Complexity Management and PLM

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1 Complexity Management and PLM Martin Eigner Eigner VPE Folie: 1

2 Complexity Management and PLM 2011 Agenda 1 Complexity based on Multidisciplinary Products 12 Solutions for Variant Handling: Neutral and Generic BOM 3 External and Internal Variance 4 Simplexity Symplify the Things 5 Strategic Product Planning and Architecture , Eigner VPE Folie: 3

3 Complexity based on more function and higher variation Example Cayenne Interior Modules: 660 Pipes: Pins: 600 bis length of pipe: approx..: m, kg 32 Vehicle-specific Cable Ducts Source: Porsche AG , Eigner VPE Folie: 4

4 Shift Variance to Software and Electronic 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 2 liter engine Differentiation based on different SW calibrations Eigner VPE Folie: 5

5 Software Becomes a Dominant Factor of the Product Mechatronic Mechanic Mechatronic IT Mechatronic Mechanic IT Mechanik Source: vgl. [me] Electronic Electronic yesterday (1968) tomorrow??? When Software and Electronic becomes stronger, why should we use methods from Mechanic & Hierarchical Requirements and Function Structure? Eigner VPE Folie: 6

6 Software/Electronic becomes stronger.. Example: Adaptive Cruise Control Mechatronic Elements Sensor and Control Unit ECU electronic components mechanics software control HIL simulation testing testing / diagnosis Quelle: BOSCH Eigner VPE Folie: 7

7 Interdisciplinary Product Design based on an Extended V-Model Anforderungsdefinition Produkt- Planung Entwicklung Prozessplanung Produktion Betrieb Recycling A/R Modellbildung, Beschreibung (z.b. in SysML, ModelicaML Eigenschaftsabsicherung virtuelle Tests physische Tests F Modellbildung und Simulation (Simulink, MATLAB, Modelica) Integrierte Funktions- und Eigenschaftsabsicherung (Model Based Design) L Dienstleistung hybride Tests (z.b. HIL) P Mechanik Disziplinenspezifische E/E Modellbildung (M-CAD, E-CAD, Software CASE) Modellbildung- und Simulation A/R: Anforderung/Requirements F : Funktion L : logische Lösungselemente P : physikalische Elemente Eigner VPE Folie: 8

8 Model based Design for Mechatronic Design 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 Eigner VPE Folie: 9

9 Interdisciplinary Product Design based on an Extended V-Model Anforderungsdefinition Produkt- Planung Entwicklung Prozessplanung Produktion Betrieb Recycling A/R Modellbildung, Beschreibung (z.b. in SysML, ModelicaML Eigenschaftsabsicherung virtuelle Tests physische Tests F Integrierte Funktions- und Eigenschaftsabsicherung (Model Based Design) L Dienstleistung hybride Tests (z.b. HIL) Mechanik P E/E Software Modellbildung- und Simulation A/R: Anforderung/Requirements F : Funktion L : logische Lösungselemente P : physikalische Elemente Eigner VPE Folie: 10

10 Systems Modeling becomes Part of the Engineering Supporting Systems Modeling - Combined structures in the early phases of product development multidisciplinary E-BOM ASURO Left drive motor gear multidisciplinary requirements modeling Multidisciplinary Requirements, Function, Behavior and Building Block Modeling pinion 1 pinion 2 Original statement pinion rotation 360 rotation around point optic rotation measurement wheel pinion 4 max speed LED collision detection opt. sensor Systeme: Doors, Requisit Pro, XML SE Systeme (SysML, ModellicML) PLM-Systeme Eigner VPE Folie: 11

11 Example: Requirements for a MicroRobot Engineering of a requirement structure with linked elements System /Functional BOM Extracted requirements Engineering BOM Satisfied by a component Satisfied by a function Eigner VPE Folie: 12

12 Example for concept models (Architecture) System structure - Block definitions - Internal structure Internal structure of the control <<electronic>> Engineering BOM MircoRobot electronics Circuit board Controller Sensor Internal structure of the drive <<mechanic>> mechanics Drive chassis motor gear wheel Eigner VPE Folie: 13

13 SE as an integrated part of a PLM concept 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 System behavior L224_300_200_HS.ASM F1_300_200_G.ASM F3_300_211_B.PRT F3_300_238_F.PRT Requirements structure Deriving Product hierarchical Lifecycle Management structure information (PLM) (e.g. via XML) System /Functional BOM System requirements System structure Engineering BOM All data in one PDM system System requirements model System structure model System behavior model Eigner VPE Folie: 14

14 Product and Process Backbone Mechatronic Plan Concept Design Validate Production Support Requirements BOM System /Functional BOM Engineering BOM Simulation/Testing BOM Manufacturing BOM Service BOM Product Lifecycle Management (PLM) Production Systems (ERP/MES) Eigner VPE Folie: 15

15 Interdisciplinary Product Design based on an Extended V-Model Anforderungsdefinition Produkt- Planung Entwicklung Prozessplanung Produktion Betrieb Recycling A/R Eigenschaftsabsicherung virtuelle Tests physische Tests F Modellbildung und Simulation (Simulink, MATLAB, Modelica) Integrierte Funktions- und Eigenschaftsabsicherung (Model Based Design) L Dienstleistung hybride Tests (z.b. HIL) Mechanik P E/E Software Modellbildung- und Simulation A/R: Anforderung/Requirements F : Funktion L : logische Lösungselemente P : physikalische Elemente Eigner VPE Folie: 16

16 Tools Modelling and Simulation Eigner VPE Folie: 17

17 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, Multidisciplinary modeling and simulation Eigner VPE Folie: 18

18 Description of the inverse pendulum in simulation model Behavior of components is described in simulations e.g. in Matlab/Simulink - pendulum and drive kinematics - Actuators and sensors - Controler - Boundary conditions Eigner VPE Folie: 19

19 Interdisciplinary Product Design based on an Extended V-Model Anforderungsdefinition Produkt- Planung Entwicklung Prozessplanung Produktion Betrieb Recycling A/R Eigenschaftsabsicherung virtuelle Tests physische Tests F Integrierte Funktions- und Eigenschaftsabsicherung (Model Based Design) L Dienstleistung hybride Tests (z.b. HIL) P Mechanik Disziplinenspezifische E/E Modellbildung (M-CAD, E-CAD, Software CASE) Modellbildung- und Simulation A/R: Anforderung/Requirements F : Funktion L : logische Lösungselemente P : physikalische Elemente Eigner VPE Folie: 20

20 Discipline specific models for example software 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 Eigner VPE Folie: 21

21 Complexity Management and PLM 2011 Agenda 1 Design Methodology Solutions for Variant Handling: Neutral and Generic BOM 3 External and Internal Variance 4 Simplexity Symplify the Things 5 Strategic Product Planning and Architecture , Eigner VPE Folie: 22

22 The Solution: Neutral or Modular BOM 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 down to round about 5000!!! BOM s Eigner VPE Folie: 23

23 Modular (Generic) BOM 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 Eigner VPE Folie: 24

24 Generic Product Structure in Automotive Machine Industry can use the same principles to simplify the Product Structure Product Family A Seats Cockpit Dashboard Meters/gages spoke Steering Wheel Dashboard upper part Dashboard lower part (default/standard) Steering column compl. Distance tube CRUISE=YES spoke Steering Wheel w/cruise Steering wheel Airbag Legend CRUISE=YES & NAVI=YES spoke St. Wheel w/cruise & Navi Product Family Component in GPS Position Variant with Rule Item (Assembly or Part) Eigner VPE Folie: 25

25 Complexity Management and PLM 2011 Agenda 1 Design Methodology Solutions for Variant Handling: Neutral and Generic BOM 3 External and Internal Variance 4 Simplexity Symplify the Things 5 Strategic Product Planning and Architecture , Eigner VPE Folie: 26

26 Solution for Product Configuration Solution Space Product Configuration (Search for valid Solutions) Sales Engineering Manufacturing Prod. Variants Options Constraints Order Configuration Customer Car Type Color Extras - Radio X25 Smith BMW 320i Convertible Black Vehicle Car body Attach. parts ext. Seats Seat, front left Seat cushion Backrest Headrest Armrest Recliner Seat rail Backrest, Sport shape Vachette leather, Heating 0810 Foam Product Structure Seat rail Structure 8786 Trim cover Backrest, Normal shape Alcantara 7451 Structure 0812 Foam 9700 Trim cover Backrest, Normal shape Textile 7451 Structure 0812 Foam 6541 Trim cover 4431 Armrest, Vachette leather Armrest, Alcantara Armrest, Textile Seat rail Deriving individual BOM Vehicle Car body Attach. parts ext. Seats Seat, front left Seat cushion Backrest Headrest Armrest Recliner Seat rail Seat cushion, Normal shape Alcantara 7452 Structure 0813 Foam 2700 Trim cover Backrest, Normal shape Alcantara 7451 Structure 0812 Foam 9700 Trim cover 2001 Headrest, Alcantara Armrest, Alcantara Recliner 0912 Seat rail Eigner VPE Folie: 27

27 External Variance Product Configuration (Search for valid soltions)) Solution Space Order 8037 Selected Options 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 Eigner VPE Folie: 28

28 Internal Variance Product Configuration (Search for valid soltions)) Solution Space Options, Rules/Constrains Color = Black, Creme, Grey AirCondition = Basic, Comfort Order 8037 Selected Options Customer Smith Car Type Z41 Color Black Extras - Radio X25 - AirCondition Basic - Crypton Light LC0 Vehicle Car body Attach. parts ext. Seats Seat, front left Seat cushion Backrest Headrest Armrest Recliner Seat rail Backrest, Sport shape Vachette leather, Heating 7451 Structure 0810 Foam 8786 Trim cover Backrest, Normal shape Alcantara 7451 Structure 0812 Foam 9700 Trim cover Backrest, Normal shape Textile 7451 Structure 0812 Foam 6541 Trim cover 4431 Armrest, Vachette leather Armrest, Alcantara Armrest, Textile Seat rail Rule based Variant-BOM Definition Analysis Rules/Constrains Derivation Vehicle Car body Attach. parts ext. Seats Seat, front left Seat cushion Backrest Headrest Armrest Recliner Seat rail Seat cushion, Normal shape Alcantara 7452 Structure 0813 Foam 2700 Trim cover Backrest, Normal shape Alcantara 7451 Structure 0812 Foam 9700 Trim cover 2001 Headrest, Alcantara Armrest, Alcantara Recliner 0912 Seat rail Orderoriented BOM Eigner VPE Folie: 29

29 Complexity Management and PLM 2011 Agenda 1 Design Methodology Solutions for Variant Handling: Neutral and Generic BOM 3 External and Internal Variance 4 Simplexity Symplify the Things 5 Strategic Product Planning and Architecture , Eigner VPE Folie: 30

30 Simplexity 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 Eigner VPE Folie: 31

31 Jeffrey Kluger Symplexity 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 Eigner VPE Folie: 32

32 Ora Ito (born 1977) Simplexity in Art and Design Eigner VPE Folie: 33

33 Optimization Reducing External Variance Eigner VPE Folie: 34

34 l, Textil, (keine), Manuell xtil, (keine), El. Memory Leder, Heizung, Manuell extil, (keine), Elektrisch der, Heizung, Elektrisch ntara, Heizung, Manuell Textil, Heizung, Manuell 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 ra, Heizung, El. Memory antara, (keine), Manuell eder, (keine), Elektrisch ara, (keine), El. Memory der, Heizung, Elektrisch tara, Heizung, Elektrisch ntara, (keine), Elektrisch, Leder, (keine), Manuell der, (keine), El. Memory eder, (keine), Elektrisch Stückzahl Quantity by Variant Accumulated Quantity Stückzahl kummuliert The inevitable Long (Thin) Tail Varying demand for individual product variants Reduce Variance - Eliminate product variants not contributing to commercial success Product Variants 0 Example: leather seat without heating Eigner VPE Folie: 35

35 The inevitable Long (Thin) Tail Technical constraints - Exclude combinations that don t work Marketing/product management constraints - Exclude/enforce combinations to guide customer Picture: Mathias Zagel Eigner VPE Folie: 36

36 Reduce Variance with Constraints Reduce possible combinations of option values - Enforce desired combinations - Avoid undesired combinations - Reduced external variance of Car Seat, front left: (-33%) - Likewise reduced internal variance of all affected assemblies IT Tool: CONFIGIT exclude ARMREST ARM_DRV (Arm rest Driver) ARM_none (none) COL_IN CLI_BLK (Black) CLI_CRM (Beige) CLI_GRY (Gray) DOORS 2DOOR (2 Door) 4DOOR (4 Door) SEAT_ADJUST SAD_ELM (El. Memory) SAD_ELE (Electrical) SAD_MNL (Manual) SEAT_CVR SAD_VACH (Vachette leather) SAD_ALCN (Alcantara) SAD_TXTL (Textile) SEAT_HEATING SEA_HEAT (Heating) SEA_none (none) SEATS SEA_SPRT (Sport) SEA_NORM (Normal) STEERING STEER_R (RHD) STEER_L (LHD) enforce Eigner VPE Folie: 37

37 Optimization Reducing Internal Variance Eigner VPE Folie: 38

38 Reduce internal Variance 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 Eigner VPE Folie: 39

39 Multi Functionality Oversize it Picture: Mathias Zagel Eigner VPE Folie: 40

40 Utilize Symmetry Eigner VPE Folie: 41

41 The new VW modular transverse product platform Examples for characteristic elements Technical length Unified engine positioning Standardized fixtures for rear axle Multi control bar axle bond control bar axle Standardized position of engine, gearbox, suspension, air conditioning unit and pedals Reduction of combinations of tilt angle and geometric distance from axle from 36 to 2 Standardized fixtures for different types of axles Source: Volkswagen Sachsen GmbH Eigner VPE Folie: 42

42 Decouple Interfaces Eigner VPE Folie: 43

43 Decouple Interfaces Dock connector Eigner VPE Folie: 44

44 Decouple Interfaces Eigner VPE Folie: 45

45 Complexity Management and PLM 2011 Agenda 1 Design Methodology Solutions for Variant Handling: Neutral and Generic BOM 3 External and Internal Variance 4 Simplexity Symplify the Things 5 Strategic Product Planning and Architecture , Eigner VPE Folie: 46

46 Strategic Product Planning Platform Strategy... E D C B A Synergie Variant Strategy... Modul Strategy (Reuse of Parts and Components across Plattforms) E D C B A Synergie Eigner VPE Folie: 47

47 Cost / Turnover Cost and Benefit of Variants Turnover Cost Optimum Variation Quelle: Prof. Dr. Schuh, University of Aachen Eigner VPE Folie: 48

48 Contact Thank you Martin Eigner Institute for Virtual Product Development (VPE) University of Kaiserslautern Postfach 3049 D Kaiserslautern T +49/172/ F +49/631/ vpe.mv.uni-kl.de Eigner VPE Folie: 49

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