Webinar: Get your complexity under controldigital.zuken.com/rs/707-ZQM-176/images/Webinar-Handout... · 2018-03-13 · Webinar: Get your complexity under control An introduction to

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Webinar:Get your complexity under control

An introduction to handling product and variant diversity, and approaching electromechanical data management with confidence.

Wolfgang Heinrichs

Head of Strategic Solutions and e-PLM Business


Agenda

Involved Engineering Data

What to do?

How to analyze? - The guideline

Product variety – why is it growing so fast and who is involved?

Data transparency & traceability

Feature versus Variant

Trends in the industry

Topic4

Topic2

Topic3

Topic1

Topic5

Topic6

Topic7



Technology area absolute % growth over the last years

Electrical Machines, Apparatus, facilities 593 98,1%

Electronics 1.591 52,1%

Pumps und Compressor 728 47,5%

Heating-, Filter-, Air-, Cleaning technic 1.898 47,2%

Motors, Power Machines, Powertrain technology 3.645 44,9%

Mechanical Measurement technology 1.107 27,9%

Agricultural machinery, Tractors 503 27,4%

Machine Tools 2.417 16,5%

Special machines / vehicles 3.328 -9,1%

Communication Technology 3.796 -20,5%

Today’s innovation is mainly driven by Electronics and SW

Patents filed absolutely in one year versus patents filed growth path across many years


Product variety – why is it growing so fast and who is involved?Who and what is driving the Product variety?

• Total costs of transport• Terms of payment• Total delivery time• Safety compliance• Reliability information• Re-use of the Component


Agenda




What to do?




Topic4

Topic2

Topic3

Topic1

Topic5

Topic6

Topic7


Product variety – Feature versus VariantWho and what is driving product variety?

Source: http://www.complexitymanager.de/en/


Agenda




What to do?




Topic4

Topic2

Topic3

Topic1

Topic5

Topic6

Topic7


Product variety - Trend seen in the industryWho and what is driving the Product variety?


81%



Product variety potentially allows companies to improve supply and demand alignment Leads to a number of challenges

• Product complexity, portfolio increase, additional internal process elements are required to handle the increased product variety

Spreads through all functional areas and operational processes

• Product development, logistics, production, marketing, sales, etc.

In some cases higher product variety leads to

• Higher manufacturing costs

• Greater manufacturing overhead

• Longer delivery times

• Higher inventory levels

• Higher components prices

• more complex Variation & Option matrix


significant impact



However: The goal is NOT to reduce complexity as far as possible

BUT, to find the optimum level of complexity that takes into account the benefits as well as the extra efforts generated by the increase of product variety.

Complexity is not an evil per se! Companies acknowledge the value of competitor differentiation effect

A diversified and complex product portfolio is considered as an important factor in achieving and sustaining advantage against competitors

Companies are aware of the importance of managing this complexity to realize a competitive advantage

First Conclusion: Variety-induced complexity and its management is an issue with increasing relevance in manufacturing companies

These manufacturing companies have to develop and applying innovative approaches to complexity management



Source: St. Gallen University

Differentiating factor?

Competitive advantage?

Successfullyimplemented?

Variant and complexity management provides plenty of room for optimization


Agenda




What to do?




Topic4

Topic2

Topic3

Topic1

Topic5

Topic6

Topic7


Product variety – what to do?

It’s all about “Transparency” on variety-induced complexity: The creation of transparency is recognized as a key task by managers – but it isn’t an easy task …

Transparency is also a critical factor for managing the complexity

Managers need to know the complexity levels their company has to handle as well as the impact on its

• Processes

• Products

• Product portfolio

• Margins

• Supply chain

• And so on

Source: The complexity challenge of manufacturing companies (Schuh 1995,p.431)

Consequently, the broadening of the product portfolio and uncontrolled adding of product variants most likely leads to a competitive disadvantage!

The objective is to identify the »optimal« variety


Steering wheel example:

25 variants in manufacturing can mean

‒ 50 variants for purchasing (dual sourcing

strategy) but only

‒ 4 variants for development due to

four different functional product

designs

Product variety – what to do?

Source: Illustration of parts belonging to a car (source: www.autchannel.com/news)


Product variety – Product configuration ontology

Source: www.bwm.de3 Component Types:1. Stable (CS

ij) component permutations2. Voluntary (CV

ij) component permutations3. Compulsory optional component (CC

ij) permutations

Source: https://www.researchgate.net/publication/301613471

BMW

….

….

….

….

Product Family

Group / Model

Features

Physical Components

Product Configurations

….

Doors

Model

Gearing

Fuel Type

Engine (ccm)

Colour

http://www.bwm.de/


Product variety – Sample (simple) Variant room calculation

2 Type Standard X-Type2 Doors 2 Doors 5 Doors2 Gasoline Diesel Patrol4 Models Advantage M Sport Sport Line Urban Line2 Gearing Manual Automatic6 Engine 1,6L 1,8L 2,0L 2,5L 4,0L 4,0LX8 Colour Alpine Weiß Saphirschwarz Metallic Schwarz Uni Melbourne Rot metallic Glaciersilber metallic Mineralgrau metallic Sparkling Brown metallic Sparkling Storm metallic3 Car Tire-inches 16" 17" 18"4 Car Tire-types Standard Wheel M-Sport Wheels Sport Line Wheels Urban Line Wheels4 Steering-wheel Standard Multi-function Sport-no-whipes Sport-whipes6 Driver assistanceCamera Auto Park Head-up Speed-Limit Park Distance front Park Distance f/b


Revenue

Cost

Product variety – what to do? “The optimal variety”

There is a specific point on the x-axis after which the impact of cost for product variety becomes more significant than the revenues. Consequently and profits start declining.To apply this concept, companies are forced to constantly determine the optimal variety that yields the maximum profit. -> Please refer to our guideline proposal on the next page.

Source: Balance of revenues and costs to define optimal variety (Rathnow 1993, p. 44; Kaiser 1995, p. 111; Danne 2009, p. 16)

The model of optimal variety only takes into account the number of variants and not the type of variant. There might be some variants which have higher complexity costs than others.


Agenda

Product variety – why growing so fast and who is involved?



What to do?




Topic4

Topic2

Topic3

Topic1

Topic5

Topic6

Topic7


Product variety – what to do? – The guideline proposal


Product variety – what to do? – The guideline

Mastering Complexity


Agenda




What to do?




Topic4

Topic2

Topic3

Topic1

Topic5

Topic6

Topic7


It’s all about Data …..... Engineering Data ...... E/E Data ......

HIL: HW in the Loop Simulation


Product variety – The next wave is coming soon …..


Product variety – The next wave is coming soon …..

Future Mobility

EE Platform

Autonomous functions

Industrialization

Future structures

Mobility services

Vehicle connectivity

EnergiespeicherEnergy storage

Systems / Multi-Agents / -UsersSysteme / Multi-Agenten / -anwender

Big Data for mobilityBig Data für Mobilität

HMI of the futureHMI der Zukunft

New structuresNeue Strukturen

Future materialsZukünftige Materialienrobotic platform

Roboterplattform

Sensors of the futureSensoren der Zukunft

SafetySicherheit

RoboticsRobotik

SecuritySicherheitsmaßnahmen

Drive- / PowertrainMotorisierung

EE ArchitectureEE Architektur

AI

MBSE

ValidationValidierung

CertificationZertifizierung

CloudComputing

UX DesignUser Interface


Industry 4.0, AI, Robots, IoT, … – The next wave is knocking already on the doors …..


Agenda

Product variety – why growing so fast and who is involved?



What to do?




Topic4

Topic2

Topic3

Topic1

Topic5

Topic6

Topic7


It’s all about Data …..... Engineering Data ...... E/E Data ......150% Design versus modular Design ….

OrganizationalAnchoring

Enabling Factors

Activity Areas

lead to

External & Internal Complexity Drivers

triggerEffectiveness and

Efficiency of Projects

Complexity Management

Conceptual Model

ProductArchitecture

ProductArchitecture


It’s all about Data …..... Engineering Data ...... E/E Data ......150% Design versus modular Design …. Strategic Advantage of modular Product development

Protect cargo from weather

Connect to Vehicle

Minimize air drag

Support cargo loads

Suspend trailer structure

Transfer loads to road

Box / Kasten

Hitch / Anhängehaken

Fairing / Verkleidung

Bed / Ladefläche

Springs / Federn

Wheels / Reifen

A modular trailer architecture exhibiting a one-to-one mapping from functional elements to physical components

Functional Elements Components

Protect cargo from weather

Connect to Vehicle

Minimize air drag

Support cargo loads

Suspend trailer structure

Transfer loads to road

Upper Half / oberer Kasten

Lower half / unterer Kasten

Nose piece / Anhängehaken

Cargo hanging straps /

Ladebefestigung

Spring slot covers / Federabdeckung

Wheels / Reifen

An integral trailer exhibiting a complex mapping from functional elements to physical components

Functional Elements Components



Strategic Advantage of

modular Product development

There are multiple ways of achieving the objective of a modular product

architecture

F: Function, C: Component, M: Module



Case study: family of drills and their family function structure, with modules shown

RegisterBattery

Un-RegisterBattery

TransmitElectricity

Hand force

BatteryForce into Opposite handBattery

Force into Opposite hand

ConvertElec. To Motion

SwitchPower Input

SignalInput

Speedselection

Transmitselection

Transform(Ƭ,ω)

TransmitPower

PermitDrill Bit

Positioning

Finger force

7.2V DC

Finger

FingerRotary Torque

transmission

Noise, HeatForce in to finger

motorSpeed changer

slip clutch

triggerswitch

Noise

Hand

Hand

DrillHole

Object

contact

drillingHot drilled object

Hot filings

Heat in bit

Un-lockDrill Bit

ReleaseDrill Bit

RegisterDrill Bit

Bit securedHand

Force chuck

Drill Bit

Force into opposite hand

SecureDrill Bit

Drill bit

casing

Current drill modules

Heavy-duty /Professional module

Integrated module for platform alternative A

2 Integrated modules for platform alternative B

functionFunction only in the Heavy-duty and the Professional models

Noise



Product variants of the product family of herbicide spraying system MANKAR-Roll

1) Analysis of product variety

2) Applying the variety Allocation Model to optimize product family

3) Allocate Module drivers to Module driver specification

4) Modular sales concept with integrated aspect of ergonomics and corporate styling

5) Result of case study



Product variants of the product family of herbicide spraying system MANKAR-Roll


It’s all about Data …..... Engineering Data ...... E/E Data ......

Idea / Innovation Concept Design Verification / Validation Production / Manufacturing Service

Requirements Structure Functional Product Structure Engineering Product Structure Validation Product Structure Manfucturing Product Structure Service Structure

Production Systems(ERP / MRP / MES)

As Defined As Designed As Produced As Serviced


It’s all about Data …..... Engineering Data ...... E/E Data ......Variance structures can be very time consuming (performance) …. Have a look to the IT & Infrastructure

Tree structure representation Cross-style representation Table / Matrix representation

Same variant Product – 3 different BOM representations & algorithms

From a PDM point of view we have to distinguish two measures of BOM performance:• Time it takes to execute an algorithm• Amount of memory needed to calculate and store resultsAccordingly, there are two measures of algorithm complexity: time and spaceAnother dimension is of course the data size (file size itself, # of sheets, # of BOM positions, etc.)

Variants Space / Room


It’s all about Data …..... Engineering Data ...... E/E Data ......Variance structures can be very time consuming….

An MRP algorithm is a time consuming algorithm, and therefore we are particularly interested in estimating the complexity of

algorithm implementation in terms of the time needed to perform operations on the data.

Time complexity of a program is measured by the number of basic operations to be performed in order to calculate the result. The

complexity unit is given to each command within the algorithm, so the time complexity of the program is calculated as the total

complexity of all commands in it.

Matrix representation

Variants Space / Room

• N will represent the number of different elements contained in the bill of material;

• O(…) will be the pessimistic (the worst case) number of steps the algorithm takes;

• Table – data in a database describing all relationships between elements (max N2);

• Descendant – material or part needed in the production of other elements;

• Requirements – list of requirements in the production of final products (max N);

• Algorithms will be described by pseudo code to preserve simplicity.

N

N


It’s all about Data …..... Engineering Data ...... E/E Data ......Variance Algorithms and Variance Design approaches can be very time consuming….

Comparison of Traditional BOM Algorithm and Improved BOM Algorithm

Algorithm Processing Capability Comparison of BOM Material Expand

BOM managing systems Flexible use of algorithms

Tree structure representation Cross-style representation Matrix representation

Depending on the size and type of the BOM, today’s BOM management systems may have to be more agile in terms of which algorithm is to be used to achieve required performance.

Customer sample data:

350+ Variants

⇒ 122.500 Data Records

⇒ above 10 * 104 !!!!!

Source: www.sersc.org/journals/IJHIT/vol7_no3_2014/7



StandardCustomized Standard

Modified Standard

Customer Specific Design to OrderEngineering to Order

Custom

Configure to Order

No. of orders

Product is Non-modular Product is ModularProcess and Organization

Impl

emen

t a m

odul

ar a

nd

stru

ctur

al A

rchi

tect

ure

Pro

cess

es, O

rgan

izat

ion

&

I/F In

frast

ruct

ure

• There will be no 100% CTO approach in the future.

• Companies needs to enter into new Market segments or niche markets

• …

150% Design approach Modular Design approach


It’s all about Data …..... Engineering Data ...... E/E Data ......Decoupling by Modularity ….

Product Leadership

Customer Orientation

Operational Excellence

Operational Excellence

Product Leadership Customer Oriented

Interfaces isolates modules in their strategic circle to optimize each in accordance with its strategic direction

• Reduce Lead-time• Optimize Costs• Maximum Re-Use• Maximum Modularity• Quality focus

• Ensure Leading edge Technology supplier

• Niche Markets• As required

standardization• As required modular• ….

• Maximum customer fit• No or very few

modules• Niche Markets driven• Early Idea and

Innovation Prototyping• …

ModularityComplexity



High performance IT Infrastructure and Controlled Modular Engineering methods enable firms to achieve a number of strategically important advantages:1. Well addressed Complexity Management operations will lead to optimal transparency enabling early analysis how to avoid and reduce complexity = product variety

2. External and Internal balanced increase in product variety can lead to solid revenue increase

3. Structured internal product variety can especially lead to significant complexity cost reductions

4. 2 & 3 applied in a structured and controlled way will eventually lead to increased profitability

Source: www.mechanicaldesign.asmedigitalcollection.asme.org

Engineering: Modularization

IT: Improved BOM Algorithm

Sales: possible higher revenue

Note:1. reduced internal product variety2. achieved complexity cost savings3. new complexity cost curve


System Design

Circuit Design

2D/3D Layout

It’s all about Data …..... Engineering Data ...... E/E Data ...... AND Transparency

MechanikMCAD

Enterprise PLM / ERPBackbone

MCAD

EngineeringData Management

Mechanical CAD

PLM / ERPIntegration Layer

Software DevelopmentEnvironment

Software ConfigurationManagement

Schematic

Panel

Harness

Mastering ComplexityPLM / ERP

Integration Layer

Innovation is today driven by Electronics (ADAS, Connected Drive, IoT, etc.) and SW (embedded and Apps). Therefore they need to be integrated on an equal level.


Executive Summary

Achieving the required transparency, balance between external product variety and internal variety allows a excellent planning and processing to achieve maximum time-, effort-, quality-, revenue- and profit optimization

Source: www.tuhh.de


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Webinar: Get your complexity under controldigital.zuken.com/rs/707-ZQM-176/images/Webinar-Handout... · 2018-03-13 · Webinar: Get your complexity under control An introduction to