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Laboratory conference

Concept specification for a prototype and test information system (PaTIS) for OSS Europe

Leipzig 2008

Emanuel Sideras in copr. with Klaus SchaalOSS / Alfdorf

© TRW Automotive Inc. 20082

Background

The product design and validation process needs to be transparent. Product information (E-BOM) has to be linked with the generated testing information in order to allow cost efficient test planning and performing.

General Requirements:

• Standardized and automated linkage between part status and test result• Standardized and automated handling of the E-BOM• Automated / integrated workflow (Engineering- Prototype Shop-

Laboratory)• Avoidance of multiple inputs of data• Possibility for automated searches over different projects, locations

regarding failure modes, parts,....• Standardized and automated reporting


Shirley Czestochowa

Areas to be involved

PaTIS

26 MilesBricherasioAschau

Airbag Component TestsSystem Tests

Seatbelt Component TestsMath. Simulation

Airbag TestsSteering wheel Tests

System TestsMechatronik Tests

Math. Simulation

Airbag TestsSteering wheel Tests

System TestsMechatronik Tests

Bag (Fabric) TestsMath. Simulation

VilanovaPortugalVigoSpainValladolidSpain

Alfdorf Germany

Aschaffenburg Germany

Shanghai

Location‘s

Design EngineerApplication Engineer

Sample Shop

Validation EngineerTest Laboratory

Testing group‘s Department‘s

Prio 1

Prio 2

Integration Priority


High Level Process Overview

Part PhaseCustomer

PartsTest

FixturesReDefineSamples

Additional Parts

Assemblefixtures

Build Test Samples

Deliver Test Samples

Prepare Test Samples

Analisis & Docum. PhaseRecherche prev. Tests

Analyse Results

Test Report Archive

Definition

Test PhasePrepareTests

PerformTests

Test Documentation

Store testedParts

DVP&RE-BOM Parts

Parts DocumentationRaw Data

EXTERNAL

EXTERNAL

COP COP

DVP&R: Design Verification Plan and Report

Cost estimation

Define Test samples

Define Testingprocedures


Workflow & Data managementWorkflow PaTIS

DefineParts / Tests

BuildParts

Test Parts

AnalyseParts / Data Archive

Process Phase

Reports

Testresults

Part

Orders

DVP&R

E - BOM

Drawing

Testplan

Raw Test Data

Dat

a Fl

ow Assebly Fixture

Machine Data

Test Fixture


Drivers for good quality

Good quality specification

Acceptance from Stakeholder

Consideration of TRW-requirements

Consideration of supplier-requirements


Questions to start off

• How can WE get an overview of the entire process?

• How can we collect and restructure the needs of our users?

• How can we collect all the relevant requirements?

• How can we give the vendors sufficient insight / overview of the total processes?

• What information is relevant for the vendors in order to understand our concerns and/or to make an offer?

• Involvement of the supplier during the concept specification


Measure (What do we have ?)

Description of the current processes in order to get all important activities which has to be considered for the concept specification.

BB Project BB06152007003Concept specification for a prototype and test information system (PaTIS) for OSS Europe

Define (What should be done ?)

The product design and validation process needs to be more transparent. Product information (BOM) has to be linked with the generated testing information via PaTIS to allow cost efficient test planning and performing.

Problem:How to make a concept specification which covers the needs of the several departments and plants in order to use it for the offering process of a PaTIS.

Control (Check if complete !)

• Meeting with all suppliers and exchange of information's and ideas, expectations • Internal customers checked the draft of the specification and make their additions• Offering process -> replay of the suppliers

Analyze (What do we additional need ? – find the gaps)

Development of the „Hot Spots“ – Issues which has to be considered, described and specified in order to have a specification for PaTIS, based on the activities of the SIPOC.

Affinity Diagram out of the SIPOC:

Improve (Close the gaps !)

A workshop was set up:• Description of the future state activities• Generating possible concepts for the “Hot Spots”• Identify potential improvements• Generating benchmark criteria

• Consolidation with specification of Aschaffenburg

• Writing of the specification & assessment lists• Business case (preliminary)


Description of the existing processes

Instructions to describe the current processes

List up for each process group each necessary information:• Name of the document / Information• Is the document/Inf. an Incoming and / or Outgoing • From Whom / To Whom• Information System (Paper, E-Mail, File, ….) • Kind of test: Design Verification / COP / Math. Simulation• Place of Test: External, Intercompany, Plant (Internal)• Functional Group• Store existing example template or screen hardcopy


Current state -> Future state

SIPOC

Realization / Priorization

Information handling

Files / metadata

Release / change processes

Current problems

Potential improvement

Functional issues

Storage / Warehouse

DVP&R

Capacity planning

Other Functional Modules

Data structure

Ordering

E-BOM

Interfaces to other systems


Interfaces (Example)


Modules of PaTIS

Capacity/Resource

planingStorage

WarehouseTest FixturesPrüfvorrichtung

Assembly Fixtures

Montage Werkzeug

SAP-BOM-Netzplan-SAP Order-SAP Project

Web - Portal

Customer/Supplier/OthersWeb – GUI (TRW Internal)A

pplic

atio

nsSu

bsys

tem

sEx

tern

al

Syst

ems

PDF Viewer

Digital Archive

Ixos

Gasgenerator

DB

X-Crash/

PulseDBCOPS

Maschines

Prüfmittelüber

wachung GQDOORS

SAP-Maschinendaten

-Leistungskatalog

Lessons

Learned DBClarity

CAD Viewer

2D / 3D

Movie Viewer

Falcon

MS-Office

Applications

Barcode

Scanner

Label

Parts / Boxes

Windchill-Rel Drawing-Lastenheft-ERDs-GIs

Launch

List

Test

Analyse

-Diadem

-QS-Stat

-Minitab

Inspection devicesPrüfmittel

Ker

nel

Workflow

ManagementReport Generator

Order

Management

Release/Change

Management

BOM

Management

Document

Management

People and

Organisation

Test Data

Management

Cost

Estimation

Web Services (D)VP & (R) ODBC

Inte

rface

s


Specification of PaTIS

Specification

• Functional assessment

• Technical assessment

• Commercial assessment

Templates for supplier benchmark:

• Risk assessment

Outcomes of the workshops were consolidated with the specification


Assessments process - plan

Comercial

Assessment

+

Technical

Assessment

+

EstimatedTotal Cost

of Ownership

Short

listed

Vendors

(3 ?)

Functional

Assessment

+

ReferenceCustomerInterview

+

ComercialNegotiation

Winner !18 Vendors


Obstacles and Surprises

• Common definition of terms

• Presentation of facts which should SOMEHOW be resolved

• Different concepts of vendors

• Weighting of assessment lists

• Corporate IT-strategie

• Who should / should not be included (Pro – Contra) Scope


Current status


Remaining Topics

• Open points / go through the assessment lists

• Elaborate / Present concepts

• Weighting

• References

• Contracts / Negotiation

• Decision


Thank you for your attention!

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