JSOL Develops World's First CAE Tool to Visualize Critical Management Points in Automotive Assembly

JSOL Corporation (hereinafter, JSOL) announced on May 11, 2026, the launch of a new CAE tool*1, "JWELD CpAnalyzer," developed with technical cooperation from a leading domestic transportation equipment manufacturer. This is the world's first*3 CAE tool that utilizes the "spot welding specific inherent strain method*2" (Patent No. 6985689) to analyze the impact of dimensional variations of individual parts in automotive assembly and visualize the most critical management points for improving assembly quality. In automotive assembly, understanding "which parts" and "what level of dimensional accuracy" need to be secured is crucial for streamlining and optimizing design and manufacturing costs. By using JWELD CpAnalyzer, companies can visualize the most critical management points of assembled products with numerical data at the upstream design stage of product development, and analyze quality considering dimensional variations. This enables the design and manufacturing departments of automotive assembly companies to grasp the most important management points of parts in advance, and to consider the best means to minimize overall manufacturing costs at the upstream stage of product development. *1 Abbreviation for Computer Aided Engineering, a simulation software that analyzes and evaluates strength, deformation, and thermal effects on a computer before actually prototyping a product. *2 An analysis method that predicts the deformation of an assembled structure after spot welding. *3 World's first CAE tool using the "spot welding specific inherent strain method*2" (Patent No. 6985689) (according to JSOL research). 【Background】 In recent years, competition in automotive development, including battery electric vehicles, has intensified, and there is a demand for strengthening the competitiveness of the domestic automotive industry. Among these, shortening the lead time for developing a single vehicle model is extremely important, as it leads to more efficient, effective, and timely reflection of market needs in development, and the creation of competitive products. To achieve shorter lead times, efforts to evaluate the impact of manufacturing processes in advance during the design stage of product development are indispensable. Welding, which is frequently used in automotive assembly, is particularly susceptible to dimensional variations in individual parts and significantly affects the final manufacturing quality. Therefore, pre-evaluating the impact of dimensional variations after welding at the design stage is effective in reducing rework and shortening lead times. However, welding involves complex physical phenomena, making it difficult to perform highly accurate simulations in a short time, and there was a reality where it could not be fully utilized in design. As a result, quality issues such as insufficient dimensional accuracy due to dimensional variations arose in production sites, leading to rework to design, mold corrections, and on-site responses such as changes in jigs and welding spot positions, which are currently hindering the shortening of lead times. In the conventional product development flow, dimensional variation effects were evaluated by manufacturing several products and actually measuring them. However, since the evaluation was done after manufacturing, insufficient dimensional accuracy was sometimes discovered at a stage where the broad outline of the design drawing had already been decided. Even if problems with dimensional accuracy due to variations were found, it was difficult to make significant design drawing changes at the actual manufacturing stage. This necessitated on-site responses (such as changing or adding jigs and welding spot positions) in the production site, leading to prolonged development periods and increased manufacturing costs due to unpredictable on-site responses. 【Design Reform Achieved with JWELD CpAnalyzer】 To analyze the impact of dimensional variations on assembly accuracy after assembly and to deal with it effectively and efficiently, it is important to take countermeasures upstream in product development. Since dimensional variations can occur due to various factors such as temperature changes in the production environment and differences in material lots, control is difficult, and on-site responses that could directly lead to delays in production plans should be minimized. If the most critical management points among the impacts of dimensional variations on dimensional accuracy can be predicted and visualized, it becomes possible to consider what can be done to secure the dimensional accuracy of those points. Furthermore, flexible countermeasures are possible upstream in product development. For example, changes to design drawings or adjustments with other departments, not just the welding department, are also options. There are five major phases in the product development flow in the automotive industry: 1. Planning, 2. Basic Design, 3. Shape Design, 4. Production Design, and 5. Production Preparation. To reflect countermeasures against dimensional variations in design drawings or to optimize the whole by coordinating with other departments, it is essential to consider them in Phase 3 (design phase) rather than Phase 4 or 5 (production phases). Previously, the pressing process for manufacturing a single part...