F. FURINI –PININFARINA: IST PRESENTATION ON : COLLABORATIVE DESIGN AND LEARNING FEBRUARY 16, 2005 1 VIRTUAL TOOLS AND COLLABORATIVE ENVIRONMENTS IN AUTOMOTIVE

F. FURINI –PININFARINA: IST PRESENTATION ON : “COLLABORATIVE DESIGN AND LEARNING” FEBRUARY 16, 2005

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VIRTUAL TOOLS AND COLLABORATIVE

ENVIRONMENTS IN AUTOMOTIVE PRODUCT DEVELOPMENT:

CURRENT SCENARIOS


2

THE REFERENCE SYSTEMS IN PRODUCT DEVELOPMENT

THE EVOLUTION TIMES OF

• PROBLEMS

• PRODUCT

• HUMAN RESOURCES

• PROCESS

ARE DIFFERENT WITH EVOLUTION TIMES OF TECHNOLOGIES:

PROBLEM TIMES ( AUTOMOTIVE, AIRCRAFT,…) 50 - 100 YEARS

PRODUCT TIMES (VAN, TRUCK, COUPE’, SPIDER ..) 30 – 50 YEARS

HUMAN RESOURCES TIMES 20 – 30 YEARS

PROCESS TIMES 10 - 20 YEARS

APPLICATION IT TOOLS 5 - 10 YEARS

HW/SW ENVIRONMENTS 3 - 5 YEARS


3

THE RAPID EVOLUTION OF COMPUTING TECHNOLOGIES, COMBINED WITH INTERNET, HAS CHANGED THE AUTOMOTIVE PRODUCT DEVELOPMENT TO A “DIGITAL BUSINESS”, WITH NEW TRENDS:

• DIGITAL INFORMATION FORMATS FOR THE MULTIDISCIPLINARY NATURE OF COMPUTERS;

• RAPID GLOBALISATION OF MARKETS AND LOCALIZATION OF SUPPLIERS;

• CHANGE OF CAPITAL: NOT ONLY PHYSICAL CAPITAL(PLANTS AND EQUIPMENTS) BUT ALSO INTELLECTUAL CAPITAL (KNOWLEDGE OF PRODUCT AND PROCESS)

• NEW COMPETITIVE DRIVER AND NEW MARKETS;• FULL PRODUCT LIFECYCLE MANAGEMENTS


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IN THIS ENVIRONMENT:


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THE “OLD WAY. . .”: WHAT IS CHANGED?

• Complexity

• Development Time

• Development Costs

• Technologies

PROCESSES


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Traditional Product Development Process

BuildBuild Fix Fix

Iteration

For Complex Products:• Cycle Time Too Long• Facility Intensive• Cost High• Convergence Not Assured

Form Function

Test Test


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CLASSICAL PRODUCT DEVELOPMENT CYCLE

CONCEPT

DESIGN

PROTOTYPE

VALIDATE

MODIFY

VERY HIGH NUMBER OF PROTOTYPES FOR EVERY TESTING AND FUNCTIONALITY STEP VALIDATION


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$1

$10

$100

$1000

Requirements

Design

Prototype

Production

The Cost Of Change

COMPETITION IS “CHANGING”


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100%100%

50%50%

00

PHASE 0PHASE 0 PHASE 1PHASE 1

FREEDOM

INFORMATIO

N

Various Phases of the VPD

TimeTime

€ € Spent Spent

€ € Committed Committed


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As Engineering designed it: new and high technical contents

As managers made it: profitable, less costs, carry over exasperated.

As Marketing interpreted it: wide spread out of the model.

As the customer wanted it: more demands on product selections, delivery time and quality

PRODUCT DESIGN: DIFFERENT VISIONS


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AT THE END THE KEY PROGRAM ELEMENTS ARE:

TIM

EC

OS

T

QUALITY


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NEW SCENARIOS

COMPETITION COMPANY REQUESTS

• INCREASE PRODUCT AND PROCESS QUALITY;

• CUSTOMERS WILL ORIENTED

• TIME REDUCTION FROM IDEA TO PRODUCT;

• COSTS REDUCTION;

• PRODUCT COMPLEXITY MANAGEMENT;

• MAXIMIZE CARRY OVER;

• DECISIONS TAKEN LATEST AS POSSIBLE;

• COMPANY SITES MANAGEMENT

OPPORTUNITY, METHODOLOGIES AND TOOLS;

• COMPUTER AIDED STYLING;

• PARAMETRIC AND ASSOCIATIVITY IN CAD;

• PRODUCT DATA MANAGER;

• DIGITAL MOCKUP;

• CONCURRENT ENGINEERING;

• CAE AND DYNAMIC SIMULATIONS;

• RAPID PROTOTYPING;

• COMPUTER AIDED MANUFACTURING AND NUMERICAL CONTROL

• OFFSHORE AND SUPPLIERS INVOLVEMENTS


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VIRTUAL BASE QUESTIONS

• HOW CHANGE COMPANY INFRASTRUCTURES WITH NEW TECHNOLOGIES AND TOOLS?

THE COMUNICATION AND HUMAN INFRASTRUCTURE:• TRANSFER - ACCESS TO INFORMATION AND WAY OF TRANSFER INFORMATION;• QUANTITY OF INFORMATIONS AND SERVICES – MULTIPLE SOURCES OF

PRODUCT DATA• NEW KNOWLEDGE MANAGEMENT AND PROFESSIONAL SHAPES • INVOLVEMENT OF MULTI SITE RESOURCES


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HUMAN RESOURCES CHANGE SPEED PROBLEM

• STRONG INCREASE OF VELOCITY IN COMPARISON TO THE CHANGE CAPACITY OF ABSORBE IT ;

• NEED OF INCREASE THE “HORIZONT VISION” ;

• NEED OF DETECT KNOWLEDGES AND SKILLS;

• PERFORM MIGRATION BEFORE IN SUCH A WAY TO DO THINGS BEFORE;

• NEED OF PROCESS CONTROL:

NEEDS OF:• TTM REDUCTION;• INCREASE PRODUCT QUALITY;• COST CONTAINED

NEW RE - ENGINEERING OF PRODUCT DEVELOPMENT:

• INTRODUCE NEW TECH• ADOPT NEW PRODUCT

DEVELOPMENT FLOW


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CAX MARKET EVOLUTION

1960+

1980+

1970+

1990+

2000+

RESEARCH IN HOME 2D TOOLS

MAINFRAME

DRAFTING INTERACTIVE

GRAPHIC USER INTERFACE

SURFACE MODELING –

LOW COST HW PORTABILITY

ADVANCED MODELING

SURFACE/SOLID/ PARAMETRIC -

WINDOWS

ADVANCED INTEGRATION –

WEB INTEGRATION

2D

3D – FUNCTIONALITY ORIENTED

PARAMETRIC MODELLING – DESIGN INTENT

INTEGRATION – KNOWLEDGE CAPTURE

FILE MANAGEMENTCAD VAULT

CHANGE CONTROL

PROCESS ANALYSIS

FULL INTEGRATION OF VIRTUAL PRODUCT DEVELOPMENT – WEB

COLLABORATIVE KNOWLEDGE


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COMPLEXITY IS A MUST TO BE COMPETITIVE

• PRODUCT:

– PARTS ( about 7000 in a vehicle)

– VARIANTS (300)

• ORGANIZATION

– TEAM AND RESOURCES NUMBER;

– SUPPLIER’S NUMBER;

– SITE DISLOCATION: OFFSHORE ACTIVITIES

• OBJECTIVES– HIGH TARGETS

• PROCESS PHASES

– CONCEPT

– DEVELOPMENT

– MANUFACTURING


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PROCESS CHARACTERISTICS

CONCEPT DEVELOPMENT MANUFACTURINGLOW

HIGH FLEXIBILITY

# OF DEVELOPMENT RESOURCES

# OF ALTERNATIVES

MODIFICATION FREQUENCY

VARIANTS


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CLASSIC DESIGN TOOLS

DESIGN PROCESS: ITERATIVE PROCESS THAT ALLOWS TO DEFINE MANUFACTURING SPECS FROM IDEA TO PHYSICAL ACHIEVEMENT. THE ITERATIONS ARE PERFORMED THROUGH THE PHYSICAL PROTOTYPE BUILDINGS.

DESIGNER USE A CODIFIED LANGUAGE TO TRANSMIT THE IDEA OF THE PRODUCT TO MANUFACTURING EXPERT:– TRADITIONAL TOOLS (70-90’s)

– COMPUTERIZED TOOLS (BEFORE 2000)


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TRADITIONAL VALIDATION

• PHYSICAL PROTOTYPES ALLOWS EVALUATION OF RIGHT DESIGN CHOICES

TECHNICAL DRAWINGS

STRUCTURED INFORMATION

+INTERPRETATION

STRUCTURED KNOWLEDGE & GENERAL BACKGROUND

PROTOTYPE

NON STRUCTURED INFORMATION


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• Rely on experts and heroes• Delta-change from previous designs• Manual system level verification• No virtual verification.• Deal with systems problems as they arise (find and fix)• Many sources for error: many databases• Difficult to develop new technologies (especially in parallel)• Complexity explosion (order n-squared) as # of subsystems

increases• Each vehicle solution depends on the specific set of

subsystems used.

TOOLS AND METHODS PROBLEMS OF A TRADITIONAL PD


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VIRTUAL DESIGN PROCESS TO DESIGN MEANS:

– DEFINE, FORESEE, ANALYZE, COMPARE, CHOOSE, SPECIFY, DOCUMENT, ITERATE

THAT IS

SIMULATE AND COLLABORATE

MODELLING

VISUALIZE

FU

NC

TIO

N S

IMU

LA

TIO

N

ER

GO

NO

MY

SIM

UL

AT

ION

PR

OC

ES

S S

IMU

LA

TIO

N


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FROM IDEA TO PROTOTYPE

VIRTUAL ENVIRONMENT

IDEA CONSTRAINTS

DEFINE

VALIDATEMODIFY

VALIDATE

BUILDCORRELATE PHYSICAL & VIRTUAL

VIRTUAL DELIVERY

PRODUCTRIGHT FIRST

TIME

PHYSICAL MODEL


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MAXIMIZE SIMULATION

• SIMULATE SHAPE AND PHYSICAL OCCUPIED SPACE (CAD)

• SIMULATE NOT ONLY GEOMETRY BUT ALSO PHYSICAL BEHAVIOUR (CAE)

• SIMULATE NOT ONLY SHAPE BUT AESTETICS (CAS)

• SIMULATE NOT ONLY OBJECT BUT ERGONOMY OF THE OBJECT (DMU)

• SIMULATE MANUFACTURING PROCESS, ASSEMBLY METHODS, CONTROL PROCESS (CAPE)

• SIMULATE INTERACTION MAN- PRODUCT (ERGONOMICS)

• SIMULATE WAY OF WORK AND LIFE CYCLE (VP)

FROM CAD TO VP - KAD


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FROM “WHAT” TO “HOW” RESULT IS OBTAINED

CODE

STRUCTURED INFORMATION

+ 2D FORM

STRUCTURED KNOWLEDGE & GENERAL BACKGROUND

BOUNDARY MODEL SPACE OCCUPIED+WIREFRAME MODEL SURFACES+DRAWING 2D 3D EDGES+

SOLID MODEL FUNCTIONAL DIM.+

+VIRTUAL PROTOTYPE

+PARAMETRIC MODEL FEATURE

+FUNCTIONAL MODEL PHYSICAL

=FUNCTIONAL KNOWLEDGE


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CAD EVOLUTION

• ’70s CAd drafting Documents

• ’80s CAD modeling Geometric models

• ’90s KAD functionality Functional models, not integrated

• 2000s Knowledge collaborative management» Problems, products, processes, people

COLLABORATIVE VIRTUAL PROTOTYPING

KNOWLEDGE

PROBLEMS PRODUCT

PROCESSES

PEOPLE IT TOOLS


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PRODUCT DEVELOPMENT PROCESS: A COLLABORATION ENVIRONMENT

PRODUCT DATA DATABASE

PRODUCT DATA DATABASE

QUOTATIONSQUOTATIONS

PRODUCT DEVELOPMENTPRODUCT DEVELOPMENT

PURCHASINGPURCHASING

MANUFACTURINGMANUFACTURING

PRODUCT COSTSPRODUCT COSTS

RESEARCH AND DEVELOPMENTRESEARCH AND DEVELOPMENT

PROTOTYPE AND TESTINGPROTOTYPE AND TESTING

ENGINEERINGENGINEERING

CAECAE

TRAININGTRAINING

REGULATIONSREGULATIONS

QUALITYQUALITY

CUSTOMERSCUSTOMERS

PROJECTPROJECTMANAGERSMANAGERS

STYLESTYLE

DIGITALDIGITALMOCKUPMOCKUPDIGITALDIGITALMOCKUPMOCKUP

VIRTUAL ENVIRONMENTSVIRTUAL ENVIRONMENTSVIRTUAL ENVIRONMENTSVIRTUAL ENVIRONMENTS

VISUALIZATIONVISUALIZATIONVISUALIZATIONVISUALIZATION


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DEVELOPMENTDEVELOPMENT PRODUCTDELIVERYPRODUCTDELIVERY

ProductPlanningProductPlanning

Development resources integration

Development resources integration

ManufacturingPlanning

ManufacturingPlanning

Detailed DesignDetailed Design

ProductLifetime Support

ProductLifetime Support

ConceptualEngineeringConceptualEngineering

Release toManufacturing

Release toManufacturing

ProductionPlanning

ProductionPlanning

MaterialManagement

MaterialManagement

PlantMaintenance

PlantMaintenance

Supply ChainOperations

Supply ChainOperations

DistributionDistribution

Visualization is an integral component for increased cooperation and data sharing at every stage in vehicle lifecycle

ReduceReduce dependence on physical prototypes by leveraging total product digital mockups and collaborative environments


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NEW DEVELOPMENT PRODUCT CHARACTERISTICS

• FOCALIZED ON INFORMATION FLOWS;• DESIGN BY ANALYSIS;• MORE MULTIDISCIPLINARY ACTIVITIES IN “CONCURRENT

ENGINEERING” (PARALLEL)• HAVE AN “ITERATIVE STRUCTURE” : MORE ANALYSIS CYCLES

ARE PERFORMED IN DEVELOPMENT;• “WHAT IF” SCENARIOS;• ARE PERFORMED FROM VERY HIGH SKILLED PEOPLE WITH “AD

HOC” TOOLS, STANDARD PROCEDURES AND HISTORICAL DATABASE AND DOCUMENTATIONS;

• RAPID PROTOTYPING TOOLS;• HIGH NETWORKING PERFORMANCE FOR DATA TRANSMISSION

WITH SUPPLIERS;• INTEGRATION OF SUPPLIERS AND OFFSHORE COMPANIES IN A

DEVELOPMENT TEAM.


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VIRTUAL INTEGRATION PROBLEM

• TECHNOLOGIES FOR TOOLS INTEGRATION (PRODUCT)– CAS - CAD – CAPE – CAM – CAE – DMU => VP

• TECHNOLOGIES FOR INTEGRATION OF DOCUMENTS AND INFOS (PROCESS)– DM – PDM

• TECHNOLOGIES FOR PLANNING AND RESOURCES MANAGEMENT (PEOPLE) IN DIFFERENT SITES

THE REAL PROBLEM:PROCESS AND TOOLS INTEGRATION


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KEY FACTORS

• DETECT CRITICAL FACTORS OF A PROJECT TESTING ALTERNATIVE SOLUTIONS WITHOUT BUILDING OF PHYSICAL PROTOTYPES.

• OPTIMIZE SHAPE, AESTETICS, CHARACTERISTICS, MATERIALS AND BEHAVIOURS;

• VERY LOW COST ACTIVITIES;• CHECK CRITICAL POINT TO BE EXPLORED DURING

PHYSICAL TESTING;• PROVIDE TARGET ACHIEVEMENT IN A VIRTUAL

DELIVERY;• AFTER PHYSICAL PROTOTYPE VALIDATION,

MODIFIED MODELS ARE COHERENT AND FAITHFUL WITH REALITY.


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TOWARD A COLLABORATIVE SOCIETY…


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Breaking Down Barriers


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Synchronous Supplier Solutions

( PAST ) ( TODAY )

Tier 1

Tier 2

Tier 1

Tier 2

«Today’s successful manufacturers make more from less, by optimizing business processes and process integration through active suppliers collaboration»


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FROM HUMAN BASED SHARING TO MULTI SITE COLLABORATION


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KEY POINTS OF NEW PRODUCT DEVELOPMENT

• FROM MULTIPLE ROLES TO DEDICATED AND SPECIFIC SKILLED RESOURCES;

• INTENSIVE USE OF VIRTUAL TOOLS;• DATA INTEGRATION IN A UNIQUE DATABASE WITH

HUMAN RESOURCES SHARING;• DEVELOPMENTS OF STANDARD;• SUPPLIERS INTEGRATION AND RISK SHARING;• OFFSHORE RIPETITIVE AND LOW COST ACTIVITIES;• PROCESS CONTROL AND CHANGES MANAGEMENT• TO FORMALIZE AND USE AVAILABLE KNOWLEDGE;

FORMALISE LESSON LEARNED• COLLABORATIVE PROCESS MANAGEMENTS USING

DIGITAL TECHNIQUES(VIRTUAL REALITY CENTERS)


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THANK YOU