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Variation AnalysisNew capabilities and enhancements

Roland Dixon

Siemens PLM Centre of Excellence EMEA

25 October 2017

October 2017 R Dixon / EMEA CoE

Variation Analysis Update

Introduction

Model-Based Quality (MBQ) and the Digital Twin

Variation Analysis Value and Use-Cases

Product Direction

Model Based Definition: Leveraging PMI for Variation Analysis

PLM: Variation Analysis in a managed environment

CAE: Combining Finite Element Analysis with tolerance simulation

Conclusion

• Customer perspectives

• Q and A


Bill of ProcessPlant Model

Bill of Materials Quality/CAQ

Common Manufacturing Model

To bring Digital Twin and Digitalization to our customers

Enabling industry 4.0 / smart manufacturing

Digital Twin

Digital twin

of the

equipment

Digital twin of

production

process

Digital twin of

the product

Physical production system

Smart Product

Smart Supply chain

Smart Factory


Integrated Solutions

Quality Lifecycle Management (QLM)

Siemens “Digital Enterprise” Software Suite

Top-down Product-driven

PLM Software Portfolio

• Product Planning, Design, Test

and Simulation

• Production Planning,

Engineering and Simulation

Bottom-up Process-driven

Integrated Automation Portfolio

• Integrated engineering and

runtime for controllers,

distributed I/O, HMI, drives,

motion control and motors

• Industrial Safety and Security

• Planning & Scheduling

• Quality Management

• Manufacturing Execution

• Manufacturing Intelligence

• SCADA / Linemonitoring

MES/MOM Software Portfolio+ +


Quality Lifecycle

Model Based Quality

Inspection Planning

BCT Inspector

Design Model

NX- PMI/CheckMateResults Analysis

NX CMM

Post Processing

NX CMM

CMM inspection

Execution – I++

CMM Programming

NX - CMM

Inspection Instruction

EWI

Shop floor data

access - SFCResource libraries

NX CAM/Tc MRL

ProductionPlanning

Data & process management - Teamcenter

Statistical Reports

DPV R&A

Single Part Reports

DPV WebTolerance Stack

Variation Analysis

October 2017Page 9 R Dixon / EMEA CoE

Variation

Analysis

Finished

Product

Critical

Process

Base

Assembly

Other Sources of Variation

Assembly Process & Sequence

PMI - Datum Features & Tolerances

CAD Geometry

Run

Simulations

& Analysis

Variation and Distribution

Measurement Definitions

Deflections, Thermal, Dynamic, Material, …

Create Model

Sources of Variation

Variation Analysis

Input and output

Deviated Mesh

Inspection Planning


Variation Analysis – Why?

Opportunites vs Cost of Quality

ProductionRamp-UpTooling & Systems

Integration

Process Design

Product Design

Cost

Exponential Cost

Growth

Example: locator design issue for transmission mount

Would have cost a couple

of hours of design time to

correct at this stage.

Actually cost ~$250k

to correct at this stage.

Would probably have cost

$M in warranty and lost

production if it had got to

this stage.

Cost of Poor Quality

Cost of Good Quality


Validation

Achieve a robust design

Maximize returns

High potential value

Requires investment

Analysts/Consultants


3 main use-cases

Verification

Identify key characteristics

Predict capability

Part of existing process

Potential for savings

Design/Manufacturing

Diagnosis

Find and fix issues

Typical entry point

Manufacturing/Quality



1. Validation – Achieving a robust design

Typical Tasks:

• Sensitivity Analysis – datum and locator strategies

• Optimise assembly process and tooling

• Validate functional requirements

• Simulate aesthetics, styling, craftsmanship

Key Capabilities:

Capture concept geometries (multi-CAD)

Create and modify real-world assembly constraints

Handle small and very large assemblies

Simulate physical behaviors (flexibility, gravity, ….)

Kinematics for assembly and product function

Visualize variations (animations, realistic rendering)

Re-use previous studies and results (closed loop)



2. Verification – Identifying key characteristics

Typical Tasks:

• Capability studies, machining processes, ..

• Drawing/tolerance checking

• Key characteristic documentation

• Set functional or aesthetic limits and targets

• Design gateways, production buy-offKey Capabilities:

Capture design configurations (integrated PLM)

Capture design tolerances (integrated PMI)

Support for change control

Simulate real assembly and measurement processes

Automate modeling to handle volume of work

Generate inputs to measurement planning (integrated DPV)

Publish and share results



3. Diagnosis – Find and fix problems

Typical Tasks:

• As-built analysis

• Quality process support (Six Sigma, etc)

• Supplier quality issues / requests

• Validate fixes – virtual process change

• Investigate change proposals Key Capabilities:

Root cause analysis

Measurement data capture

Mean shift analysis

Export deformed geometries (for FEA or visualization)

Share data with other tools (DPV)



Introduction



Product Direction




Conclusion


• Q and A


Variation Analysis Linear Plus Minus PMI Flowdown

• Enables the flowdown of linear plus

minus tolerances from NX to VSA

• Origin definition added in NX10

Enhanced PMI Flowdon (10.1.5)


Variation Analysis PMI Reconciliation

Enable JT PMI Updates (11.x)

• Enable PMI extracted from JT to be

updated

• Extension of existing feature

reconciliation functionality

• Notification of feature geometry and/or

PMI changes will be provided to user

• User will be required to take action on

whether to apply the PMI change


Variation Analysis Improved PMI Flowdown

Additional PMI enhancements (11.x)

• Associated Objects Name Flowdown

(NX12)

• Angular Plus Minus Tolerance Flowdown

(NX12)

• Support for circle U modifier

• Assy Level PMI as Single Part PMI in VSA


Variation Analysis - DemoWorking with Model Based Data (PMI)

• Start a new VA model

• Import a JT assembly

• Link PMI to get datums and tolerances

• Update the NX assembly

• Reconcile the changes in the VA model


Variation Analysis Revision Control of Managed Data

Easy Product Data Updates with Managed Data (10.1.5)

• Allows process documents with

managed product data to

selectively update part geometry

• Enables users to dynamically

react to design changes during the

analysis process


Variation Analysis Feature Reconcile Auto Update

Improved efficiency in analysis product data updates (11.x)

• Feature reconciliation enhancements

• Add the option to automatically re-

snap features to new location,

size, etc.

• Requires that the underlying CAD

reference does not change

• Move associated mating features in

assembly operations when features

are reconciled


Variation Analysis DPV Engineering Spreadsheet Creation

• Enables a DPV engineering spreadsheet to

be generated from analysis features in

Variation Analysis

• Facilitates initial creation of inspection

routines based on key features identified in

Variation Analysis

Analysis Forms the foundation for DPV (10.1.5)


Variation Analysis - DemoWorking with Teamcenter managed data

• Create a new VA model

• Import an assembly item from Teamcenter

• Update the NX assembly

• Update the Teamcenter item revision

• Import the changes to the VA model


Variation Analysis Next Generation Flex Analysis

• Next generation solution: increase functionality &

usability

• Goal: 75% workflow reduction time

• Embed meshing & FE solving capability in

Variation Analysis

• Leverage Siemens FEMAP & Nastran technology

• Represent flexed parts using a mesh

• Flexed mesh comprehends

• Variation due to tolerancing

• Bending due to clamping, welding, riveting, etc.

• Visual deformation during simulation provides

realistic feedback

Incorporation of Meshing / FE Solving in VSA (11.2.3)


Variation Analysis Flex Analysis Enhancements

Expanding Flex Analysis Capabilities (11.2.3)

• Adding support for

• Assemblies

• Component sagging due to gravity


Variation Analysis

Deviated Mesh Export

• Enables a deviated mesh to be exported for use in

downstream analyses

• Nominal mesh associated with part(s)

• New custom assy extension for export

• Part mesh(es) to be exported

• Export file path

• Monte Carlo simulation runs specified for export

• This also serves as a visual aid for viewing applied

variation

Deviated mesh from part / assembly variation (11.2.3)


Variation Analysis Minimum Feature Clearance

Feature to Feature Minimum Clearance (11.2.3)

• Determine minimum clearance between any two

features

• New measurement operation type

• No measurement points required

• Supported features include

• Planes

• General surfaces

• Pins

• Holes

• Utilizes part-level surface mesh for minimum

clearance calculation


Variation Analysis - DemoFEA integration – flexible analysis

• Take an existing VA model

• Create an FEA mesh

• Create a flexible assembly operation

• Simulate and visualize deformation



Introduction



Product Direction




Conclusion


• Q and A


Customer Success – Spirit Aerosystems


Customer Success – Chery

"This lets us assess and optimize

the product design, configure part

tolerance, improve the positioning

and assembly processes, and

manage and take control of

downstream manufacturing

errors."

Wu Shiqiang

Director, Process

Technology

Department,

Engineering Planning &

Design Institute I

Challenge:

• Improve product quality

• Reduce production & maintenance costs

• Expand brand image; strengthen

competitiveness in the global market

Solution:

• Dimensional tolerance analysis software that

simulates manufacturing and assembly

processes

• Tecnomatix data in lightweight JT format

• Siemens’ extensive knowledge of

dimensional management

Results:

• Company meets product quality targets

• Production problems identified in the product

development cycle

• Avoided errors, eliminating rework time and

costs ($150,000 saved on one mold)


Customer Success – Hewlett Packard

Challenge:

• Pen to paper spacing – critical to quality

output

• Many parts contributing to tolerance variation

• Adjustment steps causing bottleneck in

manufacturing

Solution:

• Allowed focus most important parts &

dimensions

• Optimized selection of datum features and

dimensioning schemes

• Validation provides confidence of design

updates

Results:

• Reduced tooling and metrology costs

• Robust designs / lower parts cost

• Huge cost savings

• Eliminated bottleneck in manufacturing


As such, presentations help

define the company’s reputation

and provide both internal

and external orientation.

Questions

Q&A

Answers

May 3 – May 5 2017

www.plm-europe.orgwww.siemens.com/plm

October 2017

Roland Dixon

(DF PL S&SE EU PDE COE LCS )

Life Cycle Solutions Team

EMEA CoE

Solihull UK

Phone: +44 121 745 0525

Mobile: +44 7921 247 161

E-mail:

<[email protected]>

http://www.plm-europe.org/

http://www.siemens.com/plm

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