Technisches Risikomanagement in der Automobilindustrie: Analyse und Bewertung von Entwicklungsrisiken bei Elektroantriebsmaschinen auf Komponentenebene

Abstract

This master’s thesis examines technical risk management in the development of electric drive systems within the automotive industry. The shift toward electromobility not only introduces new technological requirements but also increases system complexity, shortens development cycles, and intensifies economic pressure on OEMs and suppliers. The aim of this study is to identify typical component-level risks—such as thermal overload, electromagnetic interference, mechanical vibrations, or sensor failures—and to evaluate the effectiveness of existing mitigation strategies. The research methodology combines an in-depth literature review with qualitative expert interviews conducted with development professionals at BMW Motoren GmbH. The theoretical part provides insights into key components of electric drive units, including the inverter, rotor, stator, gearbox, and housing, as well as the structure of the automotive product development process and common risk management methods such as FMEA, APQP, SPC, and FTA. These findings are further enriched by practical experiences and perspectives obtained from the interviews. The results indicate that classical risks remain highly relevant, while new challenges—such as acoustic requirements, manufacturing tolerances, and interface problems—are gaining importance. Although risk management tools like FMEA are widely used in practice, their effectiveness strongly depends on consistent maintenance, interdisciplinary collaboration, and digital support. Accelerated development cycles often lead to last-minute design changes and reduced validation scopes, making the parallelization of development and safeguarding activities increasingly necessary. In conclusion, this thesis demonstrates that future-proof risk management requires the early integration of digital tools, flexible application of methods, and close cooperation between all involved disciplines. Only by doing so can safety, quality, and innovation be ensured under the growing pressure of time and cost constraints

Date of Award	2025
Original language	German (Austria)
Supervisor	Franz Obermair (Supervisor)