Go from virtually zero IIHS Stars to 4 Stars, in 18 months.
When a West Coast car company decided to engineer an electric vehicle for the North American market it was essential that the vehicle be designed and tested to meet US safety standards.
The Challenge
Pilot worked with an OEM, as they brought a new EV product to market.
The OEM had contracted a manufacturer to provide a “glider vehicle”. The OEM then developed, manufactured and installed the powertrain and vehicle control systems.
The glider vehicle was derived from a vehicle that was being sold in non-US markets. The initial analysis of the prototype glider (including CAD/CAE) demonstrated that the initial design was completely inadequate for the US Market.
Result
Pilot assembled and managed a team of engineers that included world recognized experts in safety and crash. The team included Pilot associates and suppliers across multiple continents working in concert. The team included Crash and Simulation Experts, CAE and CAD designers, test facilities throughout the United States and Safety Compliance engineers who were experts in safety regulations, testing and communicating effectively with the National Highway Institute Association (NHTSA), and the Insurance Institute of Highway and Safety (IIHS). Pilot was the hub for all Detroit based work. Our responsibilities included regulatory guidance, technology strategy, crash simulation, passive and active safety engineering, FMVSS testing for US and Canada, Vehicle Durability Testing, Manufacturing and Delivery of structural vehicle components.
Pilot led the Regulatory Compliance efforts. Pilot analyzed applicable regulations, identified Product Development implications of meeting those regulations, developed the OEM’s overall safety strategies, their compliance demonstration plans (including test plans) and directed their team as they created their compliance demonstration reports.
Pilot worked with the OEM and their “glider supplier” to improve the glider design. Pilot also designed and managed the manufacture of key vehicle parts. Pilot’s work led to raising the projected IIHS performance from a simulated Zero Star to a manufactured and tested vehicle demonstrating 4 Star performance.
And Pilot, the OEM and the supplier accomplished this in 18 months.
Areas of expertise: consulting services, program management, regulatory guidance, testing