Program: Interior Lower Trim Engineering — Full Design Ownership
Vehicle Platform: New Passenger Vehicle Platform
Component Area: Cowl Side Trim, Front Step Trim, Center Pillar Lower Trim, Lower Rear Step Trim, Tailgate Trim
Variants Supported: Left-Hand Drive (LHD) and Right-Hand Drive (RHD)
Program Phase Supported: Concept data (D1) through tooling release and design maturity
Overview
This program involved taking complete design ownership for multiple interior lower trim components on a new passenger vehicle platform. The Tier-1 supplier on this program did not have an internal design team. Goken team worked as an extended design team carrying full engineering responsibility from concept layout through tooling release across both LHD and RHD variants.
Goken managed the complete design development cycle, including packaging studies, DFM and DFA reviews, datum scheme development, and performance validation support . All this while coordinating across three global locations – US (supplier), OEM (Japan), and design teams (India).
Engineering Challenge
Three constraints defined the scope of this program.
No Internal Design Capability at the Supplier The Tier-1 supplier did not have an internal design team to execute the program. Full design ownership had to be with Goken functioning as the engineering team of record for all trim components from concept through tooling release.
Three-Location Global Coordination Engineering support was required simultaneously across three geographies. Maintaining technical alignment, design intent, and program pace across these three nodes with different time zones, organizational structures, and review cadences was a core program management challenge.
Dual-Architecture Development and Complex Packaging All components had to be developed for both LHD and RHD vehicle architectures in parallel. Additionally, the trim interfaces involved complex packaging requirements, including footwell lighting integration, which demanded precise coordination between the trim geometry, electrical routing, and adjacent interior systems.
Scope and Approach
Design Ownership and Layout Creation Goken assumed full design ownership for all five interior trim components. Work began at concept data stage with layout creation and interface definition, establishing the geometric basis for all downstream design decisions. Packaging studies were done for each component in BIW and interior systems.
Datum Schemes and Section Development Datum schemes and section development were carried out to define how each trim component located, sealed, and interfaced with surrounding structure. This work formed the foundation for tooling feasibility and assembly compliance reviews.
DFM and DFA Reviews Design for Manufacturing and Design for Assembly reviews were conducted throughout the development cycle to ensure each component could be produced and assembled within the supplier's manufacturing constraints.
Performance Validation Support Goken provided engineering support for performance validation requirements at the DVP stage, ensuring the designs met OEM-specified standards prior to tooling release.
24-Hour Development Cycle The India–Japan–US geographic spread was structured as a continuous development cycle. Work progressed across time zones without daily gaps, maintaining program pace and enabling rapid resolution of cross-functional issues as they arose.
Outcome
The program delivered production-ready interior trim designs for all five components across both LHD and RHD architectures, on time through tooling release. Key results:
Production-ready lower trim designs delivered for multiple interior components across both drive variants
Critical packaging challenges resolved, including footwell lighting integration across trim and electrical interfaces
Tier-1 supplier enabled to take the program as a Full-Service Supplier project rather than a build-to-print engagement, significantly expanding their program role and commercial position
Engineering confidence strengthened between the supplier and OEM teams through consistent, technically rigorous delivery
Engagement led to additional follow-on programs and ongoing collaboration, establishing Goken as a trusted global design partner for Tier-1 interior development
Capabilities Demonstrated
Full interior trim design ownership from concept through tooling release
Packaging and interface definition for multi-component interior systems
DFM and DFA reviews embedded in the design development cycle
LHD and RHD variant development in parallel
Cross-functional coordination across OEM, Tier-1 supplier, and design execution teams across three global locations
24-hour development cycle execution through India–Japan–US collaboration
Mobility industry engineering practice supporting global automotive programs
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