Expand
Testing Effort
Expanding
Product
Portfolio
Reduced Testing Efforts in Strategic Environment
As-is State

7. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Shift and Expand Strategy

8. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Key Enablers
Adoption of Shift & Expand test methodologies requires significant investment in…
Test Field Effectiveness
People
Process
Facility

9. “Customer” Relationship Management
ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Process Investment - Operational Readiness
Let’s start with the process
Experience of commissioning test installations over many years has taught us that a high level of planning and preparation is required to ensure that the KNOWN test asset sees a smooth transition into operation.
In this case, we were looking at MULTIPLE test assets, with capability that WE DID NOT HAVE before, therefore we chose to look at Operational Readiness Models (typically exemplified by Airport installations)
As a test facility within an OEM, we do not exist for the purpose of offering a testing service as a Core Value Stream. We exist to enable the product development of our vehicles.
It is CRITICAL that the capability and methodology seamlessly merge with the OEM’s product development processes!
For this, you NEED to engage the “customer” to ensure that methodology and supporting processes are developed earlier on that will enable the capability to be integrated and adopted into product development workstreams. THIS IS A CULTURE CHANGE
Changing the choice architecture
Supplier - Simplify software standardise activity into processes to enable maximum use of the means and resource available
Acceptance of this way of operation will require significant cultural change: engineers typically have their own preferences based on historical experience with test facilities in their local area. This change will be supported by the introduction of data quality detection standards which have buy-in from both testing and engineering organisations.    
Engineer acceptance that this is an environment that they want to use.
Freeing up time and space for product engineers to focus on refinement of the on-road testing across the product range
Changing the work environment and enabling high value engineering
Building capability into the automation system, tools and to enable wider realisation of the benefit and centralised support
“Customer” Relationship Management

10. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Process Investment – Customer Relationship Management
AVL Tech Centre Coventry
AVL Graz

11. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT People Investment – Importance of Training
Team Growth & Development
Team Size Ramp
Skill Ramp
Productive Facility
Training Cell in Graz
TCC in Coventry
Project Timeline

12. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Facility Investment

13. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Summary & Conclusions
People
Level 4 Apprenticeship & development of Technician population
Established Technical Training Team
Specialist training in the test field environment
Up-skilling existing population
Process
Project process and common goal of operational status
Customer relationship management
Process oriented culture with “swim lane” processes developed in advance of training and ramp-up
Facility
JLR is investing significant capital to ensure that our facility meets the needs of our business
Continued upgrade and advancement of existing facility
Enabled global connectivity
Invested in Research capability, joint AVL – JLR Technical Centre, New Propulsion Development Centre.
Making use of new rapidly deployed modular cells to ensure capability and capacity availability for JLR
While Technology changes can be “bought in”, it is essential to develop People and Teams

14. THANK YOU
Dr. Philip Lawson Senior Manager Emissions Testing M +44(0)

15. BACKUP MATERIAL

16. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Shift and Expand Strategy
Chassis-Dyno Test Cell
Plant & HVAC
Dilution Tunnel
Dilute Gas
Particle Mass
Particle Number
Data Acquisition
Raw Meas.
Raw Meas.
Raw Meas.
Mixing Tee
Cooling Fan
Dilution Air
CAT 1
CAT 2
CAT 3
4WD Dyno

17. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Shift and Expand Strategy
Powertrain (Vehicle-in-Loop) Test Cell
Data Acquisition
Raw Meas.
Raw Meas.
Raw Meas.
Cooling Fan
Exhaust Flow Meas.
CAT 1
CAT 2
CAT 3
4WD Wheel Hub Dyno

18. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Shift and Expand Strategy
Engine-in-Loop Test Cell
Road Speed Trace
Vehicle Simulation
Raw Gas Analysis
Dyno
Exhaust Flow Measurement
Cat 1
Cat 2
Engine

19. ADVANCEMENTS IN POWERTRAIN TEST ENVIRONMENT Shift and Expand Strategy
Engine-in-Loop Test Cell
Road Speed Trace
Vehicle Simulation
Catalyst Simulation
Raw Gas Analysis
Dyno
Exhaust Flow Measurement
Engine