A Case Study in Engineering Change Administration Operations in Serially Produced Vehicles: A System Dynamics Approach to Painted Body Current Product Operations

This research explores the dynamics of Engineering Change Analysis (ECA) in Painted Body Current Product Operations within the automotive industry, employing a System Dynamics model to evaluate the impact of engineering changes on error rates during car assembly. Our study focuses on a luxury car production facility in Mexico, analyzing how changes in body-in-white and painted body components affect downstream integration with other vehicle parts. Utilizing Vensim modeling, we simulate various engineering change scenarios to predict complications and assess process efficiency and error rates. Key concepts such as Quality Coordination Cost (QCC), Complexity Index, and Incorrect Physical Implementation (InPhyImp) are introduced to provide frameworks for understanding the challenges and enhancing decision-making in ECA operations. The findings underscore the critical role of properly coordinated engineering changes in minimizing production errors and ensuring seamless integration of new technologies into existing manufacturing processes. The model not only addresses immediate operational needs but also offers insights into improving strategic decision-making in ECA operations by integrating advanced simulation techniques and considering the human factors involved in engineering changes.