Mais conteúdo relacionado PLM & the Management of Complex Product Structures1. Lehrstuhl für Virtuelle Produktentwicklung
Complexity Management and PLM
Martin Eigner
© 14.3.2011 Eigner VPE Folie: 1
2. Lehrstuhl für Virtuelle Produktentwicklung
Complexity Management and PLM 2011
Agenda …
1 | Complexity based on Multidisciplinary Products
2
1 | Solutions for Variant Handling: Neutral and Generic BOM
3 | External and Internal Variance
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
© 14.3.2011, Eigner VPE Folie: 3
3. Complexity based on more function and higher variation
Lehrstuhl für Virtuelle Produktentwicklung
Example Cayenne
Interior Modules:
660
Pipes:
1.200 - 1.500
Pins:
600 bis 2.000
length of pipe:
approx..:
2.800 m, 60-70 kg
32 Vehicle-specific
Cable Ducts
Source: Porsche AG
© 14.3.2011, Eigner VPE Folie: 4
4. Shift Variance to Software and Electronic
Lehrstuhl für Virtuelle Produktentwicklung
Example BOSCH
From 1 engine to 2 engines
No Kinematic based on
electronically reverse
Dashboard space free
Example BMW
All variants based on the same
116 2 liter engine
Differentiation based on
118 different SW calibrations
120
© 14.3.2011 Eigner VPE Folie: 5
5. Software Becomes a Dominant Factor of the Product
Lehrstuhl für Virtuelle Produktentwicklung
□ Mechatronic…
Mecha-
tronic
Mechanic IT
Mechanik
Mecha- Mechanic
tronic IT
Source: vgl. [me] 2.2010 Electronic
Electronic
…yesterday (1968) …tomorrow ???
□
When Software and Electronic becomes stronger, why should we use methods from
Mechanic & Hierarchical Requirements and Function Structure?
© 14.3.2011 Eigner VPE Folie: 6
6. Software/Electronic becomes stronger….. Example: Adaptive Cruise Control
Lehrstuhl für Virtuelle Produktentwicklung
□ Mechatronic Elements
electronic components
Sensor and Control Unit ECU
mechanics
software
control
HIL simulation testing
testing / diagnosis
Quelle: BOSCH
© 14.3.2011 Eigner VPE Folie: 7
7. Interdisciplinary Product Design based on an Extended V-Model
Lehrstuhl für Virtuelle Produktentwicklung
Anforderungs- Produkt- Prozess-
Entwicklung Produktion Betrieb Recycling
definition Planung planung
Eigenschaftsabsicherung
A/R
Modellbildung, Beschreibung
(z.B. in SysML, ModelicaML virtuelle Tests
physische Tests
F Integrierte Funktions- und
Eigenschaftsabsicherung
(Model Based Design)
Modellbildung und Simulation
(Simulink, MATLAB, Modelica)
Dienst- hybride Tests
L leistung (z.B. HIL)
Mechanik
Disziplinenspezifische
E/E
Modellbildung
(M-CAD, E-CAD, CASE)
Software A/R: Anforderung/Requirements
P
Modellbildung- und Simulation F : Funktion
L : logische Lösungselemente
… P : physikalische Elemente
© 14.3.2011 Eigner VPE Folie: 8
8. Model based Design for Mechatronic Design
Lehrstuhl für Virtuelle Produktentwicklung
Interdisciplinary Product Design requires new Design
Methodologies
(„Pahl/Beitz and Rodenacker for Multidisciplinary Design“)
Functions should move into the foreground instead of
Mechanics and Geometry.
Model Based Design as part of Systems Engineering (SE)
should be established as an integrative Methodology and a
bridge between the different engineering disciplines.
PLM should be the Backbone of the SE approach
© 14.3.2011 Eigner VPE Folie: 9
9. Interdisciplinary Product Design based on an Extended V-Model
Lehrstuhl für Virtuelle Produktentwicklung
Anforderungs- Produkt- Prozess-
Entwicklung Produktion Betrieb Recycling
definition Planung planung
Eigenschaftsabsicherung
A/R
Modellbildung, Beschreibung
(z.B. in SysML, ModelicaML virtuelle Tests
physische Tests
F Integrierte Funktions- und
Eigenschaftsabsicherung
(Model Based Design)
Dienst- hybride Tests
L leistung (z.B. HIL)
Mechanik
E/E
Software A/R: Anforderung/Requirements
P
Modellbildung- und Simulation F : Funktion
L : logische Lösungselemente
… P : physikalische Elemente
© 14.3.2011 Eigner VPE Folie: 10
10. Systems Modeling becomes Part of the Engineering
Lehrstuhl für Virtuelle Produktentwicklung
□ Supporting Systems Modeling multidisciplinary E-BOM
ASURO
- Combined structures in the
early phases of product development
Left drive
motor
gear
pinion 1
multidisciplinary Multidisciplinary Requirements , Function,
requirements modeling Behavior and Building Block Modeling
pinion 2
Original statement pinion 3
pinion 4
360
rotation
wheel
360 rotation
around point
optic rotation
measurement
max speed LED
opt. sensor
collision
detection
Systeme: Doors, Requisit Pro, XML SE Systeme (SysML, ModellicML) PLM-Systeme
© 14.3.2011 Eigner VPE Folie: 11
11. Example: Requirements for a MicroRobot
Lehrstuhl für Virtuelle Produktentwicklung
□ Engineering of a requirement structure with linked elements
System /Functional BOM
Extracted requirements
Engineering BOM
Satisfied by a component
Satisfied by a function
© 14.3.2011 Eigner VPE Folie: 12
12. Example for concept models (Architecture)
Lehrstuhl für Virtuelle Produktentwicklung
□ System structure
- Block definitions
- Internal structure
Internal structure of the control Engineering BOM
<<electronic>> MircoRobot
…
electronics
Circuit board
Controller
Sensor
…
Internal structure of the drive mechanics
<<mechanic>> Drive chassis
motor
gear
wheel
…
© 14.3.2011 Eigner VPE Folie: 13
13. SE as an integrated part of a PLM concept
Lehrstuhl für Virtuelle Produktentwicklung
Plan Concept Design …
Engineering (authoring systems in concept design, M-CAD, E-CAD, CASE)
Requirements structure System /Functional BOM (e.g. SysML) Engineering BOM
Requirements management tools System requirements System structure CAD/CASE authoring systems
4XX_200.ASM
L224_300_200_HS.ASM
System behavior
F1_300_200_G.ASM
F3_300_211_B.PRT
F3_300_238_F.PRT
…
Deriving hierarchicalManagement (PLM)
Product Lifecycle structure information
(e.g. via XML)
Requirements structure System /Functional BOM Engineering BOM
System requirements System structure
System requirements model
System structure model
All data in one PDM system System behavior model
© 14.3.2011 Eigner VPE Folie: 14
14. Product and Process Backbone Mechatronic
Lehrstuhl für Virtuelle Produktentwicklung
Plan Concept Design Validate Production Support
Requirements BOM System /Functional BOM Engineering BOM Simulation/Testing BOM Manufacturing BOM Service BOM
Product Lifecycle Management Production Systems
(PLM) (ERP/MES)
© 14.3.2011 Eigner VPE Folie: 15
15. Interdisciplinary Product Design based on an Extended V-Model
Lehrstuhl für Virtuelle Produktentwicklung
Anforderungs- Produkt- Prozess-
Entwicklung Produktion Betrieb Recycling
definition Planung planung
Eigenschaftsabsicherung
A/R
virtuelle Tests
physische Tests
F Integrierte Funktions- und
Eigenschaftsabsicherung
(Model Based Design)
Modellbildung und Simulation
(Simulink, MATLAB, Modelica)
Dienst- hybride Tests
L leistung (z.B. HIL)
Mechanik
E/E
Software A/R: Anforderung/Requirements
P
Modellbildung- und Simulation F : Funktion
L : logische Lösungselemente
… P : physikalische Elemente
© 14.3.2011 Eigner VPE Folie: 16
16. Tools Modelling and Simulation
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 17
17. Multidisciplinary modeling and simulation
Lehrstuhl für Virtuelle Produktentwicklung
Programming language for simulation
- Programming language of 4th generation
and easy to use
- Textual
For example Matlab, Modelica, …
Graphical modeling
- Modeling graphs with blocks and signals
- Calculation in background
For example Matlab/Simulink, LMS
AMESim, …
Component based modeling
- Component view with energy flows
- Model multidomain problems
- Reuse of library elements
For example Matlab/Simulink Simscape,
Modelica Standard Library, …
© 14.3.2011 Eigner VPE Folie: 18
18. Description of the inverse pendulum in simulation model
Lehrstuhl für Virtuelle Produktentwicklung
Behavior of components is described in simulations
e.g. in Matlab/Simulink
- pendulum and drive kinematics
- Actuators and sensors
- Controler
- Boundary conditions
© 14.3.2011 Eigner VPE Folie: 19
19. Interdisciplinary Product Design based on an Extended V-Model
Lehrstuhl für Virtuelle Produktentwicklung
Anforderungs- Produkt- Prozess-
Entwicklung Produktion Betrieb Recycling
definition Planung planung
Eigenschaftsabsicherung
A/R
virtuelle Tests
physische Tests
F Integrierte Funktions- und
Eigenschaftsabsicherung
(Model Based Design)
Dienst- hybride Tests
L leistung (z.B. HIL)
Mechanik
Disziplinenspezifische
E/E
Modellbildung
(M-CAD, E-CAD, CASE)
Software A/R: Anforderung/Requirements
P
Modellbildung- und Simulation F : Funktion
L : logische Lösungselemente
… P : physikalische Elemente
© 14.3.2011 Eigner VPE Folie: 20
20. Discipline specific models for example software
Lehrstuhl für Virtuelle Produktentwicklung
Object oriented system and detailed Design (OOD)
Coding and Integration
- Automatic deriving of an skeleton for
class definition
- „Programming by pressing a button“ is not realistic
© 14.3.2011 Eigner VPE Folie: 21
21. Lehrstuhl für Virtuelle Produktentwicklung
Complexity Management and PLM 2011
Agenda …
1 | Design Methodology 2.0
2
1 | Solutions for Variant Handling: Neutral and Generic BOM
3 | External and Internal Variance
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
© 14.3.2011, Eigner VPE Folie: 22
22. The Solution: Neutral or Modular BOM
Lehrstuhl für Virtuelle Produktentwicklung
Whiteboard for System Engineers
Environment to define possible
neutral structures of a product
Split BOM into a neutral/generic structure,
options and an instantiated structure
To make complexity visible
To reduces the BOM´s 1020-27
down to round about 5000!!! BOM´s
© 14.3.2011 Eigner VPE Folie: 23
23. Modular (Generic) BOM
Lehrstuhl für Virtuelle Produktentwicklung
Modular BOM
- Define options (option categories)
- Create a modular BOM
Define the multi-level hierarchy
Assign Items to the modular BOM
Define product logic
- Create an order
Assign specification
Derive order specific BOM
- Instantiated BOM´s only on the low level
© 14.3.2011 Eigner VPE Folie: 24
24. Generic Product Structure in Automotive
Lehrstuhl für Virtuelle Produktentwicklung
Machine Industry can use the same principles to simplify the Product Structure
Product Family A
Seats
Cockpit
Dashboard 3004000751 3-spoke Steering Wheel
Meters/gages
Dashboard upper part
(default/standard)
Dashboard lower part
Steering column compl. 2015700309 3-spoke Steering Wheel w/Cruise
CRUISE=YES
Distance tube
Steering wheel
CRUISE=YES & NAVI=YES
…
3005600333 4-spoke St. Wheel w/Cruise & Navi
Airbag Legend
… Product Family
… Component in GPS
Position Variant with Rule
…
Item (Assembly or Part)
© 14.3.2011 Eigner VPE Folie: 25
25. Lehrstuhl für Virtuelle Produktentwicklung
Complexity Management and PLM 2011
Agenda …
1 | Design Methodology 2.0
2
1 | Solutions for Variant Handling: Neutral and Generic BOM
3 | External and Internal Variance
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
© 14.3.2011, Eigner VPE Folie: 26
26. Solution for Product Configuration
Lehrstuhl für Virtuelle Produktentwicklung
Solution Space
Product Configuration Sales
(Search for valid Solutions) Engineering
Manufacturing
Order
Prod. Variants Configuration
Options Customer
Car Type
Smith
BMW 320i
Constraints Color
Extras
Convertible
Black
- Radio X25
1132 Backrest, Sport shape
Vachette leather, Heating
Vehicle
7451 Structure
Vehicle
0810 Foam
Car body
8786 Trim cover Car body
Attach. parts ext.
1891 Backrest, Normal shape Attach. parts ext.
… Alcantara
1820
Seat cushion, Normal shape
7451 Structure Alcantara
…
7452 Structure
Seats 0812 Foam
0813 Foam
9700 Trim cover Seats
Seat, front left 2700 Trim cover
… Seat, front left
Seat cushion ... 1891
Backrest, Normal shape
1990 Backrest, Normal shape Seat cushion Alcantara
Textile
Backrest 7451 Structure
7451 Structure
Backrest
0812 Foam
Headrest 0812 Foam
Headrest 9700 Trim cover
Armrest 6541 Trim cover
Armrest
Recliner 2001 Headrest, Alcantara
4431 Armrest, Vachette leather Recliner ... …
Seat rail ... …
Seat rail 4530 Armrest, Alcantara
...
Deriving
… 4530 Armrest, Alcantara
... …
... … …
… …
… 4502 Recliner
8887 Armrest, Textile
0912 Seat rail
... …
Product Structure
0912 Seat rail
individual BOM
© 14.3.2011 Eigner VPE Folie: 27
27. External Variance
Lehrstuhl für Virtuelle Produktentwicklung
Product Configuration
(Search for valid soltions))
1027
Order 8037
Selected Options
Solution Space Customer Smith
Car Type Z41
Color Black
Extras
- Radio X25
- AirCondition Basic
- Crypton Light LC0
Variance from the customer perspective External Variance
Selection of options leads to individual order-oriented solutions
Constrains determine valid combination of options
© 14.3.2011 Eigner VPE Folie: 28
28. Internal Variance
Lehrstuhl für Virtuelle Produktentwicklung
Product Configuration
(Search for valid soltions))
1027
Order 8037
Selected Options
Solution Space Customer Smith
Car Type Z41
Color Black
Extras
- Radio X25
- AirCondition Basic
Options, Rules/Constrains - Crypton Light LC0
Color = Black, Creme, Grey
AirCondition = Basic, Comfort
Vehicle
1132 Backrest, Sport shape
Vachette leather, Heating
Vehicle
7451 Structure Car body
0810 Foam
Car body Attach. parts ext.
1820
Seat cushion, Normal shape
8786 Trim cover Alcantara
Attach. parts ext. …
7452 Structure
1891 Backrest, Normal shape
… Alcantara
0813 Foam
7451 Structure Seats
2700 Trim cover
Seats 0812 Foam Seat, front left
1891
Backrest, Normal shape
9700 Trim cover Alcantara
Seat, front left Seat cushion
… 7451 Structure
Seat cushion ... Backrest
1990 Backrest, Normal shape
0812 Foam
Textile
Backrest Headrest 9700 Trim cover
7451 Structure
Headrest Armrest
0812 Foam 2001 Headrest, Alcantara
Armrest 6541 Trim cover Recliner ... …
Recliner Seat rail 4530 Armrest, Alcantara
4431 Armrest, Vachette leather
... …
…
Seat rail
...
... …
4530 Armrest, Alcantara
... …
Analysis …
…
4502 Recliner
0912 Seat rail
… …
8887 Armrest, Textile
Rules/Constrains
...
0912 Seat rail
…
Orderoriented
Rule based Variant-BOM
Derivation BOM
Definition
© 14.3.2011 Eigner VPE Folie: 29
29. Lehrstuhl für Virtuelle Produktentwicklung
Complexity Management and PLM 2011
Agenda …
1 | Design Methodology 2.0
2
1 | Solutions for Variant Handling: Neutral and Generic BOM
3 | External and Internal Variance
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
© 14.3.2011, Eigner VPE Folie: 30
30. Simplexity
Lehrstuhl für Virtuelle Produktentwicklung
Symplicity means to reach the largest effect with the
smallest effort…..
- Albert Einstein
There is no justification for complexity if things could be
easy.
- Leonardo Da Vinci
Ora Ito, Designer
© 14.3.2011 Eigner VPE Folie: 31
31. Jeffrey Kluger Symplexity
Lehrstuhl für Virtuelle Produktentwicklung
Simplexity: Why Simple Things Become Complex (And
How Complex Things Can Be Made Simple)
By Jeffrey Kluger
WHY are the instruction
manuals for cell phones
incomprehensible?
WHY is a truck driver’s job
as hard as a CEO’s?
HOW can 10 percent of
every medical dollar cure
90 percent of the world’s
disease?
WHY do bad teams win so
many games?
Complexity, as any scientist will tell you, is a slippery idea. Things
that seem complicated can be astoundingly simple; things that
seem simple can be dizzyingly complex. A houseplant may be
more intricate than a manufacturing plant. A colony of garden
ants may be more complicated than a community of people. A
sentence may be richer than a book, a couplet more complicated
than a song.
© 14.3.2011 Eigner VPE Folie: 32
32. Simplexity in Art and Design
Lehrstuhl für Virtuelle Produktentwicklung
Ora Ito (born 1977)
© 14.3.2011 Eigner VPE Folie: 33
33. Lehrstuhl für Virtuelle Produktentwicklung
Optimization
Reducing External Variance
© 14.3.2011 Eigner VPE Folie: 34
34. Stückzahl
Quantity by Variant
0
10.000
20.000
30.000
40.000
50.000
60.000
70.000
80.000
l, Textil, (keine), Manuell
xtil, (keine), El. Memory
Leder, Heizung, Manuell
extil, (keine), Elektrisch
© 14.3.2011 Eigner VPE
der, Heizung, Elektrisch
ntara, Heizung, Manuell
Reduce Variance
Textil, Heizung, Manuell
commercial success
til, Heizung, El. Memory
antara, (keine), Manuell
tara, Heizung, Elektrisch
, Leder, (keine), Manuell
extil, Heizung, Elektrisch
Leder, Heizung, Manuell
ntara, Heizung, Manuell
ntara, (keine), Elektrisch
er, Heizung, El. Memory
Product Variants
ra, Heizung, El. Memory
- Eliminate product variants not contributing to
antara, (keine), Manuell
eder, (keine), Elektrisch
Varying demand for individual product variants
ara, (keine), El. Memory
der, Heizung, Elektrisch
tara, Heizung, Elektrisch
ntara, (keine), Elektrisch
, Leder, (keine), Manuell
der, (keine), El. Memory
eder, (keine), Elektrisch
The inevitable Long (Thin) Tail
0
Accumulated Quantity
50.000
without heating
100.000
150.000
200.000
250.000
300.000
350.000
Stückzahl kummuliert
Example: leather seat
Folie: 35
Lehrstuhl für Virtuelle Produktentwicklung
35. The inevitable Long (Thin) Tail
Lehrstuhl für Virtuelle Produktentwicklung
Technical constraints
- Exclude combinations
that don’t work
Marketing/product management
constraints
- Exclude/enforce combinations
to “guide” customer
Picture: Mathias Zagel
© 14.3.2011 Eigner VPE Folie: 36
36. Reduce Variance with Constraints
Lehrstuhl für Virtuelle Produktentwicklung
Reduce possible ARMREST
ARM_DRV (Arm rest Driver)
combinations of option values ARM_none (none)
- Enforce desired combinations COL_IN
- Avoid undesired combinations CLI_BLK (Black)
CLI_CRM (Beige)
CLI_GRY (Gray)
- Reduced external variance of
Car Seat, front left: DOORS
2DOOR (2 Door)
864 576 (-33%) 4DOOR (4 Door)
- Likewise reduced SEAT_ADJUST
internal variance SAD_ELM (El. Memory)
SAD_ELE (Electrical)
of all affected assemblies SAD_MNL (Manual)
SEAT_CVR
SAD_VACH (Vachette leather)
SAD_ALCN (Alcantara)
SAD_TXTL (Textile)
enforce
SEAT_HEATING
exclude SEA_HEAT (Heating)
SEA_none (none)
SEATS
SEA_SPRT (Sport)
SEA_NORM (Normal)
STEERING
STEER_R (RHD)
IT Tool: CONFIGIT STEER_L (LHD)
© 14.3.2011 Eigner VPE Folie: 37
37. Lehrstuhl für Virtuelle Produktentwicklung
Optimization
Reducing Internal Variance
© 14.3.2011 Eigner VPE Folie: 38
38. Reduce internal Variance
Lehrstuhl für Virtuelle Produktentwicklung
Assume external variance is fixed
Leverage reuse of parts/assemblies
- “Multi functionality”, oversize it
- Utilize symmetry
- Standardize geometry elements
- Decouple interfaces
- Remove functionality
- Relocate functionality
- Shift variation from Mechanic to Electronic and Software
© 14.3.2011 Eigner VPE Folie: 39
39. “Multi Functionality” – Oversize it
Lehrstuhl für Virtuelle Produktentwicklung
Picture: Mathias Zagel
© 14.3.2011 Eigner VPE Folie: 40
40. Utilize Symmetry
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 41
41. The new VW modular transverse product platform
Lehrstuhl für Virtuelle Produktentwicklung
1 2 3
Examples for characteristic elements
Technical length Unified engine positioning Standardized fixtures
for rear axle
bond
control bar
axle
Multi control bar
axle
Standardized position of engine, Reduction of combinations of tilt
Standardized fixtures for different
gearbox, suspension, air angle and geometric distance from
types of axles
conditioning unit and pedals axle from 36 to 2
Source: Volkswagen Sachsen GmbH
© 14.3.2011 Eigner VPE Folie: 42
42. Decouple Interfaces
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 43
43. Decouple Interfaces
Lehrstuhl für Virtuelle Produktentwicklung
Dock connector
© 14.3.2011 Eigner VPE Folie: 44
44. Decouple Interfaces
Lehrstuhl für Virtuelle Produktentwicklung
© 14.3.2011 Eigner VPE Folie: 45
45. Lehrstuhl für Virtuelle Produktentwicklung
Complexity Management and PLM 2011
Agenda …
1 | Design Methodology 2.0
2
1 | Solutions for Variant Handling: Neutral and Generic BOM
3 | External and Internal Variance
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture
© 14.3.2011, Eigner VPE Folie: 46
46. Strategic Product Planning
Lehrstuhl für Virtuelle Produktentwicklung
Platform Strategy
E
....... D
C Synergie
B
A
Modul Strategy
Variant Strategy (Reuse of Parts and Components
across Plattforms)
E
....... D
C Synergie
B
A
© 14.3.2011 Eigner VPE Folie: 47
47. Cost and Benefit of Variants
Lehrstuhl für Virtuelle Produktentwicklung
Turnover
Cost
Cost / Turnover
Optimum
Variation
Quelle: Prof. Dr. Schuh, University of Aachen
© 14.3.2011 Eigner VPE Folie: 48
48. Contact
Lehrstuhl für Virtuelle Produktentwicklung
Thank you
Martin Eigner
Institute for Virtual Product Development (VPE)
University of Kaiserslautern
Postfach 3049
D-67653 Kaiserslautern
T +49/172/1524406
F +49/631/205-3872
eigner@mv.uni-kl.de
vpe.mv.uni-kl.de
© 14.3.2011 Eigner VPE Folie: 49