Developing an integrated measurement and evaluation strategy for a preventative process control for the G80 Frontend pre- assembly process and alignment fixtures

Christopher Thomas Werner Pallamar

    Research output: ThesisMaster's Thesis


    The BMW Group has planned the production of the new BMW M3 (G80) at the BMW plant in Munich, for the beginning of November 2020. As a premium vehicle manufacturer, the BMW Group has set out to manufacture quality vehicles, while focussing on the optimal joint patterns. The BMW plant in Munich aims to achieve this goal of optimal joint patterns without the need for additional rework steps. In order to successfully accomplish this objective, each individual process has to prove its process capability. The front part of the vehicle, also referred to as the Frontend , represents the most joint patterns while illustrating highly complex geometries. Due to this reason, the quality management strategy of the BMW plant in Munich had decided to monitor and control the Frontend pre-assembly process during the series production, using the Statistical Process Control (SPC) method. To successfully integrate the SPC method into the plant for the Frontend assembly processes and the Frontend crucial alignment fixtures, an upfront measurement and evaluation strategy was developed and implemented during the pre-series production phase. For the successful development of this strategy, the fundamentals of the Tolerance Management in the automotive industry and Tolerance and Dimensioning were highlighted, followed by the Statistical Capability Study elaborated in the BMW Group Standard 98000. Also, an introduction into Metrology and the relevant Coordinate Measuring Machines (CCM) was given. Next, the Frontend assembly processes along with the process influences were highlighted, while the following chapter outlines the preparation undergone for the measurement and evaluation strategy. The preparation included the determining of relevant measurement characteristics and points, as well as illustrating the documentation structure of the strategy. Furthermore, the Process Performance Study (PPS) performed during the Statistical Capability Study according to the BMW GS 98000 was discussed, which resulted in the Process Performance (PP) indices being calculated. Concurrently to the PPS, the evaluation strategy was conducted, which made use of the assembled Frontend PP indices and captured the crucial characteristics as the evaluation starting point throughout all pre- series phases. Thereafter, the significant process influences were traced back. Lastly, the process and part quality measures established during the evaluation strategy were documented and should be continuously controlled during the series production.
    Translated title of the contributionEntwicklung einer integrierten Mess- und Auswertestrategie für die präventive Prozesskontrolle des G80 Frontend Vormontageprozess und der dazugehörigen Sonderbetriebsmittel
    Original languageEnglish
    Awarding Institution
    • Montanuniversität
    • Sifferlinger, Nikolaus August, Supervisor (internal)
    • Prenner, Michael, Co-Supervisor (internal)
    • Niebert, Lukas, Supervisor (external), External person
    Award date18 Dec 2020
    Publication statusPublished - 2020

    Bibliographical note

    embargoed until 11-12-2025


    • Statistical Process Control
    • Tolerance Management
    • Quality Management
    • Tolerance and Dimensioning
    • Coordinate Measuring Machine
    • Articulated Arm Coordinate Measuring Machine
    • Quality Control

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