Some insights into the queries regarding test mules

I find test mules to be very interesting. Everytime I see one, lots of thoughts and questions pop up in my mind.

BHPian porsche_guy recently shared this with other enthusiasts.

I find test mules to be very interesting. Everytime I see one, lots of thoughts and questions pop up in my mind. Tried to search the forum but couldn't find a similar thread, so decided to make one. So feel free to put forward all the queries here and hope to have a great discussion around this topic! So to start off, here are my questions. Hope the experts can answer them.

1. How is the Insurance dealt with in these vehicles? Do OEMs have to take a seperate car insurance like for other cars or is it a different policy?

2. What happens if say, one gets in an accident with a test mule? How is that dealt with generally?

3. What about the challans and traffic violations? Since they don't use the conventional number plates and aren't listed on the VAHAN portal, how are traffic violations and fines issued or are they entirely exempted from such stuff?

4. How do the drivers deal with vandalism or people trying to pull off the camouflage and tamper with the vehicle in crowded areas where such cars stand out?

Here's what GTO had to say on the matter:

Don't know about test mules, but I can add some perspective from the fresh production cars that we test-drive before their actual launch.

Insurance is a split. The media cars we receive sometimes have only 3rd-party insurance, while some have full comprehensive coverage. Because of the huge volume of business from OEMs, am sure the insurance company will happily provide a minimum of 3rd-party insurance to the test mule. Imagine the insurance premiums they receive from covering the factory etc! No one says no to OEM business simply because the volumes are so high once you get your foot in the door.

Regarding accidents, I think it would be the same as with any other road accident on an unregistered car (dealer TD cars are also unregistered, as are customer cars that are being transported from the yard to the dealer). As long as you have temp plates, it's not a problem. Cops are well familiar with the process.

The temp numbers are unique to the owner, hence it could be that the authorities pull them up too for speeding by sending challans against that number. But to the manufacturer, a 1000-rupee speeding fine is a small price to pay for high speed testing of their brand new car and its suspension + engine etc.

What is unique about the temp plate is that it can be re-used across multiple cars (unlike permanent number plates which are linked to a single car).

That said, I must say that no manufacturer has ever reached out to us in reference to a speeding ticket for an unregistered TD car running on temp plates. Can't say for sure if they receive tickets or not.

We have seen on Team-BHP that these cars are mostly parked / caught closely at food stops only. Overnight parking is usually only on the OEM's private property, although there have been rare cases of test mules being parked outside the employee's home / apartment.

The drivers are quite vigilant and try to avoid anyone taking pictures as much as possible. A few also get aggressive, either by driving hard or physical threats. I remember a BHPian posting that he took a pic of some Mahindra / Tata test mule on the expressway, then pulled into the expressway petrol pump. The test mule followed him in and the driver walked up to said BHPian, telling him to delete the pictures, threatening him with an "or else...". BHPian removed his watch, gave it to his wife, stepped out and rolled up his sleeves. Test mule driver ran away.

Here's what BHPian saikarthik had to say on the matter:

GTO answered almost all questions. But for the use of temp plates comes with discipline of the user (firm), there have been instances in my experience where the temp plates are just picked at random by the driver for a quick drive and front/back plates won't even match.

Earlier it was enough to have temp plates even in the windshield or on glass area and fonts are forgiven. But now it's seriously monitored to have them fastened (removable, not riveting as in general rule) in designated number plate area. These are done to improve readability by speed trap cameras and traffic cops.

I have driven these test mules in couple of companies for testing of my work. They aren't for PR or advertisement and also they need to go on public roads to test some realistic scenarios, which in some cases can't be simulated. And every time engineers go on a drive, it's a pain of documentation for the tools/equipment they carry and also the liability of their reputation in case of loss/damage. So they are taken out only on purpose for at lease 99%. In some rare cases some still misuse it, and I have also witnessed it.

Here's what BHPian Torque_Curve had to say on the matter:

2. It's not much different from a mainstream accident except that the drivers of these test-mules would probably end up putting a cover on the car to avoid prying eyes around.

3. In majority of the cases, they aren't caught. I've driven a few vehicles with a temporary registration (post-launch media drive kinda stuff) and have been stopped by cops. They have argued at times saying that we cannot fine the vehicle as it's not a permanent number and hence go on to fine the driver in most cases (unless you're let off, that is).

4. There's only so much you can do to stop random people from getting involved. The drivers of these cars usually don't let people near these vehicles as they're said to have been threatened(?) by their employers that they could stand to lose their job if photos of the car are leaked or surface anywhere. The drivers usually politely ward off people if they notice photos are being taken (speaking from personal experience). There have also been a few odd instances where drivers (in the late stages of testing) have freely allowed photos to be clicked, exterior as well as interior.

Here's what BHPian Fiestaboy had to say on the matter:

Some insights into the queries with no specific order of significance.

1. Test mules bear temporary registered - Red plates(when we want to register those cars, it needs to be in Govt register with vehicle name & homologation done completely. Hence they are run in temp registered trade plates). Hence comprehensive insurance can't be provided & third party insurance will suffice. As far as 3rd party insurance, there are 2 ways. either the OE manages the fleet & take the insurance with their agent or the entire fleet is managed by a contractor who will run end to end business for the OE (toll, fuel bill, challans, temp registration plates, salary of driers etc.).

2. If a test mule deals with an accident, the contract agency will go through normal process of an accident. (For this matter, the drivers will be thoroughly screened for their skills & behaviors during on boarding).

3. Challans & traffic violations - these are directly linked to red plates or driving licenses. Hence taken care by fleet management or contract agency.

4. Vandalism - Drivers are given instructions to stop at designated areas, Dashcam are installed in all vehicles (mostly) with GPS tracking & additional camo tapes will be provided in the car along with car covers if the vehicles are taken for overnight drive.

5. Test mules will not be driven for publicity (what I believe from my experience in this industry). They are run to take real world driving data - like city FE, Highway FE, brake pad wear etc.. Also things like maps, radio reception, wipers, Powertrain NVH, seat comfort & HVAC efficiency in real world driving will be tracked in the fleet run.

6. Late changes in vehicles during Engineering build/design will force team to re run certain tests with new parts & hence weekend drive is needed to compensate the overall timing plan delay. No OE will run vehicle in a weekend for publicity.

7. As SaiKarthik mentioned, earlier enough attention or importance was not given to trade plates, but now Govt had given strict protocols to be followed & I see most of the OE's in TN follow that.

8. Its not easy to peel the camo as we think. It's tough & will take time to peel off, if properly applied. At least 5-10min is needed for a common man to take camo from a fender. In my experience I never saw a public tearing a camo to take picture.

9. Yes, we will be questioned/Question - if people take photo. Normally good amount of training is given with clear Do's & Dont's of public drive in a test mule. We had times where we went cross country drive & public took photo & it will come in newspaper or online forums & we will answer the management with clear facts & data during the end of that day's drive. (This is done only when they sneak into interiors or take photos in night by removing car covers. A general photo while the car is in running will not be questioned as anyone can take that).

10. The fleet drivers are normal drivers with some good driving skills selected by agency for fleet management group. They will be given training about the features, what to see or check & what to ignore etc. Things like BLIS, AEB etc. will be properly guided through them as most of them would not have good education background to understand the features.

11. In today's world, most data are checked against objective targets & Engineers themselves tests the cars extensively in test tracks. These test mules will most probably be driven on highways or public road for durability to do high mileage checks & issues arising from durability.

Check out BHPian comments for more insights and information.