Lead Time Reduction using Automatic Reporting Director (ARD) for MAHLE

© MAHLE
Scott Janowiak
Numerical Simulation Engineer
ENDES
Lead Time Reduction using Automatic
Reporting Director (ARD) for MAHLE
1

MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
Agenda
 Introduction of MAHLE
 Background of FEA at MAHLE
 Areas for Improvement
 The Altair Connection
 Challenges Faced
 Special Developments
 The Result
 Video Demo
 Questions
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© MAHLE
Quick Introduction of MAHLE
 MAHLE is a Tier 1 automotive systems supplier
 Based in Stuttgart, Germany – Over 64,000 employees
– 10 R&D centers around the world
– Over $13 Billion in sales globally in 2014
 North America – Over 10,000 employees in 29 locations
– Over $2.6 Billion in sales
– N.A. Headquarters located in Farmington Hills, MI
 All light vehicle and truck OEM’s with production
operations in NA are supplied by MAHLE
 Business Units include:
– Engine Systems and Components
– Aftermarket and Motorsports
– Filtration and Engine Peripherals
– Thermal Management (Previously Behr)
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© MAHLE
FEA at MAHLE
 Finite Element Analysis has become a major tool in the
development process
– Multiple design variants
– Several load and test cycles considered
– This leads to a lot of results to report!
 Globally, MAHLE has a standard process for doing FEAs,
but no official reporting process
 In FH, there are several engineers doing FEAs
– Pistons represent a bulk of the work
– Several engineers could work on the same engine
program
– Reports can take several hours to create
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© MAHLE
Areas for Improvement
 Standardized reports
– Each engineer has a slightly different
way of presenting the same results
 Hard to compare variants if layout
is different
 Speed / Cutting down wasted time
– A lot of the reporting time is spent doing
non-engineering work
 Setting up the HyperView session
 Cropping/aligning pictures
 Picking nodes
 Results Organization
– Summary tables require extra work
 Picking nodes and changing
results
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© MAHLE
The Altair Connection
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 MAHLE has been using HyperWorks for over 6 years
– Good relationship with Altair team
 Altair’s Product Development (PD) team approached MAHLE
with the concept of Automated Reporting
– MAHLE brought several reports for reference at the kick-
off meeting
– Also brought a wish-list of functions for an automated tool
 Table generator
 View Flexibility
 MAHLE Master Template
– Altair PD quoted a 4-6 week lead time for customized
solution
 Project started January 2014

© MAHLE
Challenges Faced
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 Some of the challenges that we encountered:
– MAHLE has some unique files and results types
 Internal Lifetime/Fatigue Calculation program
 Needed special consideration for the table
maker
– The first program created skewed pictures
 Image had white space all around
 Aspect ratio not locked in PowerPoint
interface
– The hot spot finder was rounding the results
 Found minimum, but not necessarily in
correct location
 Working together with the Altair PD team, the issues
were able to be solved and great tool was created
Boundary Box in PPT Template
Correct Skewed
Correct
Min=4.71
Rounded
Min=4.74
Absolute
Min=4.71

© MAHLE
Special Developments
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 HyperView Automation
– Takes model and all result files
– Creates a 15 page HyperView
session
 Special MAHLE page layout
– Custom legends applied
– Some pages left blank for text
– Session can be saved/reopened
later
– Director Window is easy to navigate

© MAHLE
 Hotspot Finder
– Finds local hot spot of selected nodes
 User selects Max or Min
 Note created in HyperView
– Adds Lifetime/Fatigue result to summary
table
 Also gathers stress and temperature
results for the node
– Also can be used for other results like
Pressure or Temperature
 Results not added to summary table
– Exports results in a table in PowerPoint
 Table can be edited
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© MAHLE
 Some of the other customized features are:
– A special high resolution image of our the
mesh
– A picture cropping tool that automatically
crops the white space
 Separate Legend Picture
– Automatic Notes for Temperature
– A special interface with PowerPoint to
properly insert the pictures and ensure
the best quality image
– Ability to run in Batch-mode
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High Resolution Std. Resolution

© MAHLE
The Result
 Working with Altair PD, the Automatic Reporting
Director was developed and customized to fit
MAHLE’s needs
– 5 weeks for delivery of final solution
 The estimated reduction in lead time for a report
– From over 4 hours
– Down to less than 1 hour
 Some of the other benefits are:
– Less wasted time of engineers
– Standardized layouts
– More details of the results with the
automatic table generator
 The ARD tool was developed and is currently
being used in the US office, but is planned to be
deployed to the other MAHLE offices globally
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Lead Time Reduction using Automatic Reporting Director (ARD) for MAHLE

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