Siemens VDO Automotive AG Benefits from the Digital Factory

Siemens VDO Automotive AG functions as the HQ and as a prime development center for all commercial vehicle activities of Siemens VDO worldwide. The products it develops and produces for commercial vehicles include tachographs, complete display instruments, like revolution counters and speedometers, sensors, and on-board computers.

“We are market leaders in the fields in which we operate, both in terms of revenue and of item quantity – most notably with our tachographs,” said vice president with responsibility for production, Johann Gurtner.

Gurtner explained that in order to maintain this competitive edge and if possible extend it further, Siemens implemented the seamless and continuous interlinking of all manufacturing processes and sequences from the CAD phase. This integration continued right through to the production machinery and the handling of relations with external suppliers. Gurtner stepped up the company’s collaboration with DELMIA after 1997.

“We are above all concerned with the planning: planning time sequences, designing the production layout, designing the workplace, line balancing and simulation of balancing of machinery and plants – together with overall process simulation, sequence simulation and material flow simulation,” explained Gurtner.

Other work being done concerns SAP linking and the integration of the company’s ERP landscape. Parts lists, material master data, working plans, workplaces, equipment, product data and product information, and geometrical objects were already mapped both in DELMIA and in SAP, but were still being processed separately. Now both spheres are integrated, so that at the surface all work is done in a single unified system. “Nowadays we can achieve implementation times for new layouts in about two days. That is to say, within 48 hours we can assemble a printed circuit board, pass it on to the development staff under serial manufacturing conditions, and go on to have it tested,” said Gurtner. This compares with standard industry times of between five to ten times longer, depending on the complexity of the product. “For us, speed is of the essence, in the final assembly as well, because the products of our customers are exceedingly varied and subject to frequent change,” Gurtner explained.

“From 1996 or 1997, our model was adopted as a standard by all Siemens VDO locations,” said Gurtner. “The result is that a single employee can now calculate product costs, plan the assembly concept process sequences, determine assembly times, define the equipment, the ergonomics, simulate production lines and create working instructions.”

Ten years ago, the interval between the conclusion of a contract and the start of production used to be between 24 and 36 months; today it is 15 months on average. In one recent instance, the time was cut to just eight months and almost right from the start of production; maximum capacity was achieved, operating in three shifts a day with a seven day week, producing 3,000 units a day. To achieve results like this, the external suppliers need to be integrated into the process in the most effective way possible. All the standard parts and processes are stored in DELMIA Process Engineer. The various different operations can then be put together as if from a toolbox, and if changes have to be made, assembly times and costs can be rapidly adjusted at any point.

“Even if customers ask for a significantly higher item quantity on short notice, no one is going to suffer from sleepless nights. We have become extremely rapid and efficient,” said Gurtner. “We can rework the figures in the space of two days.” Parts lists are used to develop layouts and working plans for final assembly; anyone can have access to these, but no one can alter them without authorization. “Without clear structures we would get into tremendous difficulties,” Gurtner explained, “if the systems were to diverge as a result of differences in the data.” It is more frequently the case that customers want to be presented with a system layout right from the very earliest phase – if possible, one on which all the workflows are illustrated. “3D layouts and simulations are a must to demonstrate that the prescribed item quantities can be achieved without difficulty,” Gurtner said. “The required reliability of planning,” he added, “can be provided by DELMIA’s virtual tools in such a transparent way that the customers’ demand to contemplate the final phase right from the start of the process can be fully satisfied.” Besides DELMIA Process Engineer, the process planning tool DPM Assembly, based on 3D product models and offering seamless access to data relating to products, processes and equipment, also plays an important part in this process. Indeed, it is often the elaboration of several alternative variants that proves decisive for the award of a contract, according to Gurtner. “Simulation saves us unnecessary expense. That is another reason why corporate management is just as keen as our customers are to see the various possible development options at an early stage!”

Ford Customer Service Division Improves Service Checks on Final Vehicle Design with Kineo Path Planner™

Ford Customer Service Division, in order to ensure that Service targets can be achieved on final vehicle design, carries out a wide range of service checks throughout the development cycle of a vehicle. A critical point, of course, is to resolve service issues for key components like the AC compressor as soon as possible in the design process. Typically, AC compressor removal is one of the key checks undertaken.

Technical Issues and Challenges
Validating the extraction feasibility for the compressor is the key part of the Serviceability Study so it is also important to precisely assess the robustness of the extraction path result including any production tolerance variation. Moreover, due to ongoing design development, it is often necessary to repeat removal studies several times as the design evolves either at a component level (the AC compressor itself) or at a package level (surrounding items with close proximity to the AC compressor). The ability to document the results (snapshots, movies) with high quality rendered Images for effective communication purposes is the final challenge of a successful Serviceability Study.

Before working with Kineo Path Planner™, we used to manually move the compressor along a desired extraction path within a VisMockup session containing items close to the compressor that would influence the removal process and then to check the extraction path validity with the dynamic collision functionality. Beyond the time required to complete the removal study, the challenge in the process was to identify and communicate precise design change information (when removal was not feasible) so as to lead to the issue resolution. If a removal path had been found, there was no chance to easily and quickly analyze the path with different tolerance values. Furthermore, with no possibility to re-use the path from the initial check, repeating the study (for instance after a design modification) was the only viable method of validating a design change and was just as time consuming as the initial check. Different results would be obtained by different users for the same study.

Removal Study with traditional tools
Time for first removal study: 4 hours
Time for repeating removal study: 3 hours

Removal Study with Kineo Path Planner™
Time for first removal study: 2 hours
Time for repeating removal study: 1 hour

Service check with Kineo Path Planner
Today, with Kineo Path Planner™, we directly import from the VisMockup session JT files representing the compressor and the obstacles and we launch the powerful "Automatic Path Planning" capability of the tool in order to passes the extraction feasibility for the compressor. If no removal solution exists, we can easily identify and document the bottlenecks for a precise communication of design changes. If the compressor removal proves to be feasible, we save the path extraction result for eventual future re-use on repeating studies so as to speed up the search. From a path result, we can also rapidly assess different scenarios with differing tolerances/obstacles and repeat the study to assess robustness of extraction path result.

Conclusion
Here are the main benefits of using Kineo Path PlannerTM for our Serviceability studies: Different users achieve very similar results

Confidence in results is high in all cases due to the ease and speed with which it is possible to re-run the solution with differing tolerances/obstacles allowing different scenarios to be assessed

Repeat studies are speeded up with the re-use of the previous path (1h instead of 3h before). "Using Kineo Path Planner™, we are quickly able to see where a design proposal prevented component removal in Service. Being able to communicate precise change information to Engineering led directly to a design modification and issue resolution. The ability to accurately assess and resolve Service issues early in the design phase is key to reducing repair costs and increasing Customer Satisfaction. The speed and accuracy of Kineo Path Planner™ has enabled us to move from being a reactive force to a proactive one; a key challenge for any function in today's world of ever shorter development cycle times", says Peter Kinch, C3P Supervisor - Service Engineering Operations, Ford- Europe

About Kineo Path Planner
Kineo Path Planner™ is a software tool specialized in finding and generating collision-free trajectories in a totally automatic way within a highly constrained 3D environment. It perfectly fits in your current CAD/PDM methodology and environment thanks to direct data exchange capabilities and therefore ideally complements the existing tools for diverse assembly/disassembly studies throughout the whole vehicle design cycle.

More information on Kineo Path Planner

About Kineo C.A.M.
Kineo C.A.M., based in Toulouse, France, is a spin-off company from the LAAS/CNRS (French National Center of Scientific Research). Active worldwide in the automotive and aerospace industries, Kineo C.A.M. develops, markets and supports best-in-class path planning solutions that rely on 15 years research and dramatically improve the computation of automated collision free path finding for digital mock-ups.

For more information, visit www.kineocam.com or send an email to contact@kineocam.com

A Developer’s Musings

Hello all,

I would like to share some of my thoughts about the Companion and related stuff. Perhaps, the Companion is an issue for me since I don’t have access currently to this resource. But, I did see it as a very good resource, albeit somewhat frustrating at times (but, what isn’t?).

In general, though, people writing about technical issues ought not, in my opinion, go from a blank sheet. That’s asking for trouble (too prone to error, redundant work, waste). You would think that DS would see this, if they want their suite to be as pervasive and ubiquitous as it seems (they’re buying and integrating all the world’s best domain tools in an attempt to provide the PLM “ONTOLOGY”).

DS offers their 3D XML for free. I have it. And, Microsoft is seeing the light. I have a freebie copy of Visual Studio (C++, VB, Java, C#). Now, it’s called ‘Express’ and has limits. But, I can do what I need to, for the most part.

I’ve been a developer for 30+ years and am speaking from a ‘reuse’ viewpoint, which has always been problematic. It’s to the benefit of vendors to let people see their stuff (we can [ought to, will] have a discussion about this issue that is of paramount importance to knowledge/trust/… [yes, trustworthiness is one attribute that we desire of our providers, our software...]).

By the way, note this recent development (http://www.coe.org/forums/messageview.cfm?catid=19&threadid=7619) includes ‘reuse’ as a requirement.

Over and out, at least on the issue of the Companion (for now, that is).

Thanks,
John M. Switlik

Rand Worldwide Accelerates Everham’s NASCAR Racing Performance

Evernham Motorsports, started in 1999 by Ray Evernham, is the flagship representing Dodge in North American motor sports, including the NASCAR Nextel Cup racing series. More than 200 people work in three state-of-the-art Evernham design, fabrication, assembly and R&D facilities in North Carolina.

The Challenge
To help them win races, Evernham Motorsports (EMS) built a strong technical organization with mechanical and aerospace engineers using computer-aided design, simulation, and manufacturing tools to produce cars that are lighter, stronger, and faster on the track. EMS had previously adopted their CAD/CAM tools in an ad hoc fashion over a period of a few years. This resulted in a disjointed collection of various third-party software packages that no longer met their needs for better drawings, design and analysis data, and CAD models for simulation purposes. Not only was effort, time and possibly even data integrity lost in transferring data between different systems, the existing tools couldn’t handle the large number of components involved in complex car assemblies. They also didn’t offer the advanced capabilities required in areas such as surface design. In addition, the tools weren’t helping EMS to properly manage and make better re-use of all its engineering data. They needed a new set of tools that would support advanced development and fabrication activities and provide a platform for better engineering data management.

The Solution
Evernham Motorsports chose to standardize its operation on a single, integrated suite of CAD/CAM tools, and engaged the services of RAND Worldwide. RAND Worldwide’s mandate was to implement IBM CATIA along with IBM SMARTEAM, a platform for managing their engineering data.
EMS selected CATIA not only because they felt it was technologically advanced but it would also make it easier for them to share design information and development techniques with Dodge Engineering, Daimler- Chrysler and its Formula One McLaren Team. RAND Worldwide provided EMS with consulting and software installation, which included developing a SMARTEAM data model integrated into their existing design processes. In addition, RAND Worldwide’s implementation effort included a comprehensive training program. The training consisted of expert-led classroom instruction on CATIA and SMARTEAM basics and best practices, followed by on-site mentoring days covering more advanced functionality.

The Results
By significantly enhancing and streamlining its in-house engineering and manufacturing capabilities, EMS was able to develop and build its own chassis. Not only were they able to cut days off the process, they can now assess the impact of design changes more quickly. Instead of having to go outside for manufacturing help with complex body surface shapes, EMS now has multi-axis programming support. This allows their milling machines to make small changes to parts that can yield big benefits in terms of extra horsepower. EMS is now able to handle large volumes of surface design more accurately and efficiently, and extend their structural analysis capabilities. They can also manage a complete car design in a single package with no more data transfer between different systems as before. As a result, these improvements have enabled EMS to respond to NASCAR rule changes in a more timely and efficient fashion. The 2004 racing season was Evernham’s best year on the track to date. They credit a lot of that performance to the SMARTEAM and CATIA tools that support their advanced engineering approach, and to the efforts of RAND Worldwide in helping them use these tools effectively.

About RAND Worldwide RAND Worldwide is one of the world’s leading providers of professional services and technology to the engineering community and companies looking to improve their competitiveness, productivity and profitability by enhancing key aspects of their Product Lifecycle Management (PLM) and Architecture, Engineering and Construction (AEC) capabilities, including planning, development, and management. As a leading technology independent systems integrator in the world, RAND Worldwide employs more than 380 people in over 70 sales and client service centers around the world.