The redesigned 2016 Pilot that was just launched by Honda is the product of a new computer-driven development process in which the automaker was able to eliminate the production of hand-built prototypes, company officials said today.
The manufacturing processes used to build the Pilot were engineered and proofed entirely by computer simulation, while design and equipment changes were validated by using test parts quickly produced by 3-D printers.
The newest Pilot was developed "in a virtual world," said Jeff Tomko, president of Honda Manufacturing Alabama, the assembly complex in Lincoln where the Pilot is built. "We developed the manufacturing process virtually so we can make changes before we start with actual builds."
Tomko said the approach cut "several months" from the nearly three-year effort from when the new Pilot was envisioned to the start of mass production.
He also noted that Honda is producing many more variations of the redesigned Pilot than it did of the outgoing vehicle.
The Alabama plant will be the sole global production site for the Pilot and is expected to export the vehicle to China, Europe and South America -- 46 markets in all.
Automakers have traditionally tested the manufacturability of a vehicle by assembling prototypes by hand in a research facility before starting test production on the assembly line. At Honda, an r&d group in Ohio usually builds prototypes to test and validate manufacturing techniques before assembly processes are transferred to the production site.