The employee magazine
of the Volkswagen brand


The Data Collector

The WLTP consumption measurement cycle is changing everything – including in IT. Development Manager Peter Warncke and his team have introduced a new IT system.

The countdown has started. From September 2018, all new cars in Europe must be tested in accordance with the WLTP fuel consumption and exhaust gas measurement procedure. This will change everything. It will affect every version of every model. Because accessories like sport rims or sun roofs change the weight of a car, which affects its roll and air resistance. This also has an effect on fuel consumption. For the data collected in accordance with the WLTP test cycle, Peter Warncke and his team have designed a new system. It combines all the information required for the calculation – a considerably sized database that incorporates data from around 20 systems in the Volkswagen brand and group.

When it comes to complex data, Warncke knows his stuff. In 1991, the now 54-year-old mechanical engineer started working for the former Volkswagen subsidiary, Gedas, as an application consultant and later as a software developer. In 2010, Uckermark-born Warncke became a project manager at Volkswagen. His project: a logistical parts system called “ProLog” with the data for the models that are planned for production and their part numbers. It shows which parts are installed and how long supplies on the production line and in the warehouse will last, and predicts bottlenecks for models by Volkswagen, Audi and Seat in various plants worldwide. That is quite an undertaking. Thousands of cars are produced at the production locations every day. Today, the average car consists of around 4,000 individuals parts, which are assembled on the production line. Logistically, this constitutes a huge amount of data – almost unimaginable.

The new IT system is no smaller or less complex. It has been constructed using data from around 50 departments in Technical Development. The Volkswagen brand is one of seven corporate brands involved. The database is supplied with data on the weight, aerodynamics, roll resistance and consumption values measured on the dynamometer. This, along with other data, forms the basis for the official type approval. This is the go-ahead that determines that a model may go into production. Whenever WLTP data is required, it will be possible to find it reliably in the system.

Warncke remembers well how it all started, late in 2015: “From the very beginning, we didn’t know if we would manage it in such a short time.” The challenge was to build, test and implement a whole new system with high data complexity.

With his team of six, Warncke coordinated around 50 analysts, mathematicians, testers, architecture and system development specialists, network experts and security specialists. They worked closely together in an agile organization with “sprints”, i.e. in small, manageable work packages. These were implemented, tested and evaluated in three-week cycles. “You quickly notice when something goes wrong, and can see when something is finished,” explains Warncke. “The agile work structure was very helpful in getting the WLTP system up and running on time.”

It was also ready in time for the up! GTI1, which went into production only a few days ago. The nippy little car from Bratislava is the first Volkswagen model to be tested and approved in accordance with the WLTP cycle – using data from Warncke’s WLTP system.

“From the very beginning, we didn’t know
if we would manage it in such a short time.”

Peter Warncke, Development Manager

For more information about the WLTP Test Procedure, visit our website.