VIRTUAL TOOLS AND COLLABORATIVE ENVIRONMENTS IN AUTOMOTIVE PRODUCT DEVELOPMENT: CURRENT SCENARIOS

1. VIRTUAL TOOLS AND COLLABORATIVE ENVIRONMENTS IN AUTOMOTIVE PRODUCT DEVELOPMENT:CURRENT SCENARIOS

2. 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 THE REFERENCE SYSTEMS IN PRODUCT DEVELOPMENT

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

4. IN THIS ENVIRONMENT:

5. THE “OLD WAY. . .”: WHAT IS CHANGED? • Complexity • Development Time • Development Costs • Technologies PROCESSES

6. Traditional Product Development Process Build Test Fix Iteration FormFunction • For Complex Products: • Cycle Time Too Long • Facility Intensive • Cost High • Convergence Not Assured

7. CONCEPT MODIFY DESIGN VALIDATE PROTOTYPE CLASSICAL PRODUCT DEVELOPMENT CYCLE VERY HIGH NUMBER OF PROTOTYPES FOR EVERY TESTING AND FUNCTIONALITY STEP VALIDATION

8. The Cost Of Change COMPETITION IS “CHANGING”

9. Various Phases of the VPD 100% FREEDOM 50% € Committed € Spent INFORMATION 0 Time PHASE 0 PHASE 1

10. PRODUCT DESIGN: DIFFERENT VISIONS As the customer wanted it: more demands on product selections, delivery time and quality As Marketing interpreted it: wide spread out of the model. As managers made it: profitable, less costs, carry over exasperated. As Engineering designed it: new and high technical contents

11. AT THE END THE KEY PROGRAM ELEMENTS ARE: COST TIME QUALITY

12. 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 NEW SCENARIOS

13. HOW CHANGE COMPANY INFRASTRUCTURES WITH NEW TECHNOLOGIES AND TOOLS? VIRTUAL BASE QUESTIONS 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

14. 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: HUMAN RESOURCES CHANGE SPEED PROBLEM • NEW RE - ENGINEERING • OF PRODUCT DEVELOPMENT: • INTRODUCE NEW TECH • ADOPT NEW PRODUCT • DEVELOPMENT FLOW • NEEDS OF: • TTM REDUCTION; • INCREASE PRODUCT QUALITY; • COST CONTAINED

15. FULL INTEGRATION OF VIRTUAL PRODUCT DEVELOPMENT – WEB PROCESS ANALYSIS CHANGE CONTROL FILE MANAGEMENT CAD VAULT INTEGRATION – KNOWLEDGE CAPTURE PARAMETRIC MODELLING – DESIGN INTENT 3D – FUNCTIONALITY ORIENTED 2D CAX MARKET EVOLUTION 2000+ 1990+ COLLABORATIVE KNOWLEDGE 1980+ ADVANCED INTEGRATION –WEB INTEGRATION 1970+ ADVANCED MODELING SURFACE/SOLID/ PARAMETRIC - WINDOWS 1960+ SURFACE MODELING – LOW COST HW PORTABILITY DRAFTING INTERACTIVE GRAPHIC USER INTERFACE RESEARCH IN HOME 2D TOOLS MAINFRAME

16. 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 COMPLEXITY IS A MUST TO BE COMPETITIVE

17. # OF DEVELOPMENT RESOURCES FLEXIBILITY MODIFICATION FREQUENCY VARIANTS # OF ALTERNATIVES PROCESS CHARACTERISTICS HIGH LOW CONCEPT DEVELOPMENT MANUFACTURING

18. 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) CLASSIC DESIGN TOOLS

19. NON STRUCTURED INFORMATION PROTOTYPE TECHNICAL DRAWINGS INTERPRETATION STRUCTURED INFORMATION STRUCTURED KNOWLEDGE & GENERAL BACKGROUND TRADITIONAL VALIDATION • PHYSICAL PROTOTYPES ALLOWS EVALUATION OF RIGHT DESIGN CHOICES +

20. 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

21. TO DESIGN MEANS: DEFINE, FORESEE, ANALYZE, COMPARE, CHOOSE, SPECIFY, DOCUMENT, ITERATE THAT IS SIMULATE AND COLLABORATE VISUALIZE FUNCTION SIMULATION PROCESS SIMULATION ERGONOMY SIMULATION MODELLING VIRTUAL DESIGN PROCESS

22. MODIFY VALIDATE BUILD PHYSICAL MODEL CORRELATE PHYSICAL & VIRTUAL PRODUCT RIGHT FIRST TIME FROM IDEA TO PROTOTYPE IDEA CONSTRAINTS VIRTUAL ENVIRONMENT DEFINE VIRTUAL DELIVERY VALIDATE

23. 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) MAXIMIZE SIMULATION FROM CAD TO VP - KAD

24. =FUNCTIONAL KNOWLEDGE + FUNCTIONAL MODEL PHYSICAL + PARAMETRIC MODEL FEATURE + SOLID MODEL FUNCTIONAL DIM. + BOUNDARY MODEL SPACE OCCUPIED 2D FORM CODE + WIREFRAME MODEL SURFACES + DRAWING 2D 3D EDGES STRUCTURED KNOWLEDGE & GENERAL BACKGROUND STRUCTURED INFORMATION FROM “WHAT” TO “HOW” RESULT IS OBTAINED + VIRTUAL PROTOTYPE +

25. ’70s  CAd  drafting  Documents ’80s  CAD  modeling  Geometric models ’90s  KAD functionality  Functional models, not integrated 2000s  Knowledge collaborative management Problems, products, processes, people KNOWLEDGE PROBLEMS PRODUCT COLLABORATIVE VIRTUAL PROTOTYPING PROCESSES PEOPLE IT TOOLS CAD EVOLUTION

26. RESEARCH AND DEVELOPMENT STYLE PROJECTMANAGERS PURCHASING VIRTUAL ENVIRONMENTS CUSTOMERS CAE PRODUCT COSTS ENGINEERING VISUALIZATION PRODUCT DATA DATABASE PRODUCT DEVELOPMENT TRAINING QUOTATIONS DIGITAL MOCKUP REGULATIONS QUALITY PROTOTYPE AND TESTING MANUFACTURING PRODUCT DEVELOPMENT PROCESS: A COLLABORATION ENVIRONMENT

27. Visualization is an integral component for increased cooperation and data sharing at every stage in vehicle lifecycle Detailed Design Distribution Development resources integration ManufacturingPlanning Supply ChainOperations DEVELOPMENT PRODUCTDELIVERY ConceptualEngineering Release toManufacturing PlantMaintenance ProductPlanning ProductLifetime Support MaterialManagement ProductionPlanning Reduce dependence on physical prototypes by leveraging total product digital mockups and collaborative environments

28. 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. NEW DEVELOPMENT PRODUCT CHARACTERISTICS

29. 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 VIRTUAL INTEGRATION PROBLEM

30. 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. KEY FACTORS

31. TOWARD A COLLABORATIVE SOCIETY…

32. Breaking Down Barriers

33. Tier 1 Tier 1 Tier 2 Tier 2 Synchronous Supplier Solutions ( PAST ) ( TODAY ) «Today’s successful manufacturers make more from less, by optimizing business processes and process integration through active suppliers collaboration»

34. FROM HUMAN BASED SHARING TO MULTI SITE COLLABORATION

35. 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) KEY POINTS OF NEW PRODUCT DEVELOPMENT

36. THANK YOU