This document provides an A3 report format for analyzing and improving the seat structure of a 2013 Tata Ace vehicle to meet strength requirements. The problem is that the current seat structure fails physical seat back strength testing and does not meet the required +20% strength in computer analysis. The report outlines modifying the seat structure to withstand higher torque levels in both computer modeling and physical testing, with no parts exceeding plastic strain limits or breaking during testing.

1. Basic Engineering Process A3 Report Format
A3 Number (Insert Here ) Originated: 4-Oct-13
Customer/BU (Insert Below ) Model Year (Insert Below ) Program Name (Insert Below) Row (Pick One Below ) Component (Pick One Below ) Prob. Description (Pick One ) Revised:
TATA MOTORS (TML) 2013 ACE IMPROVED Manual Recliner Structures/Frames Other Approver (VP, Exec Dir, LPL, Dir etc.) Checker (CE, Dir, LPL, Auditor etc.) Owner (Engineer, Writer, Eng Mgr, CE etc.)
Issue Title: Seat structure does not meet SBS performance requirment as per IS 15546 +20% strength requirement in CAE. 1-7) SANKET KHINVASARA Date8-10) Date 1-7) C B SHARMA Date 8-10) Date 1-7) NARENDER BISHT Date 4/12/2013 8-10) Date
Problem Statement: Analyze and Rank Alternatives:
Establish Targets:
Understand the Physics:
Check Impact in all Areas:
This change is only for ace improvment.
2) This change is only for ace improvment.
Create Visual, Detailed Double-Ended Schedule :
Brainstorm Alternatives
Confirm: Reflect:
1) Modified seat structure to withstand 640 N-m torque applied on back in CAE and same should reflect in Phyisical testing.
1) Drilled hole is required in cushion tube to see whether actual length of
tube is inserted or not.
Modified seat back frame fails to meet Seat Back Strength test
requirment in terms of strength in physcial which is reflecting in
CAE (IS regulation +20%) as per customer agreed DVP.
CUSHION
SEAT FAILED IN SBS Revision Level (Insert Here )
2) No part should cross respective plastic strain limit. No brekage should take
place at any part of structure in Physical testing.
BACK
Tube in Tube arrangment at ob side of cushion dia 19 thk 1.2 Reinforcement bracket form outside of back ob bracket
Tube in Tube
arrangment
Reinforcment
to OB bracket
84 % STRONG 46.5 % STRONG
PRIMARY FALIURE
TO AVOID FAILURE
RBM≥IBM
Position indicator line
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