Development Process

The product development cycle follows the APQP (Advanced Product Quality Planning) framework and is structured as a V-Cycle. This links and traces customer requirements, technical and legal requirements, design, analysis and risk management, verification, validation, and final product approval.

Each stage has defined inputs, activities, outputs, and evaluation criteria, and its results are the basis for entering the next stage. At each control point, design results, engineering analysis, risk assessments, and tests are reviewed, and the decision to proceed is made on the evidence.

Together, APQP and the V-Cycle manage development from requirements definition to final approval and controlled transfer to production in a way that is structured, traceable, and focused on risk prevention and quality assurance.

For each requirement and important product characteristic, a specific, measurable verification method is defined to check that design outputs meet the set requirements and specifications. This can include engineering reviews, analysis, dimensional inspection, functional tests, and other methods suited to the requirement.

Once verification is complete and the design is confirmed to conform, validation checks how the product performs in real or simulated use, in line with customer needs. This stage assesses performance, reliability, and fitness for the intended application and customer requirements.

Verification and validation results are documented and serve as objective evidence of conformity and as the basis for final design approval and release to mass production.

The optical system is designed and optimised with specialist optical simulation and analysis software, including LucidShape, Ansys Speos, and LightTools. Light distribution, intensity, uniformity, beam coverage, and photometric performance are assessed for each lamp type.

Simulation results are used before the first prototype to refine the optical geometry, light sources, reflectors, lenses, and other parts that affect optical performance. This cuts the number of prototype and test rounds and reaches the functional and legal requirements faster.

Optical performance is assessed to the regulations that apply to the lamp type and target market, including UN R149, R148, R48, R87, R19, R6, R7, R23, R38, and R91.

CAE vibration simulation before the first prototype predicts structural behaviour, finds critical points, checks stress and deformation, and lets the design be corrected before parts are made and physically tested. This shortens development and lowers its cost while giving more confidence in the design.

Once the design is approved, a vibration test assesses how the lamp and its internal parts withstand the vibration and mechanical loads of real vehicle use. It checks the strength of joints and parts, deformation, cracking or breakage, and the lamp's optical, electrical, and mechanical function. Mechanical load conditions are set by mounting location to ISO 16750-3:2023 (Mechanical Loads).

The UN/ECE requirements for the lamp type and application also apply: UN R48 for installation of lighting and light-signalling devices, UN R148 for light-signalling devices, and UN R149 for road illumination devices.

To make sure the lamp performs and lasts in real conditions, CAE thermal simulation is carried out before the first prototype. Analysing temperature distribution and heat transfer and finding hot spots lets us optimise the design and prevent thermal problems early. Once the design is approved, thermal performance and durability are also assessed in thermal and climatic tests.

These tests check how parts, light sources, and electronics behave, the stability of optical performance, sealing, and the assembly's resistance to temperature changes and thermal stress. The process covers every lamp type, including headlamps, rear lamps, fog lamps, indicators, DRL, and side lamps, according to product requirements and mounting location.

Combining CAE simulation with physical tests lets us optimise the design before production, reduce the risk of failure, and make sure the lamp performs reliably and lasts in different operating and environmental conditions. Thermal tests and assessments follow the project requirements and the relevant standards and regulations, including ISO 16750-4:2023, UN R48, UN R148, and UN R149.

Potential design risks are identified and assessed systematically. DFMEA is used during design and development to prevent possible failures, identify critical characteristics, and define risk-reduction actions. Its results are a key input to design validation and production process development.

Design and development information and documents are controlled and kept up to date throughout the product lifecycle. Links between requirements, product specifications, design, DFMEA, test results, engineering changes, and PPAP documents make the development process traceable.