Application of a Hybrid Risk Model for Automotive Aftermarket Product Development

Independent automotive manufacturing (IAM) in Australia comprises approximately 300 small and medium-sized enterprises (SMEs) and contributes A$4 billion to the Australian economy. The lower production volumes from the SME environment result in smaller development budgets which contributes to the need for a modified approach to product development. This risks safety, reliability, and regulatory defects if the new product development processes are found to be ineffective. Analysis of modified vehicle inspection data identified 329 defects on a sample of 64 vehicles. This identified that SMEs are challenged in the development of new products due to this shortened version of the development process. The field study also provided data from which a risk-based framework called the hybrid risk model (HRM) was developed as a potential solution. The HRM combines a specific risk identification and treatment model with an enhanced problem-solving process to support derivation of the correct root cause from potential risks. The addition of problem solving fills the gap in typical risk management to provide an effective input to product design. The enabler of this model is that standardised design inputs form the basis of deriving potential root causes of defects. In contrast, attempting to base designs on risks is problematic because the root cause of issue may not be directly addressed. The HRM therefore provides an improved model for guiding the effective development and assessment of vehicle modifications.