Case-Study: Brake System Replacement

60 New Vehicles. 8 Mechatronics Technicians. 5 Days.

Project Overview

How a safety-critical field action on electro-hydraulic brake systems was successfully completed within a tight timeline

At a series of imported new vehicles, a technical optimization requirement was identified in the brake system. These brake systems had to be replaced before the vehicles were delivered to end customers.

The measure was preventive, but non-negotiable: the affected system is safety-critical.

The Challenge

Brake System Replacements require Advanced Mechatronics Expertise

An integrated electro-hydraulic brake system combines brake booster, hydraulic control unit, and ECU in a single compact assembly. It controls stability control, regenerative braking management, and advanced driver assistance systems.

Replacing this assembly in new vehicles is not a standard workshop job. It requires mechatronics expertise, software-side initialization, complete brake bleeding, and full traceability documentation for every individual vehicle.

The available window: 5 days for nearly 60 vehicles.

High Technical Complexity

The technical complexity was significant but manageable. The greater challenge was the combination of time pressure, an out-of-country deployment, and the expectation of zero ramp-up losses from the very first vehicle.

The replacement process includes

parallel work in the engine bay and cabin,
precise handling of brake fluid in new vehicles,
exact bleeding procedures, and
software parametrization including calibration of stability control and regenerative braking.

Even minor deviations during installation or software initialization can compromise system safety.

Added to this was the organizational challenge caused by the very short lead time: We brought together eight mechatronics engineers and a supervisor from different locations to form a highly effective team capable of working productively right away in an unfamiliar environment.

Solution Story

Detailed Deployment Planning
The responsible project manager set up a detailed deployment plan immediately: travel logistics, team composition in two-person crews, allocation of the four available lifts, and cycle time planning for the entire job scope. The goal was an execution flow that required no improvisation.
Documentation Adapted Upfront
Before the first vehicle went on the lift, work instructions, checklists, and inspection protocols were finalized and in place.
Digital Documentation
Every vehicle was fully documented end-to-end, from vehicle intake through component replacement to final brake and functional inspection.
The customer received a complete quality record for each individual vehicle.
Ramp-Up Ran as Planned
After an intensive orientation phase on day one, the process ran with high repeatability. Technical and software-related questions were resolved directly on-site with the customer’s staff, without disrupting overall throughput.

Results

We completed this field action within the planned timeframe: 100% of scheduled vehicles processed and released.

Eight mechatronics technicians replaced nearly 60 new vehicles in five working days, with no delays to the customer’s delivery schedule.

Despite safety-critical interventions and stringent documentation requirements, process quality remained consistently high throughout the entire action week.

EuroQ – Performance

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Customer Reviews

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“Competent team, self-managed organization, straightforward communication.
Exactly what you need for a deployment like this.”

Quality Manager of the automotive supplier

This project is a reference case for OEMs and Tier-1 suppliers that need to execute technically demanding field actions under tight time constraints without building internal capacity.

Particularly relevant when the measure involves safety-critical assemblies and full documentation traceability is required.

If you are facing a similar challenge, please contact us.

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