Product Development Process


At Plastic Omnium, upstream activities for developing the geometry, architecture, functionalities and manufacturing process of the system are supported by state of the art simulation and robust validation technologies.

Our breakthrough solutions like mechanical, electrical, acoustic, virtual prototyping become the benchmarks that consistently drive the industry forward.

Program Management




Validation & Testing




INPRO, an efficient product development and launch process

In our industry, quality, cost and timing with strict risk management are key.

INPRO is the program management system developed by Plastic Omnium’s Division Clean Energy Systems. It describes the essential rules and principles for efficient fuel system development and production launch.

INPRO has been designed to be seen as the division’s “constitution” applicable by all, everywhere in the division. It has the purpose of harmonizing development practices, around coherent procedures and clear and consistent processes.

INPRO represents for all the division’s associates solid foundations which enable us to achieve excellence and outstanding performance through high quality level of activities and deliverables, lower costs, increased efficiency, strong competitiveness and improved customer satisfaction.

In order to reach EXCELLENCE in development, INPRO is based on the following principles:

  • METHODOLOGY: structuring program management process and clarifying roles and responsibilities.
  • TEAMWORK: building cross functional teams focused on the same project objectives.
  • EMPOWERMENT: delegating decision power the closest possible to the action.
  • ACCOUNTABILITY: giving team members responsibilities and recognizing successes and failures of individuals.
  • STEERING: installing regular project reviews for adjustment all along program life.


INPRO Plastic OmniumINPRO Plastic Omnium

INPRO illustrates the way Plastic Omnium’s Division Clean Energy Systems integrates the management of:
• people
• processes
• activities
to enable sustained performance improvements possible in all business conditions.
The way to properly run a simple, harmonized and efficient program management process is by structuring organization, work and product.
Coherence between the three structures brings consistency and efficiency to the whole process.


– Jean-François Berard

Vice-President R&D, Strategy, Marketing, Industrial

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Design: our fuel system architecture know-how

Design and development of new products whether this is based on current technology, new concepts or innovative solutions from new market requirements is at the heart of Plastic Omnium.

Taking into account the space allocated for the product within the OEM vehicle packaging constraints, Plastic Omnium’s design teams think and develop the complete system to meet customer’s objectives on cost, performance and timing by using their system know how on product architecture, manufacturing feasibility and components.

Using state of the art CAD technology, the Division Clean Energy Systems applies its fuel system design standards to design the most appropriate system, “right first time” according to technical and economical targets.

From the very beginning of the design phase, the Division Clean Energy Systems integrates manufacturing constraints and uses internally developed computer aided tools to optimize:

  • Venting: definition and optimization of the venting architecture.
  • Gauging: establishment of gauging rules & definition of the best position of the gauge.
  • Volume: determination of usable volume to reach target fixed by customer.
  • Filling: determination of Nozzle position ensuring the most appropriate rooting and flow optimization for refueling.

Plastic Omnium is able to generate 3D models and 2D drawings compatible with most systems currently used in the industry.

Product design capabilities are hosted in the division’s 5 technical centres and 5 engineering offices worldwide. They share the same tools and standards and are linked together. Proximity to car manufacturers is key to ensure an efficient partnership especially during the design phase.

R&D Fuel system Plastic Omnium


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Plastic Omnium operates validation labs in each region with the capability to entirely validate fuel and SCR systems performance for its customers.

Our experience, test equipment, test procedures and quality systems verify that our materials, components and systems meet and exceed the requirements of the automotive industry.

R&D Fuel system Plastic OmniumR&D Fuel system Plastic Omnium


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Simulation: optimizing development time

Simulation at Plastic Omnium is an integral part of product development: it is used at early stages of project's life for concept definition and product development, but comes also along with prototyping trials and pre-test numerical validations.

Numerical simulation is one of the means used by Plastic Omnium in order to ensure that our products are innovative and of the highest quality.

Relying on simulation means lower development costs, a better management of risks, and finally a better product that gets quicker to the market.

R&D Fuel system Plastic OmniumR&D Fuel system Plastic Omnium


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