New generations of environmentally friendly and safe vehicles require manufacturing of light weight materials with higher strength and, as a consequence, tougher machining conditions and increased machining robustness. There is a lack of practical and reliable methods and tools to meet these challenges in the automotive industry. The very complex system of machine tool, fixture, cutting tools and the machined part is almost impossible to model without complementary measurements of the real system at the factory floor in full production. Using Virtual Engineering together with studies of machining processes the project team will assess these challenges.