vpm in the product development process - ibm · vpm in the product development process mark...

VPM in the Product DevelopmentProcess

Mark WilliamsBusiness Development Manager, AP

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Preview• INCAT

• Who are we? Why are we here?

• Introduction to Digital Mock Up (DMU)• Problems & Solutions• Benefits• Case studies• How to ensure a successful VPM

implementation

• Preview• INCAT overview• Digital Mock-up• Problems & Solutions• Benefits• Case Studies• How to implement VPM• Summary

INCATINCAT’’s s BusinessBusiness

“To help leading engineering

and manufacturing

companies be more

successful.”

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Company Overview

• £40 million revenue in FY99• 350+ people in nine locations worldwide

• UK, US, Japan, Germany, Holland


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• Large international customer base

Honda

VW

Boeing

Fiat

Nedcar

SAAB Military Aircraft

De Havilland

Chrysler

RockwellAerospace

Canadair

Automotive

Aerospace

Freightliner

Volvo

BMW

Mercedes

BritishAerospace

WestlandAerospace



Company Overview• Preview• INCAT overview• Digital Mock-up• Problems & Solutions• Benefits• Case Studies• How to implement VPM• Summary

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Company Overview

• No 1 CATIA reseller in UK and USA

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Company Overview

• No 1 CATIA reseller in UK and USA• Market coverage - complete CAx solution

Design Services Design Services SolutionsSolutions ConsultingConsulting

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Company Overview

• No 1 CATIA reseller in UK and USA• Market coverage - complete CAx solution• Complementary suite of CATIA products

I/TRANS

I/Assembly Manager

I/CHECK

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• £40 million revenue in FY99

• 350+ people in nine locations worldwide• UK, US, Japan, Germany, Holland

Company Overview

• No 1 CATIA reseller in UK and USA• Market coverage - complete CAx solution• Complementary suite of CATIA products• Strategic partnership with Dassault Systemes

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• 15 year pedigree and track record• Financially strong and independent



• £40 million revenue in FY99

• 350+ people in nine locations worldwide• UK, US, Japan, Germany, Holland

Company Overview

• No 1 CATIA reseller in UK and USA

• Market coverage - complete CAx solution

• Complementary suite of CATIA products

• Strategic partnership with Dassault Systemes

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INCAT In Japan• Globalisation is key

• support global customers• share resources & knowledge• provide local support

• Our mission:“To offer a unique high-value add service solution to the

Japanese marketplace by combining world-widepresence and capabilities with local infrastructure andexperience.”

• Our partners:• Fasotec Co Ltd.• IBM Japan


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Technology Trend

Paper Drawings

Digital Drawings

3D Part Masters

Digital MockupDigital Mockup

Digital Manufacturing

Associative Design


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Issues Associated with Trend

• Large assemblies (Digital Mock-Up)• More people sharing data

• manufacturing• purchasing• suppliers

• Process changes:• existing processes need to be changed• new processes and methodologies introduced

2D 3D

PRODUCTPRODUCTPEOPLEPEOPLE

PROCESSPROCESS


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Investing in CAx

New CAD Product(only)

New CAD Product(only)

Similar OutputSimilar Output

Some Limited Benefits


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Getting Return from CAx

Pro

du

ctP

rod

uct

Ch

ang

ep

rocesses

Ch

ang

ep

rocesses

Ed

ucate

Ed

ucate

Newmethodologies

Newmethodologies I D A c t i v i t y D u r a t i o nS c h e d u l e d S t a r tS c h e d u l e d F i n i s h

1 P R O J E C T M A N A G E M E N T 1 3 5 d 9 3 / 1 / 1 29 3 / 7 / 1 9

2 P L A N N I N G 1 3 5 d 9 3 / 1 / 1 29 3 / 7 / 1 9

3 S Y S T E M E N G I N E E R I N G 3 0 5 d 9 3 / 7 / 2 09 4 / 9 / 1 9

4 R E Q U I R E M E N T S 1 3 0 d 9 3 / 7 / 2 09 4 / 1 / 1 7

5 A N A L Y S I S 4 0 d 9 4 / 1 / 1 89 4 / 3 / 1 46 I N T E G R A T I O N 4 5 d 9 4 / 3 / 1 59 4 / 5 / 1 6

7 M I S S I O N O P E R A T I O N S 3 0 d 9 4 / 5 / 1 79 4 / 6 / 2 7

8 S Y S T E M T E S T P L A N N I N G 6 0 d 9 4 / 6 / 2 89 4 / 9 / 1 9

9 S y s t e m E n g i n e e r i n g C o m p l e t e 0 d 9 4 / 9 / 1 99 4 / 9 / 1 9

1 0 S P A C E C R A F T E N G I N E E R I N G 8 9 8 d 9 3 / 1 / 1 29 6 / 6 / 2 0

1 1 C O M M A N D A N D C O N T R O L 5 0 0 d 9 3 / 1 / 1 29 4 / 1 2 / 1 2

1 2 A T T I T U D E C O N T R O L 1 3 2 d 9 4 / 1 2 / 1 39 5 / 6 / 1 4

1 3 P O W E R 9 0 d 9 5 / 6 / 1 59 5 / 1 0 / 1 8

1 4 T H E R M A L 1 7 5 d 9 5 / 1 0 / 1 89 6 / 6 / 1 9

1 5 O R B I T A D J U S T P R O P U L S I O N 1 d 9 6 / 6 / 1 99 6 / 6 / 2 0

1 6 TANK 2 0 d 9 3 / 1 / 1 2 9 3 / 2 / 8

1 7 V A L V E S 3 0 d 9 3 / 2 / 99 3 / 3 / 2 2

1 8 THRUSTER 3 5 d 9 3 / 3 / 2 39 3 / 5 / 1 0

1 9 D E S I G N 2 0 d 9 3 / 5 / 1 1 9 3 / 6 / 7

2 0 F A B R I C A T E 4 0 d 9 3 / 6 / 8 9 3 / 8 / 2

2 1 A S S E M B L E 2 0 d 9 3 / 8 / 39 3 / 8 / 3 0

2 2 T E S T 2 0 d 9 3 / 8 / 3 19 3 / 9 / 2 7

2 3 C O N T A I N M E N T S Y S T E M 8 5 d 9 3 / 9 / 2 89 4 / 1 / 2 4

2 4 S p a c e c r a f t E n g i n e e r i n g C o m p l e t e 0 d 9 4 / 1 / 2 49 4 / 1 / 2 4

2 5 A I R B O R N E S U P P O R T E Q U I P M E N T 1 d 9 3 / 1 / 1 29 3 / 1 / 1 2

2 6 M E C H A N I C A L 6 0 d 9 3 / 1 / 1 3 9 3 / 4 / 6

2 7 E L E C T R I C A L 5 0 d 9 3 / 4 / 79 3 / 6 / 1 5

2 8 T H E R M A L C O N T A M I N A T I O N 5 0 d 9 3 / 6 / 1 69 3 / 8 / 2 42 9 P R O D U C T A S S U R A N C E 1 d 9 3 / 8 / 2 59 3 / 8 / 2 5

3 0 Q U A L I T Y A S S U R A N C E 3 7 1 d 9 3 / 8 / 2 69 5 / 1 / 2 6

3 1 R E L I A B I L I T Y A S S U R A N C E 2 5 d 9 3 / 8 / 2 69 3 / 9 / 2 9

3 2 P A R T S C O N T R O L S 6 0 d 9 3 / 9 / 3 09 3 / 1 2 / 2 2

3 3 S Y S T E M S A F E T Y 2 0 d 9 3 / 1 2 / 2 39 4 / 1 / 1 9

3 4 M A T E R I A L S & P R O C E S S E S C O N T R O L S2 5 d 9 4 / 1 / 2 09 4 / 2 / 2 3

3 5 I N T E G R A T I O N A N D T E S T 1 d 9 4 / 2 / 2 49 4 / 2 / 2 4

SOND J F MAM J J AS ONDJ F MAMJ J ASON DJ F M AMJ J A SOND J F MA MJ J AS O

1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6

Many More BenefitsMany More Benefits


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Can we do DMU today (without VPM)?• Yes, if:

• Small products (<50 parts)• Few variants• Few designers to coordinate

But....

• Many companies have• Large products (>1000 parts)• Many variants• Many engineers working on projects

• Multiple sites, suppliers, etc.


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What are the problems?• Searching for data

• How long does it take to find the rightdata?

• Is it the right data?

• Managing assemblies• Where is this part used?• What parts should be in assembly?• What is the hierarchy?

• Controlling change• Is this the latest version?

• Security• Who has been changing my data?!


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Searching for data in file-based CATIA

Which version?Which version?Which version?

Which file?Which file?

Which models?Which models?


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Searching for data with VPM

Shows model infoeg. Representation, release status

Shows model infoeg. Representation, release status

Enter search stringEnter search string

Shows part information eg. maturity

Shows part information eg. maturity


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Representations

Analysis representationAnalysis representation

Detailed representationDetailed representation

Filletsremoved

Filletsremoved


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Assembly management in file-based CATIA

“Flat” assembly“Flat” assembly

Are all the partsthere?Right versions?Right place?

Are all the partsthere?Right versions?Right place?


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Assembly management in VPM

Latest version onlydisplayed

Hierarchical assemblyHierarchical assemblyHierarchical assembly


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Additional Information

Can check for infosuch as•“where used”•Parent / Child

Can check for infosuch as•“where used”•Parent / Child


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Duplicatethisassembly

Rename“Front” to “Rear”

Design Re-useCut & paste sub-assembliesCut & paste sub-assembliesCut & paste sub-assemblies

Rear Right Tire assemblycreated fromFront Right Tire assembly

Parts and Models identical

Paste it here


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Data Security and Process Security• DMU requires controlled access to data,

otherwise unauthorized modifications to:• Other design teams’ work• Released data

WIP

CHECK

RELEASED

345 728345 728SS

345 728345 728SS

Without datamanagement system,difficult to control:

Without datamanagement system,difficult to control:

•read only access•access by person/group

WIP, Checking andReleased security access


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Security and Workflow with VPM• VPM security features define

• people grouped in organizations• processes assigned to roles• groups of data

• Also defines

??WHO can do WHAT to WHICH DATA

at WHAT STAGE

RELRELCHKCHKWIPWIP


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Design in Context

Design parts whilebeing able to seesurrounding parts


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Communication: Current Situation

Same locationSame language“Round the table”

Same locationSame locationSame languageSame language““Round the tableRound the table””

I D Activity DurationScheduled StartScheduled Finish1 PROJECT MANAGEMENT 135d 93/1/12 93/7/192 PLANNING 135d 93/1/12 93/7/193 SYSTEM ENGINEERING 305d 93/7/20 94/9/19

4 REQUIREMENTS 130d 93/7/20 94/1/175 ANALYSIS 40d 94/1/18 94/3/146 INTEGRATION 45d 94/3/15 94/5/167 MISSION OPERATIONS 30d 94/5/17 94/6/278 SYSTEM TEST PLANNING 60d 94/6/28 94/9/19

9 System Engineering Complete 0d 94/9/19 94/9/1910 SPACECRAFT ENGINEERING 898d 93/1/12 96/6/2011 COMMAND AND CONTROL 500d 93/1/12 94/12/1212 ATTITUDE CONTROL 132d 94/12/13 95/6/14

13 POWER 90d 95/6/15 95/10/1814 THERMAL 175d 95/10/18 96/6/1915 ORBIT ADJUST PROPULSION 1d 96/6/19 96/6/2016 TANK 20d 93/1/12 93/2/817 VALVES 30d 93/2/9 93/3/22

18 THRUSTER 35d 93/3/23 93/5/1019 DESIGN 20d 93/5/11 93/6/720 FABRICATE 40d 93/6/8 93/8/221 ASSEMBLE 20d 93/8/3 93/8/3022 TEST 20d 93/8/31 93/9/27

23 CONTAINMENT SYSTEM 85d 93/9/28 94/1/2424 Spacecraft Engineering Complete 0d 94/1/24 94/1/2425 AIRBORNE SUPPORT EQUIPMENT 1d 93/1/12 93/1/1226 MECHANICAL 60d 93/1/13 93/4/627 ELECTRICAL 50d 93/4/7 93/6/15

28 THERMAL CONTAMINATION 50d 93/6/16 93/8/2429 PRODUCT ASSURANCE 1d 93/8/25 93/8/2530 QUALITY ASSURANCE 371d 93/8/26 95/1/2631 RELIABILITY ASSURANCE 25d 93/8/26 93/9/2932 PARTS CONTROLS 60d 93/9/30 93/12/22

33 SYSTEM SAFETY 20d 93/12/23 94/1/1934 MATERIALS & PROCESSES CONTROLS 25d 94/1/20 94/2/2335 INTEGRATION AND TEST 1d 94/2/24 94/2/24

S O N D JF MA M JJ A S O N D JF MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O1993 1994 1995 1996


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Communication with VPM

Change to the fan?

Pipe designeris notified

Otherinterestedpeople are

notified

People can “Subscribe” to eventsPeople can People can ““SubscribeSubscribe”” to events to events


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Summary of BenefitsVPM enables you to:• Improve the quality by

• design in context• one source of data• ensured standard & process compliance


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• Reduce the number of physical prototypesand hence• reduce lead times• find problem areas quicker• test many more design iterations

Summary of Benefits

ID Activity Duration Scheduled StartScheduled Finish1 PROJECT MANAGEMENT 135d 93/1/12 93/7/19

2 PLANNING 135d 93/1/12 93/7/19

3 SYSTEM ENGINEERING 305d 93/7/20 94/9/194 REQUIREMENTS 130d 93/7/20 94/1/17

5 ANALYSIS 40d 94/1/18 94/3/14

6 INTEGRATION 45d 94/3/15 94/5/16

7 MISSION OPERATIONS 30d 94/5/17 94/6/278 SYSTEM TEST PLANNING 60d 94/6/28 94/9/19

9 System Engineering Complete 0d 94/9/19 94/9/19

10 SPACECRAFT ENGINEERING 898d 93/1/12 96/6/20

11 COMMAND AND CONTROL 500d 93/1/12 94/12/1212 ATTITUDE CONTROL 132d 94/12/13 95/6/14

13 POWER 90d 95/6/15 95/10/18

14 THERMAL 175d 95/10/18 96/6/19

15 ORBIT ADJUST PROPULSION 1d 96/6/19 96/6/2016 TANK 20d 93/1/12 93/2/8

17 VALVES 30d 93/2/9 93/3/22

18 THRUSTER 35d 93/3/23 93/5/10

19 DESIGN 20d 93/5/11 93/6/720 FABRICATE 40d 93/6/8 93/8/2

21 ASSEMBLE 20d 93/8/3 93/8/30

22 TEST 20d 93/8/31 93/9/27

23 CONTAINMENT SYSTEM 85d 93/9/28 94/1/2424 Spacecraft Engineering Complete 0d 94/1/24 94/1/24

25 AIRBORNE SUPPORT EQUIPMENT 1d 93/1/12 93/1/12

26 MECHANICAL 60d 93/1/13 93/4/6

27 ELECTRICAL 50d 93/4/7 93/6/1528 THERMAL CONTAMINATION 50d 93/6/16 93/8/24

29 PRODUCT ASSURANCE 1d 93/8/25 93/8/25

30 QUALITY ASSURANCE 371d 93/8/26 95/1/26

31 RELIABILITY ASSURANCE 25d 93/8/26 93/9/2932 PARTS CONTROLS 60d 93/9/30 93/12/22

33 SYSTEM SAFETY 20d 93/12/23 94/1/19

34 MATERIALS & PROCESSES CONTROLS 25d 94/1/20 94/2/23

35 INTEGRATION AND TEST 1d 94/2/24 94/2/24

S ON DJ F MA MJ J A S ON D J F M A M J J A S O ND J F M A MJ J A S ON DJ F M A M J J A S O

1993 1994 1995 1996

CO

ST

OF

CH

AN

GE

TIME


• Reduce cost by• “Right first time”• design standardisation & re-use

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Does it work? - 2 Case Studies

• Automotive companyproducing 4M vehiclesper year


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Does it work? - 2 Case Studies• Preview• INCAT overview• Digital Mock-up• Problems & Solutions• Benefits• Case Studies• How to implement VPM• Summary • Established 1887

• Plants in 34 countries

• 428,000 employees

• $130bn revenue

• CATIA users since early1990s

• Currently 3500 seats

• “The largest automotiveuser of the software inthe world”


• Specializing in thedesign and building ofprogressive dies

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Does it work? - 2 Case Studies• Preview• INCAT overview• Digital Mock-up• Problems & Solutions• Benefits• Case Studies• How to implement VPM• Summary • Established 1887

• Plants in 34 countries

• 428,000 employees

• $130bn revenue

• CATIA users since early1990s


• “The largest automotiveuser of the software inthe world”


• Specializing in thedesign and building ofprogressive dies

• Established 1980

• Located in Michigan

• 60 employees

• $20m revenue

• Before 08/98, 1 seat ofCATIA only


• Major customers includeDaimlerChrysler andautomotive suppliers

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VisionVision• Single CAD/CAM System - CATIA

• All aspects of product and process design to be performedwith CATIA:

• styling• packaging• body• interior

• assembly tooling• conveyors• plant• paint shop

• power-train• electrical• chassis• stamping tools


99-10-08 36

VisionVision• Preview• INCAT overview• Digital Mock-up• Problems & Solutions• Benefits• Case Studies• How to implement VPM• Summary

• CDM/VPM for information management

• Encourage suppliers to adopt CATIA

• minimise transfer errors & delays

• 100% CAD environment for paperless communication

• CATIA 100% 3D Master Model

• Virtual manufacturing• Reduce manufacturing down-time between models• Right-first-time production on new lines• (a million dollars on the bottom line for every day

recovered)

99-10-08 37

Achievements so far...Achievements so far...

• On one large car program:• found over 1,5001,500 part interferences and fixed them

before the first physical prototype was made• number of physical prototypes reduced from

50 50 èè 27 27• saved at least $80m$80m• development time reduced by 8 months8 months

• Development cost per vehicle in 1997 was$540$540, compared to Toyota’s $1080$1080.( Source: Associated Press)


99-10-08 38

CommentsComments

“INCAT’s focus on the overallprocess,

on engineering designtechniques

and their in-depthknowledge

on how to selectively apply the fullrange of capabilities of the CATIA

family of products, have all been animportant contribution

to our business.”

“INCAT’s focus on the overallprocessprocess,

on engineering designtechniquestechniques

and their in-depthknowledgeknowledge

on how to selectively apply the fullrange of capabilities of the CATIA

family of products, have all been animportant contributionimportant contribution

to our business.”

Ron BienkowskiDaimlerChrysler Executive Engineer,Technical Computing.


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Move away from:Move away from:Move away from:

• 2D based diedesign systems, 3Dsurfacing for NC

• Multiple datatranslation

• Multi-CAD

• Chrysler supplierrating of 41%

VisionVisionTo:To:To:

• New system technologyfor new designs andcustomer requirements• Contoured surface

parts• Reduced time frames• Paperless system• System integration

with OEMs andsuppliers


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SolutionSolution• Use CATIA 3D technology and

methodologies, including data managementsystem

• CDM/VPM, GSM, SolidE, Param3D, 4DNav

• Best practice methods

• Associativity throughout process

• Automated BOM

• Semi-automated detailing process

• Selected CATIA due to INCAT’s support andcommitment

• Started project in August 1998


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Activity Reduction in Time

Achievements so far...Achievements so far...

(“No. 1 sheet” modification at DaimlerChrysler reducedfrom 2-3 days to 3 minutes)

• Cost reductions• Fewer engineering and BOM errors• 1999 DaimlerChrysler supplier rating increased from

41% to41% to 95%95%• 11 new projects for DaimlerChrysler, 5 without quoting• DaimlerChrysler Outstanding Achievement AwardOutstanding Achievement Award

• Strip design• Tool design• Drawing• Engineering change

è 40 - 50%è 30% (minimum)è 98%è 80% +


99-10-08 42

CommentsComments

Alan JaniszewskiFounding Partner

Majestic Industries, Inc.

“The combined capabilities and commitment of Majestic and INCAT

have allowed Majestic to develop a stronger competitive advantage

and the potential of gaining significant increases in business”

“The combined capabilities and commitment of Majestic and INCATMajestic and INCAT

have allowed Majestic to develop a stronger competitive advantagecompetitive advantage

and the potential of gaining significant increases in businessincreases in business”


99-10-08 43

The Key to Success: DaimlerChrysler

• Executive sponsorship:• Throughout the Project• Including both Engineering and Manufacturing• Not viewed as an “Information Technology” initiative

• Implement on a Production Program:• Synchronize project implementation and program milestones• Realistic matching of opportunity to system capability

• Dedicated Team:• Support people that will be co-located with the users• Domain Experts• Technology Providers

• Manage the Execution :• Combine program management and implementation

management• Working sessions• Well-defined reporting and escalation processes


• Our industry will continue to undergomajor structural changes which areaccelerating

Summary

• VPM: People, Process and Technology

• Proven success in very differentcompanies

• Remember WHY the changes areneeded.........

•Preview• INCAT overview•Digital Mock-up•Problems &

Solutions•Benefits•Case Studies•How to implement

VPM•Summary

44

Change

Change or

Survive and Thrive

Fail and Die

“Change is good, but dollars are better”

LstewartLstewart@@ukuk..incatincat.com.com

vpm in the product development process - ibm · vpm in the product development process mark...

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