Detailed explanation of Volkswagen PEP development process
Latest update time：2024-10-31
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North Bay South Lane
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Automotive Electronics and Software
In the automotive industry, the product development process is a complex and rigorous process that involves multiple stages from concept design to market launch. As one of the world's leading automakers, Volkswagen's Product Entstehungs Prozess (PEP) is a structured product development framework that aims to ensure efficient progress at every stage from concept to mass production. The core of PEP is to shorten the product development cycle, improve development efficiency and product quality, and respond quickly to changes in market demand.
#01
Overview of the PEP Process
PEP, the full name of which is "Product Entstehungs Prozess", means "Product Birth Process". This process covers the entire automobile formation process from project start (PM) to market launch (ME). Volkswagen's PEP process focuses on the systematic, scientific and forward-looking nature of the project, ensuring that every step from product concept to mass production is strictly verified and optimized.
1.1 Major Milestones of the PEP Process
Volkswagen's PEP process includes several key milestones, which mark important nodes in the project progress. The following are the main milestones in the PEP process and their detailed analysis:
1. Project Initiation (PM)
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Project initiation is the first stage of the PEP process, marking the official start of the project. At this stage, it is necessary to clarify project goals, form a project team, and develop a project plan. Volkswagen will conduct preliminary market research and feasibility analysis to ensure that the project direction meets market demand and company strategy.
2. Solution determination (KE)
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Solution determination is one of the key nodes in the PEP process. At this stage, the project team will plan the product's technical solution, styling solution, etc. in detail to lay the foundation for subsequent work. Volkswagen will organize an expert review team to review the solution to ensure its feasibility and innovation.
3. Modeling decision and freezing (DE, DF)
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The styling decision and styling freeze are the styling design stages in the PEP process. In this stage, designers will design the styling according to project requirements and market trends, and determine the final styling through multiple rounds of review and modification. After the styling is frozen, the styling plan will serve as the benchmark for subsequent work.
4. Purchase approval (BF)
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Procurement approval is an important part of the PEP process. During this stage, Volkswagen will negotiate and cooperate with suppliers to ensure the quality and supply of key components and raw materials. Procurement approval marks the entry of the project into the substantive procurement and production preparation stage.
5. Production of the first mold (T0)
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The first mold production is the production preparation stage in the PEP process. In this stage, the mold manufacturer will make the first mold according to the product drawings and requirements, and conduct trial production and verification. The successful production of the first mold means that the product can enter the mass production stage.
6. Offline Tooling Sample (OTS)
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The OTS stage is the sample verification stage in the PEP process. In this stage, samples under full tooling and non-beat production conditions are used for verification to evaluate the product's design capabilities, manufacturing feasibility, and quality feasibility. The successful verification of OTS samples is an important prerequisite for subsequent trial production and mass production.
7. Volume License (LF)
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The volume license is one of the important milestones in the PEP process. At this stage, Volkswagen will conduct a comprehensive assessment of the project to ensure that the project is ready for mass production. The acquisition of the volume license marks the final preparation stage before the project enters mass production.
8.VFF
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The preliminary batch is the pre-batch approval stage in the PEP process. In this stage, a small batch trial production will be carried out to verify the reliability and stability of the production equipment and production process. The successful implementation of the preliminary batch will help to discover and solve potential problems in advance and make full preparations for formal batch production.
9. Trial batch production (PVS)
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Trial production is one of the key stages in the PEP process. During this stage, large-scale trial production will be carried out to evaluate the production rhythm and product batch stability. The results of trial production will directly affect the smooth progress of subsequent batch production.
10. Engineering Sample Approval (BMG)
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Engineering sample approval is the quality verification stage in the PEP process. In this stage, engineering samples involving key components such as safety parts and functional parts will be approved to ensure the stability and reliability of product quality.
11. Two-day trial production (2TP)
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Two-day trial production is the production verification stage in the PEP process. In this stage, a two-day trial production will be carried out to verify the supplier's batch supply capacity and the production capacity of the production line. The successful implementation of the two-day trial production indicates that the project has the ability to start formal batch production.
12. Zero batch production (OS)
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Zero batch production is the final exercise stage in the PEP process. At this stage, the final batch production verification will be carried out to ensure that all equipment and processes meet the requirements of batch production. The successful implementation of zero batch production marks that the project is about to enter the formal batch production stage.
13. Mass production (SOP)
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Mass production is the final stage of the PEP process. At this stage, the project will officially start mass production and the product will begin to be sold on the market. The successful implementation of mass production marks the successful completion of the project and the successful launch of the product.
#02
Key features of the PEP process
The core of PEP is to shorten the product development cycle, improve development efficiency and product quality, and respond quickly to changes in market demand. The following are several key features of the PEP process:
1. Project Planning and Initial Phase:
The PEP process starts with conceptual design and feasibility analysis. This phase mainly defines the product's technical specifications and market demand, and conducts project planning and resource allocation.
2. Concurrent Engineering and Integrated Development:
PEP emphasizes simultaneous engineering, and through cross-departmental collaboration, it synchronizes design, manufacturing, procurement and other links to reduce the development cycle. This integrated development model ensures information sharing and seamless cooperation between different functional teams.
3. Digital product development:
With the advancement of technology, PEP increasingly relies on digital tools, using virtual prototypes and simulation technology to replace some physical prototype tests. This not only reduces development costs, but also speeds up product verification.
4. Modular and platform development:
Volkswagen's product development emphasizes modular design and platform sharing, which allows multiple models to share basic components, improving production efficiency and flexibility. For example, Volkswagen's MQB platform can support models of different sizes and share major components such as engines and transmission systems.
5. Product verification and production preparation:
In the PEP process, each development stage has a strict testing and verification procedure to ensure that the product meets quality and safety requirements during the design stage. The production preparation stage includes the final quality review, supply chain coordination and production line layout.
Through the PEP process, Volkswagen is able to quickly launch new models around the world while ensuring high product quality and consistency. This framework has also become the basis for Volkswagen's collaboration with suppliers, especially in terms of time management and cost control.
2.1 Digitalization and virtual development
Digitalization and virtual development play a key role in Volkswagen's product creation process (PEP). By adopting virtual simulation and digital twin technology, Volkswagen is able to simulate the performance and interaction of the entire vehicle and its components during the development phase, thereby reducing the need for physical prototypes, significantly shortening the development cycle and reducing costs.
1. Digital Twin Technology
Volkswagen uses digital twin technology to build virtual models that cover all aspects from design to manufacturing. By simulating the physical behavior of vehicles, production line operations, and system integration, Volkswagen can detect and solve potential problems in advance to ensure the smooth progress of the development process. In addition, these virtual models can also help optimize designs to ensure that products are in the best condition before entering production.
2. Virtual simulation
Virtual simulation technology enables Volkswagen to test various parts of new models, such as chassis, powertrain and electronic architecture. This not only improves product quality, but also speeds up testing and verification. Volkswagen uses these tools to optimize product development processes, especially when developing MEB electric platform models, which significantly improves production efficiency through highly automated and standardized production processes.
3. Cross-platform collaboration
Volkswagen and partners such as Siemens jointly promote the integration of digital tools, such as Siemens' automation solutions and digital enterprise platforms. Through these platforms, Volkswagen can achieve seamless integration from design to production and promote information flow and collaboration between departments. The VASS standard implemented by Volkswagen in its Zwickau plant, which is a comprehensive standard for automated and digital production, has helped to achieve flexible mass production of different models on the same production line, which has not only improved production efficiency, but also laid the foundation for further digitalization.
In summary, Volkswagen has not only effectively improved development and manufacturing efficiency by deeply applying digital twin and virtual simulation technologies, but also created conditions for future innovation and flexible production. These digital tools enable Volkswagen to respond to market demand more quickly while ensuring a high degree of consistency in vehicle quality and design.
2.2 Cross-departmental collaboration
In Volkswagen's product creation process (PEP), cross-departmental collaboration is key to ensure seamless integration of R&D, production, supply chain, and marketing. Through this cooperation model, Volkswagen can achieve efficient collaboration throughout the entire process from the initial concept to the final delivery stage.
1. Cross-departmental collaboration mechanism
PEP strengthens close cooperation between different departments through a systematic engineering approach, especially in the early stages of requirement definition and function development. By clarifying the requirements and interdependencies of each department, it ensures that systems and components can work seamlessly, thereby reducing duplication of work and errors in development. This close cross-departmental collaboration helps shorten the development cycle and reduce costs.
2. System and function-centered development concept
Volkswagen's PEP process has shifted from the traditional "component first" to "system and function first". This means that when developing new cars, priority is given to the design of functions and systems rather than individual hardware components. This approach stems from more complex vehicle electronic architectures and the need for user experience and software updates.
By adopting this system engineering approach, Volkswagen has reduced its dependence on hardware, allowing software to flexibly adapt to the different needs of vehicles, thereby speeding up the overall development speed. For example, Volkswagen's Scalable Systems Platform (SSP) is a unified platform based on software-driven, which can support a variety of models from small cars to high-end cars, which greatly enhances the flexibility and efficiency of its vehicle development.
3. Software-first development strategy
As the degree of vehicle digitalization increases, Volkswagen has introduced more "software-first" development strategies in the PEP process. Its software company CARIAD is responsible for developing the core software stack of the vehicle, so that functions and services can be updated and expanded through OTA (Over-The-Air). In this way, Volkswagen can not only improve the flexibility and user experience of the vehicle, but also continue to provide customers with value-added services during the life cycle of the vehicle.
In summary, Volkswagen's PEP process achieves efficient product development from concept to market through cross-departmental collaboration and a "system-centric" development concept. These strategies help Volkswagen maintain its innovative advantage in the highly competitive automotive industry.
2.3 Optimization and improvement of PEP process
Volkswagen has shortened the vehicle development cycle from the traditional 54 months to 40 months by optimizing and streamlining its product development process (PEP), improving development speed and overall efficiency. This optimization is mainly reflected in the adjustment of technology and organizational structure. First, Volkswagen has adopted a "system and function-centric" development concept, focusing on integrating software and hardware, reducing the dependence on separate physical components in development, and achieving faster iterative development. "If the car is gradually becoming an electrically driven software product, its development must also continue to evolve in all dimensions. We make technology development more interconnected and efficient by shifting the process and organizational focus from components to systems and functions. First of all, it is software, not hardware. This will enable us to shorten development time by 25%-in the future, starting from the basic software architecture is ready, vehicle projects will be completed in 40 months instead of the previous 54 months," said Thomas Ulbrich, member of the Volkswagen Management Board responsible for technical development.
Volkswagen's PEP adjustment emphasizes the closer integration of development, production, supply chain and other departments. By clarifying the interdependencies of various systems and components at an early stage, it ensures that functions can work together seamlessly. The new development process is more customer-driven and relies on systematic engineering methods (such as the system engineering methods commonly used in the aviation industry) to make the development process more efficient and flexible.
In addition, the new organizational structure has set up an integration center to promote close collaboration between different business departments. By shortening the approval and decision-making paths, the development team can respond more quickly to market needs and technological changes, which not only significantly shortens development time, but also improves production processes and product quality.
These adjustments are also accompanied by the optimization of the production line. Volkswagen's goal is to control the production time of each vehicle to less than 10 hours, a speed currently achieved by Tesla, and Volkswagen hopes to catch up with or even exceed this standard through better integration of development and production.
2.4 Future Development Direction
In the future, Volkswagen plans to further promote the deep integration of digitalization and automation technologies by continuously optimizing the PEP process. The improvement of the PEP process focuses on reducing the development cycle, improving production efficiency and optimizing resource allocation, especially through the application of digital twins and virtual simulation technologies to achieve real-time data analysis and product verification, thereby reducing the demand for physical prototypes. In addition, Volkswagen is vigorously promoting the integration with electric platforms (such as the SSP platform) to support the development of a new generation of smart electric vehicles.
SSP (Scalable Systems Platform) is a new architecture designed by Volkswagen for future electric vehicles, combining software-driven and highly integrated hardware platforms. The platform aims to simplify the development process and achieve cross-brand function sharing and technology updates through standardized software architecture, which means that new technologies and services can be applied to different brands and models more quickly, improving the flexibility and efficiency of overall development. Volkswagen Group expects to reduce version complexity and investment costs through the SSP platform while ensuring differentiation between brands.
In the further digital transformation, Volkswagen is implementing the "ACCELERATE" strategy, taking software integration, digital user experience and data-based business models as the core development direction. Through these measures, Volkswagen not only hopes to improve the level of vehicle intelligence, but also strives to maintain a leading position in future autonomous driving and car networking applications.
To sum up, Volkswagen’s future development direction is not only to optimize the existing PEP process, but also to achieve the transformation from a traditional automobile manufacturer to a smart mobility solution provider through new technology platforms and digital strategies.
#03
Summarize
Volkswagen's PEP process is a mature and efficient product development process that ensures that every step from product concept to mass production is strictly verified and optimized. This process improves the efficiency and consistency of the project through systematic management, enabling Volkswagen to continuously launch high-quality products that meet market demand and consumer expectations. Through close collaboration in design, development, production and marketing, the PEP process not only optimizes resource allocation, but also speeds up product launch.
Volkswagen's PEP process has several significant advantages:
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Systematic: The PEP process covers the entire process from project initiation to market launch, ensuring orderly connection and collaborative work between each stage. This systematic process design helps the project team clarify their respective roles and responsibilities and reduces barriers to information communication.
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Standardization: Through the PEP process, Volkswagen has achieved standardization of product development processes. Each project follows the same process and standards, thereby improving the consistency and efficiency of project execution. Standardization not only helps with the training of new employees, but also ensures predictability in quality and time.
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Quality Control: The PEP process sets up multiple quality control points, such as OTS (Operational Testing) and PVS (Product Verification System), to ensure the quality stability and reliability of the product during the development process. These control points can identify potential defects in a timely manner and ensure that the product meets the design standards and market needs.
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Risk Management: The PEP process focuses on risk management. Through periodic review and verification, potential problems can be discovered and resolved in advance to reduce project risks. This proactive risk control method can effectively avoid major mistakes that may occur during the development process.
However,
the PEP process
also faces some challenges:
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High complexity: The PEP process consists of multiple stages and nodes, and each stage requires a lot of work and coordination, which increases the complexity and difficulty of the project. Efficient communication and coordination between team members is essential, otherwise it may lead to delays and waste of resources.
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Long cycle: Since the PEP process covers the entire process of product development, it often takes several years from project launch to market launch, which places high demands on the company's capital, technology and market forecasting capabilities. In a rapidly changing market environment, this long cycle may result in the product being unable to adapt to changes in market demand in a timely manner.
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Fast market changes: The automotive market is changing rapidly, and consumer demands are diverse and constantly changing. The PEP process needs to remain flexible enough to respond to market changes and adjust project directions and strategies in a timely manner. Companies need to establish an effective market feedback mechanism to respond quickly based on consumer feedback.
However, in the face of an increasingly complex market environment and rapidly changing technological trends, Volkswagen continues to optimize and improve the PEP process to maintain its competitive advantage and innovation capabilities. In the future, Volkswagen can further strengthen cooperation and communication with suppliers, scientific research institutions and consumers, and improve the intelligence and digitalization of the PEP process by introducing more innovative technologies and design concepts. For example, using big data analysis and artificial intelligence technology can make more accurate predictions of market trends, thereby optimizing product design and production decisions.
At the same time, Volkswagen should also pay attention to sustainable development and environmental protection requirements, and promote the development of green manufacturing and green travel. This includes reducing resource consumption and waste emissions during the production process, and developing low-emission and zero-emission electric vehicles to respond to global environmental advocacy and regulatory requirements. Through these efforts, Volkswagen can not only achieve its own sustainable development goals, but also contribute to the sustainable development of the global automotive industry.
Overall, Volkswagen's PEP process provides it with strong support in the highly competitive market, and future optimization and innovation will further consolidate its leading position in the industry.
refer to:
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German Volkswagen Development Process Manual (Part 1).pdf_Document Sharing Network
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Volkswagen Group (China) Media Center
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Volkswagen Group Product Development Process--Major Milestones - Zhihu
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Volkswagen realigns Technical Development: shorter product cycles and faster digital offerings | Volkswagen Newsroom
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Produktentstehungsprozess – Wikipedia
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Goals and Strategies - VW Annual Report 2023
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Volkswagen invests 1 billion euros in localized R&D in China, the elephant turns around and sprints away
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Volkswagen and Xiaopeng Motors jointly establish a joint R&D center_Tencent News
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