New Markets, New Standards?

Transcription

1 New Markets, New Standards? Challenges within an OEM-oriented, heterogeneous CAx-Environment Dr. Klaus Zamazal AVL List GmbH Johannes Kern CADENAS GmbH

2 Company profile AVL is the world s largest private and independent powertrain engineering company Development of powertrain systems with internal combustion engines Software for engine and vehicle simulation Prof. Helmut O. List Owner and CEO Instrumentation and test systems for engine and vehicle development 2

3 Enterprise Development Turnover [M ] Total growth : 1987: 52 Mio 2007: 620 Mio Total increase in employees: 1987: : Average R&D spending: 10 % of turnover Average export quota: 96 % of turnover 3

4 The Global Network of AVL Powertrain Engineering USA Plymouth Ann Arbor UNITED KINGDOM Millbrook Dunton SWEDEN Stockholm (Haninge) Södertälje GERMANY Remscheid Munich Stuttgart Filderstadt Neuenstadt Iran Russia KOREA Seoul Belgium + local offices* California FRANCE Poland Japan Paris Czech Republic Turkey Mexico Spain Switzerland HUNGARY Budapest Taiwan Italy Brazil SLOVENIA Maribor** INDIA Thailand Malaysia Indonesia Argentina AUSTRIA (HQ) Graz Steyr CROATIA Zagreb** Delhi (Gurgaon) CHINA Shanghai (Pu Dong) * No Test Facilities ** Analysis only 4

5 AVL BASE ENGINE TEAM Status Q4/2008 USA Germany Austria France Hungary Croatia Slovenia Slowenia India China Design 45 Simulation 30 Testing 10 Total 85 Design 312 Simulation 114 Testing 79 Total 505 Design 42 Simulation 22 Testing 15 Total 79 More than 600 Engineers globally - near to all customers Competence in production development projects 25 Engines in 10 years Standardized processes, methods and quality management 5

6 AVL has been involved in the development of more than 1000 combustion engines Power / Cylinder [kw] Displacement / Cylinder [L] 6

7 CONTENT AVL s Design Challenges Business Drivers for Modern Solutions Implemented Solution Project s Organisation Next Steps Summary and Conclusion 7

8 CONTENT AVL s Design Challenges Business Drivers for Modern Solutions Broad Variety Following AVL s Engine Development Processes Multi Site & Project Orientation Global Customers Focus Heterogenous Tool Environment Implemented Solution Project s Organisation Next Steps Summary and Conclusion 8

9 AVL s DESIGN CHALLENGES Modern Solutions with Broad Variety Number of Design Projects (*) PKW Passenger V s NFZ Commerzial V s GM Large Engines (*) executed in Headquarter Graz 9

10 AVL s DESIGN CHALLENGES Modern Solutions with Broad Variety Con Rod Length 138 mm Big end bolts: M8 x 1,0 Mass: 0,49kg Con Rod Length Big end bolts: Mass: 825 mm 4 x M30 150kg Con Rod Length 243 mm Big end bolts: M12 x 1,25 Mass: 5,3kg 10

11 AVL s DESIGN CHALLENGES AVL Engine Development Process (standardized and continuously improved since 1998) Project kickoff meeting Basic concept selection Concept FMEA Concept design Concept design update 42 Concept study Thermodynamic calculation Mechanical calculation Concept definition and choice of major suppliers Thermodynamic layout EMS specification Release of concept design Mechanical calculation Detail design Acoustic calculation 36 CAD data transfer Procurement engine generation 1 Engine build / first engine run Gen. 1 FIE rig tests EMS preparation Component development Design Thermodynamics EMS-Calibration Mechanics Acoustics Target costing Development support 30 Baseline performance & emission development Baseline engine mapping & ECU calibration Cold start development 24 Tolerance investigations Emission development (dyn. test bed) Driveability & emission development in vehicles Functional development (test bed & vehicle) Durability development (test bed) Baseline acoustic development (test cell) Pass-by noise & vehicle interior noise development Specification engine Gen. 2 Hot & cold climate tests Mechanical calculation engine generation 2 Vehicle endurance testing: mileage accumulation Release of concept for preproduction development Design update for engine generation 2 Procurement engine generation 2 First engine run generation 2 Performance & emission verification Release of casting pattern and forging die procurement OBD software development (if required) 18 Advanced Prototype development Tolerance investigations Component development & fatigue tests Functional development EMS optimization (steady state and dynamic test beds) Durability development (test bed) Engine & vehicle acoustic verification Update of engine documentation Driveability & emission optimization in vehicles EMC tests & OBD calibration Functional development in vehicles; hot & cold climate tests Vehicle endurance testing Production validation 12 Preproduction development Mileage accumulation Release procedures for supplier developed systems Analysis of acoustic vehicle conformity Design freeze MLI Design freeze SLI ECU data release for validation tests Engines & vehicles from production tooling Start of pilot production 6 Vehicle validation (fleet tests): emissions & OBD-system Hot & cold climate tests EMC validation Durability validation (test bed) Homologation Acoustic validation Vehicle endurance validation Months before SOP EMS data release Quality assurance tests Start of production 0 11

12 AVL s DESIGN CHALLENGES AVL Engine Development Process - Detailed view of development tasks Definition of development tasks Description of the logical links between the tasks Optimisation of the technical data flow in an engine development project 12

13 AVL s DESIGN CHALLENGES AVL Frontloading Process for First Time Right product development Concept Study Virtual Powertrain AVL Engine Development process First engine enabling fully relevant performance, emission, and also durability targets Product Maturity Pre-Production Development Effort Traditional Development Process Production Development Production Validation Frontloading Development Time 13

14 AVL s DESIGN CHALLENGES New Customers New Markets Number of Design Projects (*) (*) executed in Headquarter Graz 14

15 AVL s DESIGN CHALLENGES Multi Site & Global Solutions Corresponds with SES P 1202d - Hexagon Bolts with Flange EN 1662 Sechskantschrauben mit Flansch 15

16 AVL s DESIGN CHALLENGES Historical Overview of Tools for Product Development - Design PDM PLM PDMLink Teamcenter TDM EDM SmarTeam uwgm ProIntralink ProPDM DMU VisMockup CATIA V5 DMU Navigator UG NX 3D CAD I-DEAS CATIA V4 Pro/E CATIA V5 Bravo 3 I-DEAS 2D CAD Cadam Bravo Draft All licenses are floating in WAN 01/14 03/84 05/94 08/04 05/08 Today 16

17 AVL s DESIGN CHALLENGES Multi CAD & Multi TDM & Single PDM PDMSystem Modul PDMLink uwgm Pro/E uwgm CatiaV5 uwgm UG NX uwgm SWX Pro/I SmarTeam TDM TCEng KeyTech PRO File System GateWay ProI GateWay SmarTeam GateWay TCEng GateWay KTP Pro/E CATIA V4 CATIA V5 I DEAS UG NX Solid Works 17

18 AVL s SOLUTION APPROACH Standardizing supports Innovation PDMSystem Modul PDMLink uwgm Pro/E uwgm CatiaV5 uwgm UG NX uwgm SWX Pro/I SmarTeam TDM TCEng KeyTech PRO File System CADenas Teilemanagement GateWay ProI GateWay SmarTeam GateWay TCEng GateWay KTP Pro/E CATIA V4 CATIA V5 I DEAS UG NX Solid Works 18

19 CONTENT AVL s Design Challenges Business Drivers for Modern Solutions Implemented Solution Overview: 4 CAD systems, 4 EDM systems, 2 PDM systems Installation type and update strategy Project s Organisation Next Steps Summary and Conclusion 19

20 AVL s SOLUTION Situation in 2006 SAP-MM uwgm SWX KeyTech PRO PARTsolutions GateWay KTP Solid Works 20

21 Major non-it-targets: AVL Power Train One solution for standard parts needed CAD independent solution needed EDM independent solution needed PDM-Link as master required Easy to use Solution has to support PDM-Link as PDM (no new master system) PDM/ERP independent solution needed Especially with different OEM environments the solutions should be easy to use. (What is preferred and allowed this time?) 21

22 Major IT-targets: AVL Power Train Manual process was easiest solution from IT point of view In the past: Processes were ignored very often. Everybody did what he wanted lots of duplicates and wasted engineering recources (remember the discussion at kickoff workshop) Note: The new solution was mostly requested by the Key-Engineers! 06/2008: PARTsolutions implementation starts Project thread: IT solution will get too complex 22

23 AVL s SOLUTION Situation in 2009 PDMSystem Modul PDMLink SAP-MM uwgm Pro/E uwgm CatiaV5 uwgm UG NX uwgm SWX Pro/I SmarTeam TDM TCEng KeyTech PRO File System CADENAS Teilemanagement PARTsolutions PARTsolutions GateWay ProI GateWay SmarTeam GateWay TCEng GateWay KTP Pro/E CATIA V4 CATIA V5 I DEAS UG NX Solid Works 23

24 Basic EDM Workflow 24

25 CADENAS installation example SmarTeam/CATIA Before 1. Before PARTsolutions 25

26 CADENAS installation example SmarTeam/CATIA 2. PARTsolutions CAD integration only (box product) 26

27 CADENAS installation example SmarTeam/CATIA 3. PARTsolutions CAD + PDM integration 27

28 CADENAS installation example SmarTeam/CATIA 4. PARTsolutions CAD + PDM + EDM integration 28

29 PARTsolutions installation facts No Client installation To use PARTsolutions just use the start_catia_with_psol.bat, start_wf_with_psol.bat Software binaries, configurations and catalogs are on a net-folder: n:\iparts\cadenas no new server needed Also an existing server replication is used (n:\ in Graz = \\hpsrv12, n:\ in other locations is a mirrored copy of hpsrv12) One installations for all PowerTrain CAD/PDM systems Clear update and rollout scenarios Easy test vs. productive system handling Rollout and update by just copying a file share CAD / PDM handling All CAD files are in the coresponding PDM system (no additional replication needed! standard PDM processes) none or only very few modifications in EDM and PDM systems done 29

30 CONTENT AVL s Design Challenges Business Drivers for Modern Solutions Implemented Solution Project s Organisation Team Deliverables Internal Effort Next Steps Summary and Conclusion 30

31 PROJECT ORGANISATION Team, Deliverables & approx. Effort (Internal) Initial Phase (11/07 02/08) 2 Workshops with 12 CAD-Users & 2 Sys.-Admin Scope of Solution 4 Step Approach Commercial Phase (03/08 04/08) PM & GF Implementation Phase (05/08 11/08) 3 CAD-Key User & 3 Sys.-Admin & 2 IT & 1 PM-PDM PM Roll-Out & Training Efforts (250h) (30h) (300h) (100h) (60h x 0,5h) 31

32 CONTENT AVL s Design Challenges Business Drivers for Modern Solutions Implemented Solution Project s Organisation Next Steps Optimization Roll-Out WorldWide Phase 2 Summary and Conclusion 32

33 NEXT STEPS Optimization PARTsolution replaces SP-Part Creator as a Role Roll-Out WorldWide Improve in STY & HTC Implement in USA Initiate in Asia (STC, ITC, ) Phase 2 Supplier Components (SCs) Support for Prüfstands-DMU incl. Tools 33

34 NEXT STEPS Prüfstands-DMU (Virtual Engine Build-Up) step igs/iges native CAD 34

35 NEXT STEPS Prüfstands-DMU (Virtual Engine Build-Up) 35

36 NEXT STEPS Prüfstands-DMU (Virtual Engine Build-Up) Serial Part Advanced Prototyp 36

37 CONTENT AVL s Design Challenges Business Drivers for Modern Solutions Implemented Solution Project s Organisation Next Steps Summary and Conclusion 37

38 SUMMARY & CONCLUSION Implementation Done for Phase 1 (cw 49/08) (nearly) in Time in Budget What else Do s and Dont s Implementation in steps leading system defined by most experience Testing and Documentation by Key-User Hang-Over Phase Holidays Roll-Out with enough licenses Don t focus on future dependencies Support from CAD-System Provider Early Wins and Hungry Designers 38

39 AVL S NEW LOGO IS VISION AND PROGRAM Combustion Engine Transmission Battery System Electric Engine Control Strategy 39