Project Description

Delivering a Production-Ready Custom Module for a Global OEM

Challenge

A large global OEM came to us with a pressing need. They required a custom control module for an upcoming vehicle program, but did not have the internal team in place to deliver it on their own.

The module would need to:

  • Support unique control and telemetry features that were hard requirements for the OEM. These were not commonly found in existing controllers, which meant that a minor SKU customization or simple adaptation would not work.

  • Achieve ISO 26262 ASIL-D certification for functional safety.

  • Demonstrate compliance with EMC, SAE, and ISO requirements.

  • Be in production within a year, an extremely aggressive schedule by automotive standards.

The OEM also wanted confidence that their solution was competitive with the best available options, so we were asked to perform an evaluation of the state of the industry and available products as part of the project.

Solution: Leveraging FlexCase and FlexConnect Platforms

We delivered a custom hardware variant built on our proven FlexCase and FlexConnect platforms. These platforms provided a foundation of safety, connectivity, and modularity, while allowing us to rapidly customize the hardware and software for the OEM’s requirements.

Our work included:

  • Safety & Compliance: We set up a dedicated team to handle all ISO 26262 ASIL-D certification activities and lead the compliance process for EMC, SAE, and ISO requirements.

  • Application Development: Hardware and software were developed in parallel, then validated together on the OEM’s custom hardware, ensuring both functionality and reliability.

  • Timeline: The schedule called for the unit to be ready for testing within 5 months, with informal homologation passed by month 6.

  • Cost Planning: The OEM provided an aggressive price target. We completed a preliminary design review early in the project, which confirmed that the design was on track to meet this target.

Technical Approach

A disciplined, step-by-step process ensured success. Our engineering process was built on industry-standard practices and tailored to the OEM’s needs:

  1. Requirements & Architecture – We began by defining requirements for a production-ready FlexCase variant, informed by a survey of industry offerings. This ensured that the OEM’s module would be competitive while also meeting their custom requirements.

  2. Safety & Compliance – A dedicated team managed and executed all safety and compliance work. TÜV supported us in achieving certification, while we retained ownership of the work itself.

  3. Hardware Development – We designed a cost-optimized PCB and enclosure that satisfied thermal, EMC, and environmental requirements. The design also integrated the OEM’s unique control and telemetry requirements, which were not available in existing controllers.

  4. Software Development – We leveraged our existing model-based tools and UDS framework to accelerate application development. This allowed us to move quickly while maintaining robustness and traceability.

  5. Testing & Validation – All compliance and validation testing, including EMC and ISO requirements, was led by our team. Informal homologation was successfully completed within 6 months.

  6. Production Integration – The design was engineered so that it could be integrated into our standard production lines. This allowed the OEM to scale into production without requiring significant additional resources on their side.

Results & Impact

The outcome was measurable improvements in cost, speed, and functionality.

  • Speed: Delivered functional samples in 4 months and achieved production readiness in 9 months.

  • Cost: Reduced unit costs by 30% compared to a similarly configured standard FlexCase. The final production price of the module was within 1% of the predicted cost established at the beginning of the project and the project cut total production costs by 50% compared to the OEM’s existing solution.

  • Compliance: Achieved ISO 26262 ASIL-D certification and passed all required EMC, SAE, and ISO standards.

  • Functionality: The control and telemetry features delivered were unique, OEM-specific hard requirements that could not be achieved with minor SKU customization. Meeting these requirements was critical to the OEM’s success.

  • Efficiency: The OEM did not need to hire additional staff to support the program, reducing overhead and complexity.

  • Scalability: The module was integrated into our standard production process, enabling a smooth path from prototype to volume production.

Conclusion

Within just 9 months, we took a complex, safety-critical system from concept to a certified, production-ready solution. The OEM gained a module with unique functionality, complete compliance, and accurate cost performance, all without needing to expand their internal team.

By leveraging our FlexCase hardware and FlexConnect platform, supported by disciplined engineering and cost accuracy, we enabled the OEM to bring a differentiated, production-ready product to market faster and more reliably than traditional development approaches.