Full Vehicle End-of-Line Testing
Optimize vehicle production quality by testing new vehicles right off the assembly line with an operator in and around the vehicle, listening for BSR noises and making final vehicle production assessments.
Full vehicle end-of-line testing is critical for verifying production quality and identifying noise, fit, and functional issues before vehicles leave the assembly plant. These evaluations ensure that squeak, rattle, and buzz concerns, as well as basic drivability attributes, meet quality targets under controlled conditions. End-of-line testing is typically conducted by automotive OEM manufacturing teams, quality engineers, and plant-level NVH specialists responsible for final vehicle signoff and continuous production quality improvement.
Test Methods
End-of-line vehicle testing methods focus on reproducing representative road-induced excitations while allowing operators to evaluate vehicle quality in real time. Vehicles are subjected to controlled vertical and longitudinal tire inputs that simulate common road features such as rough surfaces, cleats, and low-speed events known to excite buzz, squeak, and rattle conditions. These inputs are applied through tire-coupled interfaces that preserve realistic tire behavior while maintaining safe access for operators inside or around the vehicle. Test sequences are standardized to ensure repeatability across shifts and production volumes, with rapid execution to match assembly-line takt times. Subjective operator feedback is often combined with basic objective measurements to document issues and support corrective action. These methods are widely adopted in manufacturing environments because they balance realism, throughput, and consistency without requiring external proving-ground testing.
Test Results
End-of-line testing results are used to identify assembly-related issues, confirm vehicle quality, and prevent noise or functional defects from reaching customers. Manufacturers rely on these assessments to support production release decisions, track quality trends, verify corrective actions, and maintain consistent vehicle performance across high-volume manufacturing operations.
MTS Product Solutions
MTS provides comprehensive solutions for full vehicle end-of-line testing that combine realistic road-input reproduction with operator-safe, high-throughput operation. Its tire-coupled road simulators, available in both electric and servohydraulic configurations, deliver precise, repeatable tire forces aligned with manufacturing quality targets. Integrated control systems and First Road Interact software enable standardized test execution, rapid identification of buzz, squeak, and rattle issues, and consistent evaluation across vehicles, shifts, and production facilities.
Test Methods
End-of-line vehicle testing methods focus on reproducing representative road-induced excitations while allowing operators to evaluate vehicle quality in real time. Vehicles are subjected to controlled vertical and longitudinal tire inputs that simulate common road features such as rough surfaces, cleats, and low-speed events known to excite buzz, squeak, and rattle conditions. These inputs are applied through tire-coupled interfaces that preserve realistic tire behavior while maintaining safe access for operators inside or around the vehicle. Test sequences are standardized to ensure repeatability across shifts and production volumes, with rapid execution to match assembly-line takt times. Subjective operator feedback is often combined with basic objective measurements to document issues and support corrective action. These methods are widely adopted in manufacturing environments because they balance realism, throughput, and consistency without requiring external proving-ground testing.
Test Results
End-of-line testing results are used to identify assembly-related issues, confirm vehicle quality, and prevent noise or functional defects from reaching customers. Manufacturers rely on these assessments to support production release decisions, track quality trends, verify corrective actions, and maintain consistent vehicle performance across high-volume manufacturing operations.
MTS Product Solutions
MTS provides comprehensive solutions for full vehicle end-of-line testing that combine realistic road-input reproduction with operator-safe, high-throughput operation. Its tire-coupled road simulators, available in both electric and servohydraulic configurations, deliver precise, repeatable tire forces aligned with manufacturing quality targets. Integrated control systems and First Road Interact software enable standardized test execution, rapid identification of buzz, squeak, and rattle issues, and consistent evaluation across vehicles, shifts, and production facilities.
- FlexTest® Controllers provide deterministic, real-time control for end-of-line vehicle testing. Their reliability, repeatability, and high-speed data handling support standardized test execution and consistent road-input reproduction in high-volume manufacturing environments.
- Model 320 Tire-Coupled Road Simulators, available in electric and servohydraulic configurations, reproduce realistic road inputs through the tires while allowing operator access. They are ideal for end-of-line detection of buzz, squeak, rattle, and assembly-related quality issues.
- First Road Interact Software guides operators through standardized end-of-line test sequences while capturing observations and results. It helps ensure consistent execution, efficient issue documentation, and traceability of vehicle quality assessments across production lines.
