lehrstuhl für virtuelle produktentwicklung complexity ... · 05/10/2011 · plm should be the...

© 14.3.2011 Eigner VPE Folie: 1

Lehrstuhl für Virtuelle Produktentwicklung

Martin Eigner

Complexity Management and PLM

© 14.3.2011, Eigner VPE Folie: 3


Agenda

1 |

3 | External and Internal Variance

…

2 | Solutions for Variant Handling: Neutral and Generic BOM

4 | Simplexity – Symplify the Things

5 | Strategic Product Planning and Architecture

Complexity Management and PLM 2011

1 | Complexity based on Multidisciplinary Products



Example Cayenne

Interior Modules: 660

Pipes: 1.200 - 1.500

Pins: 600 bis 2.000

length of pipe: approx..: 2.800 m, 60-70 kg

32 Vehicle-specific Cable Ducts

Source: Porsche AG

Complexity based on more function and higher variation



Example BOSCH From 1 engine to 2 engines

No Kinematic based on electronically reverse

Dashboard space free

Shift Variance to Software and Electronic

Example BMW

All variants based on the same 2 liter engine

Differentiation based on different SW calibrations

116

118

120



□ Mechatronic…

□

Mechanik Mechanic

Electronic

IT

Mecha- tronic

IT

Mechanic

Electronic

Mecha- tronic

…yesterday (1968) …tomorrow ???

Source: vgl. [me] 2.2010

When Software and Electronic becomes stronger, why should we use methods from

Mechanic & Hierarchical Requirements and Function Structure?

Software Becomes a Dominant Factor of the Product



□ Mechatronic Elements

Sensor and Control Unit ECU electronic components

software

control

mechanics

testing / diagnosis

HIL simulation testing

Quelle: BOSCH

Software/Electronic becomes stronger….. Example: Adaptive Cruise Control



Interdisciplinary Product Design based on an Extended V-Model

Anforderungs-

definition

Produkt-

Planung Entwicklung

Prozess-

planung Produktion Betrieb Recycling

Mechanik

E/E

Software

Dienst-

leistung

…

virtuelle Tests

Eigenschaftsabsicherung

Modellbildung- und Simulation

A/R

F

L

P A/R: Anforderung/Requirements

F : Funktion

L : logische Lösungselemente

P : physikalische Elemente

Integrierte Funktions- und Eigenschaftsabsicherung

(Model Based Design) Modellbildung und Simulation (Simulink, MATLAB, Modelica)

Disziplinenspezifische Modellbildung

(M-CAD, E-CAD, CASE)

Modellbildung, Beschreibung (z.B. in SysML, ModelicaML

physische Tests

hybride Tests

(z.B. HIL)



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

Model based Design for Mechatronic Design




Anforderungs-

definition

Produkt-

Planung Entwicklung

Prozess-


Mechanik

E/E

Software

Dienst-

leistung

…

virtuelle Tests



A/R

F

L


F : Funktion




(Model Based Design)

Modellbildung, Beschreibung (z.B. in SysML, ModelicaML

physische Tests

hybride Tests

(z.B. HIL)



Systems Modeling becomes Part of the Engineering

multidisciplinary requirements modeling

360 rotation

360 rotation around point

max speed

collision detection

Original statement

Systeme: Doors, Requisit Pro, XML PLM-Systeme

Left drive

motor

gear

wheel

pinion 1

pinion 2

pinion 3

pinion 4

optic rotation measurement

LED

opt. sensor

ASURO

SE Systeme (SysML, ModellicML)

Multidisciplinary Requirements , Function, Behavior and Building Block Modeling

multidisciplinary E-BOM □ Supporting Systems Modeling

- Combined structures in the early phases of product development



Example: Requirements for a MicroRobot

□ Engineering of a requirement structure with linked elements

System /Functional BOM

Satisfied by a function

Extracted requirements

Satisfied by a component

Engineering BOM



Example for concept models (Architecture)

□ System structure

- Block definitions

- Internal structure

Internal structure of the control

<<electronic>>

Internal structure of the drive

<<mechanic>>

Engineering BOM

MircoRobot

Circuit board

…

Drive chassis

Controller

Sensor

motor

gear

wheel

…

…

electronics

mechanics



CAD/CASE authoring systems

All data in one PDM system

Requirements structure System /Functional BOM (e.g. SysML) Engineering BOM

Product Lifecycle Management (PLM)

Plan Concept Design …

Engineering (authoring systems in concept design, M-CAD, E-CAD, CASE)

Engineering BOM

System structure model

System behavior model

System requirements model

System /Functional BOM

System requirements System structure

System requirements System structure

System behavior

SE as an integrated part of a PLM concept

Requirements management tools

Deriving hierarchical structure information (e.g. via XML)

Requirements structure

F1_300_200_G.ASM

F3_300_211_B.PRT

F3_300_238_F.PRT

…

4XX_200.ASM

L224_300_200_HS.ASM



Plan Concept Design Validate Production Support

Requirements BOM System /Functional BOM Engineering BOM Simulation/Testing BOM Manufacturing BOM Service BOM

Production Systems

(ERP/MES)

Product Lifecycle Management

(PLM)

Product and Process Backbone Mechatronic




Anforderungs-

definition

Produkt-

Planung Entwicklung

Prozess-


Mechanik

E/E

Software

Dienst-

leistung

…

virtuelle Tests



A/R

F

L


F : Funktion




(Model Based Design) Modellbildung und Simulation (Simulink, MATLAB, Modelica)

physische Tests

hybride Tests

(z.B. HIL)



Tools Modelling and Simulation



Multidisciplinary modeling and simulation

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, …



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




Anforderungs-

definition

Produkt-

Planung Entwicklung

Prozess-


Mechanik

E/E

Software

Dienst-

leistung

…

virtuelle Tests



A/R

F

L


F : Funktion




(Model Based Design)

Disziplinenspezifische Modellbildung

(M-CAD, E-CAD, CASE)

physische Tests

hybride Tests

(z.B. HIL)



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



Agenda

1 |


…




1 | Design Methodology 2.0




The Solution: Neutral or Modular BOM

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 1020-27

down to round about 5000!!! BOM´s

Whiteboard for System Engineers



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



Product Family A

Cockpit

Steering column compl.

Dashboard

…

Distance tube

Steering wheel

…

Meters/gages

Dashboard upper part

Dashboard lower part

Airbag

…

(default/standard)

CRUISE=YES

CRUISE=YES & NAVI=YES

Legend

Product Family

Component in GPS

Position Variant with Rule

Item (Assembly or Part) …

Seats

3-spoke Steering Wheel 3004000751

4-spoke St. Wheel w/Cruise & Navi 3005600333

3-spoke Steering Wheel w/Cruise 2015700309

Generic Product Structure in Automotive

Machine Industry can use the same principles to simplify the Product Structure



Agenda

1 |


…








Order Configuration

Customer Smith

Car Type BMW 320i Convertible

Color Black

Extras

- Radio X25

Solution for Product Configuration

Product Structure

Product Configuration (Search for valid Solutions)

Prod. Variants Options

Constraints

…

Attach. parts ext.Attach. parts ext.

Car bodyCar body

……

VehicleVehicle

SeatsSeats

Seat, front leftSeat, front left

Seat cushionSeat cushion

BackrestBackrest

……

Foam0810

Backrest, Sport shape

Vachette leather, Heating1132

Structure7451

Trim cover8786

Foam0810 Foam0810





Structure7451 Structure7451

Trim cover8786 Trim cover8786

Seat rail0912 Seat rail0912

HeadrestHeadrest

ArmrestArmrest

ReclinerRecliner

Seat railSeat rail

...

Foam0812

Backrest, Normal shape

Alcantara1891

Structure7451

Trim cover9700

Foam0812 Foam0812


Alcantara1891


Alcantara1891



Armrest, Vachette leather4431

…...

Armrest, Vachette leather4431 Armrest, Vachette leather4431

…... …...

Foam0812


Textile1990

Structure7451

Trim cover6541

Foam0812 Foam0812


Textile1990


Textile1990



……

Armrest, Alcantara4530

…...

Armrest, Alcantara4530 Armrest, Alcantara4530

…... …...

Armrest, Textile8887

…...

Armrest, Textile8887 Armrest, Textile8887

…... …...

……

...

Deriving individual BOM

…


Car bodyCar body

……

VehicleVehicle

SeatsSeats



BackrestBackrest

……

HeadrestHeadrest

ArmrestArmrest

ReclinerRecliner

Seat railSeat rail

Foam0812


Alcantara1891

Structure7451

Trim cover9700

Foam0812 Foam0812


Alcantara1891


Alcantara1891



Headrest, Alcantara2001

…...

Headrest, Alcantara2001 Headrest, Alcantara2001

…... …...


Foam0813

Seat cushion, Normal shape

Alcantara1820

Structure7452

Trim cover2700

Foam0813 Foam0813


Alcantara1820


Alcantara1820




…...


…... …...

Recliner4502 Recliner4502

Sales

Engineering

Manufacturing

Solution Space



External Variance

Variance from the customer perspective External Variance

Selection of options leads to individual order-oriented solutions

Constrains determine valid combination of options

Solution Space

Product Configuration (Search for valid soltions))

1027

Order 8037

Selected Options

Customer Smith

Car Type Z41

Color Black

Extras

- Radio X25

- AirCondition Basic

- Crypton Light LC0



Internal Variance

…


Car bodyCar body

……

VehicleVehicle

SeatsSeats



BackrestBackrest

……

Foam0810



Structure7451

Trim cover8786

Foam0810 Foam0810








HeadrestHeadrest

ArmrestArmrest

ReclinerRecliner

Seat railSeat rail

...

Foam0812


Alcantara1891

Structure7451

Trim cover9700

Foam0812 Foam0812


Alcantara1891


Alcantara1891



Armrest, Vachette leather4431

…...

Armrest, Vachette leather4431 Armrest, Vachette leather4431

…... …...

Foam0812


Textile1990

Structure7451

Trim cover6541

Foam0812 Foam0812


Textile1990


Textile1990



……


…...


…... …...

Armrest, Textile8887

…...

Armrest, Textile8887 Armrest, Textile8887

…... …...

……

...

Derivation

…


Car bodyCar body

……

VehicleVehicle

SeatsSeats



BackrestBackrest

……

HeadrestHeadrest

ArmrestArmrest

ReclinerRecliner

Seat railSeat rail

Foam0812


Alcantara1891

Structure7451

Trim cover9700

Foam0812 Foam0812


Alcantara1891


Alcantara1891



Headrest, Alcantara2001

…...

Headrest, Alcantara2001 Headrest, Alcantara2001

…... …...


Foam0813


Alcantara1820

Structure7452

Trim cover2700

Foam0813 Foam0813


Alcantara1820


Alcantara1820




…...


…... …...

Recliner4502 Recliner4502

Orderoriented

BOM

Analysis Rules/Constrains

Options, Rules/Constrains Color = Black, Creme, Grey AirCondition = Basic, Comfort

Rule based Variant-BOM

Definition

Solution Space

Product Configuration (Search for valid soltions))

1027

Order 8037

Selected Options

Customer Smith

Car Type Z41

Color Black

Extras

- Radio X25

- AirCondition Basic

- Crypton Light LC0



Agenda

1 |


…








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



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.



Simplexity in Art and Design

Ora Ito (born 1977)



Reducing External Variance

Optimization



The inevitable Long (Thin) Tail

Varying demand for individual product variants

Reduce Variance

- Eliminate product variants not contributing to commercial success

0

10.000

20.000

30.000

40.000

50.000

60.000

70.000

80.000

Norm

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Manuell

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0

50.000

100.000

150.000

200.000

250.000

300.000

350.000

Stü

ckza

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Stü

ckza

hl k

um

mulie

rt

Accum

ula

ted Q

uantity

Quantity

by V

ariant

Product Variants

Example: leather seat without heating



Picture: Mathias Zagel

The inevitable Long (Thin) Tail

Technical constraints

- Exclude combinations that don’t work

Marketing/product management constraints

- Exclude/enforce combinations to “guide” customer



Reduce Variance with Constraints

Reduce possible combinations of option values

- Enforce desired combinations

- Avoid undesired combinations

- Reduced external variance of Car Seat, front left: 864 576 (-33%)

- Likewise reduced internal variance of all affected assemblies

SEATS SEA_SPRT (Sport) SEA_NORM (Normal)

SEAT_CVR SAD_VACH (Vachette leather) SAD_ALCN (Alcantara) SAD_TXTL (Textile)

SEAT_HEATING SEA_HEAT (Heating) SEA_none (none)

SEAT_ADJUST SAD_ELM (El. Memory) SAD_ELE (Electrical) SAD_MNL (Manual)

STEERING

STEER_R (RHD) STEER_L (LHD)

DOORS 2DOOR (2 Door) 4DOOR (4 Door)

COL_IN

CLI_BLK (Black) CLI_CRM (Beige) CLI_GRY (Gray)

ARMREST ARM_DRV (Arm rest Driver) ARM_none (none)

exclude

enforce

IT Tool: CONFIGIT

http://localhost/agileConfigurator/



Reducing Internal Variance

Optimization



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



“Multi Functionality” – Oversize it

Picture: Mathias Zagel



Utilize Symmetry



The new VW modular transverse product platform

Source: Volkswagen Sachsen GmbH

Reduction of combinations of tilt angle and geometric distance from

axle from 36 to 2

Unified engine positioning

Examples for characteristic elements

Standardized position of engine, gearbox, suspension, air

conditioning unit and pedals

Technical length

Standardized fixtures for different types of axles

Standardized fixtures for rear axle

bond control bar

axle Multi control bar

axle

1 2 3



Decouple Interfaces



Decouple Interfaces

Dock connector



Decouple Interfaces



Agenda

1 |


…








Variant Strategy

E D C B A

Synergie

E D C B A

Modul Strategy

(Reuse of Parts and Components across Plattforms)

Platform Strategy

.......

.......

Strategic Product Planning

Synergie



Cost and Benefit of Variants

Quelle: Prof. Dr. Schuh, University of Aachen

Turnover Cost

Optimum

Cost

/ T

urn

ove

r

Variation



Contact

Martin Eigner

Institute for Virtual Product Development (VPE) University of Kaiserslautern Postfach 3049

D-67653 Kaiserslautern

T +49/172/1524406

F +49/631/205-3872

[email protected]

vpe.mv.uni-kl.de

Thank you

mailto:[email protected]



lehrstuhl für virtuelle produktentwicklung complexity ... · 05/10/2011 · plm should be the...

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