00 HELLA PLM Lecture ALL Script PDF

PLM with SAP PLM at UPT 2012
1/23/2013
Product Lifecycle Management with SAP PLM

Dr. Emanuel Slaby, Timisoara, October 2012
F-7761EN_C (2011-06)
Product Lifecycle Management with SAP PLM Agenda

Introduction Referee and Hella Todays challenges in the manufacturing industry Introduction PLM Project PDM goes PLM Organization of next sessions
Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012
1/23/2013
Introduction of Hella KGaA Hueck & Co. Company profile

Partner of the automotive industry and the aftermarket for over 100 years Global family-owned company with 70 locations in more than 30 countries Sales of 4.8 bn. FY 2011-2012 More than 27,000 employees worldwide, thereof 4,800 in Research & Development One of the top 50 automotive suppliers in the world and the 100 largest German companies
Business Divisions:
Lighting
Headlamps Signal Lamps Interior Lighting Lighting Electronics Front-end Modules
Electronics
Driver Assistance Body Electronics Energy Management Vehicle Electric Systems
Aftermarket/Special OE
Lighting Electrics Electronics Thermal Management Technical Service
Industries
LED - Street Lamps Airfield Lighting
3
People Counter Interior Lighting systems


Introduction Referee and Hella Todays challenges in the manufacturing industry Introduction PLM Project PDM goes PLM Organization of next sessions
1/23/2013
Product Lifecycle Management with SAP PLM Todays challenges in the manufacturing industry
1. Less time available for developing new products 2. Higher product complextity 3. Growing competition and tighter budgets 4. Internationalisation of business 5. Shortening delivery times 6. Regulations and common industry standards
Product Lifecycle Management with SAP PLM Changes in Product time on market
Source: Feldhusen, RWTH Aachen
1/23/2013
Product Lifecycle Management with SAP PLM Changes in Product time on market
Sold units [mio]
Time on market [years]

Source: Feldhusen, RWTH Aachen
Product Lifecycle Management with SAP PLM The engineers use of time
Project Management
Communication Information Engineering work
Source: VPE, M. Eigner
1/23/2013
Product Lifecycle Management with SAP PLM Product complexity 1980
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Product Lifecycle Management with SAP PLM Product complexity 2009
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Product Lifecycle Management with SAP PLM Product complexity 2012: Headlamp with adaptive cut off line
http://www.youtube.com/watch?v=lVxIB84 ETNE&list=UUTuzRa0kw5iMhsZRNA3AL QA&index=7&feature=plcp
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Product Lifecycle Management with SAP PLM Willingness to pay
What the customer wants...
What the customer is willing to pay...
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Product Lifecycle Management with SAP PLM Today: Many locations and suppliers
Lead-Konstrukteur
z. B. Lippstadt
Konstrukteur
z. B. USA
China
PDM
Konstrukteur Konstrukteur
z. B. Mexiko z. B. Indien
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Product Lifecycle Management with SAP PLM Past: Sequential processes
Sales
Design engineering
Process engineering
Production planing
Production
Shipping
Source: Dr. Montau, ETH Ztich
Sales
Design engineering
Process engineering
Production planing
Production
Shipping
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Product Lifecycle Management with SAP PLM Today: Concurrent engineering

Past:
Sales Design engineering Process engineering Production planing Production Shipping
Today:
Sales Design engineering Process engineering Production planing Production Shipping
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Product Lifecycle Management with SAP PLM Projects to keep all focused on a common goal
Why Projects?
Cooperation of departments over the borders of organisation
Focus activities of many people from different units towards one common goal
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Product Lifecycle Management with SAP PLM Customer Requirements Documents
norms / laws
terms of delivery technical & quality specifications

VDI DIN ISO
customer requirement documents

customer norms
... ... ...
... ... ...
requirements
project specific requirements
packaging regulations
company specific conditions
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PEP Product Engineering Process
F-7761_C (2011-06)
Introduction to PEP Product Engineering Process

Problem description Situation today How do we get on top efficiently?
SOP
4
Qualifik. Prozess
Betriebsm. Freigabe
2
K-Freigabe
1
Vorbereitung/ Planung
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PEP it self is useless. Better behaviour of people is the target. Without smart PEP this will maintain a vision
Status order
E B prepare project C find & select development concept D detail & describe product & process realize production & supply
F qualify product & process
G stabilize operation & quality
A develop draft & create quote
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Gate Transition
request: PJM approval: steering commitee (all domains)
main process 1
main process 2
WP WP
WP
WP WP
SP
WP tollgate
request: core team / PJM confirmation: dedicated line manager
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Process Management: Introduction
Timisoara, Nov 2012
F-7761_C (2011-06)
Process Management: Introduction Definition
What is a process?
Customer Input
Tasks
Output
Customer
A Process is: is a set of interrelated tasks which transform inputs into outputs
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Process Management: Introduction Definition
Customer Input
Tasks
Output
Customer
Resources
These tasks need the allocation of resources like people or materials.

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Process Management: Introduction Inputs and outputs of processes

Produced goods: produced workpieces Services Software Documents / Records
Customer Input
Loaned goods: Workpieces Information Obtained goods: Operation materials auxiliary materials Production materials
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Tasks
Output
Customer
Resources
Humane Rolle Tools / operating resources operation locations warehouse
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Process Management: Introduction How? efficiency What? effectivity
Cooperation
Input
Tasks
Output
Efficienc y
Effectivity
Resources
Improvement
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Process Management: Introduction
Why do organisations need processes?
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Process Management: Introduction Why Processes?
Interfaces
+
Functional barriers Hierarchical barriers
Operative Islets
Fragmented Organisation
Growth and specialization tend to build operative islets.
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Process Management: Introduction Why Processes?
Management
Sales
Development
Production
Process
Functions included in the order processing
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Product Lifecycle Management with SAP PLM Expectation of audience
What is your understanding of PLM?
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Product Lifecycle Management with SAP PLM Definition of PLM
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Product Data Management at Hella A structured procedure to tackle data chaos

Product Lifecycle Management (PLM)
Product lifecycle management is a strategic concept to support engineering processes (PEP, ECM,) through a structured and consistent management of all engineering data as well as the implementation of processes.
PDM System
Organisation Data System

CAD PDF ...
PDM
Processes
A PDM system enables an IT supported die IT based creation and management of product data during the entire product lifecycle.
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Product Data Management Typical PDM Functions
Master Data and Structure
Document Management
Group Techniques
Project Management
Change and Release Management
Integration
Identity and Access roghts Managemnt
Data Replication
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Product Lifecycle Management with SAP PLM Definition of PDM: Document Management
Which product is concerned? Which is the current? What means V1.0 resp. V2.0? Who released it? The author?
Which one was rejected?
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Product Lifecycle Management with SAP PLM Definition of PDM: Master Data
Characteristic master data Description - semantic meaning - alleviates searching Identification (material-no.) - clear in the system Function specific data - status, revisions level, responsible dept. Other master data - Specific information like e.g. weight
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Repetition: Why Projects and Processes? PEP: Many IT tools Product Data Management PDM as 1st step Product Lifecycle Management PLM as holistic approach Organization of next sessions
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Product Lifecycle Management with SAP PLM Many IT Tools as Islets

Tool landscape today
SAP PS PV
GMT
iPC CATIA DW
MS Project
B e a rb e itu n g s s ta n d : 3 0 .0 1 .2 0 0 4
F o rd C D 340 E rf llu n g s g ra d g e s a m t
100% 100%
100% 90% 80%
P r o z e s s r e if e g r a d e [ % ]
70% 60% 50% 40% 30%
PMR
88% 88% 75% 50% 0% 0% 25% 25%
50% 50%
20% 10%
13%
25% 13%
Lnder
0 % 0% 19.09.200521.10.2005 0 % 0% 24.10.200516.12.2005 0 % 0% 19.12.200503.02.2006
0% 27.08.200407.10.2004 Daten W erk z euge Las tenheft W erk z euge 01.12.200421.12.2004 B em us terung W erk z euge 13.06.200505.08.2005 Daten M ontagelinie
Las tenheft M ontagelinie
B em us terung M ontagelinie
F ull run tes t
PDM Excel
ERP P2R
eMPlanner
P ro ze s s re ife (i.O .Me rkm ale ) E rg e b nis lie g t no c h nic ht vo r
Me rkm al n.i.O . Z ie lwe rt
NIS
DOORS Audit DB
Word MKS
LoP FMEA
RMT
Heterogenous landscape of methods and
tools
Appr. > 200 IT tools with many manual
interfaces
Huge controlling effort because all functions
have to be synchronized
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Repetition PEP: Many IT tools Product Data Management PDM as 1st step Product Lifecycle Management PLM as holistic approach Organization of next sessions
43
Product Lifecycle Management with SAP PLM Many IT Tools as Islets
PDM System
PDM
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Product Lifecycle Management with SAP PLM Product Lifecycle Management PLM as holistic approach
Release and Eng. Change Mgmt Document Management
Group Techniques
Project Master DataManagement and Structure
Change and Release Management Document Management
Integration
Access rights Managemnt
Data conversion
Data Replication
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Product Lifecycle Management with SAP PLM Core of PLM
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Product Lifecycle Management with SAP PLM Access to Product Data
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2D Format tiff Clutch.tiff

(pdf, postscript,...)
2D
3D
3D Format jt Clutch.jt
(STEP, 3D pdf, 3D xml, 3D CAD native formats...)
CATIA V5: Clutch.CatProduct
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2D Format tiff Clutch.tiff
3D Format JT Clutch.jt
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Group Techniques
Integration
Data conversion
Data Replication
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Product Lifecycle Management with SAP PLM Data Formats for Archiving: JT
JT: - 3D data format developed by Siemens PLM Software - for product visualization, collaboration, and CAD data exchange - can contain any combination of - approximate (faceted) data - exact boundary representation surfaces (NURBS) - Product and Manufacturing Information (PMI) - Metadata (textual attributes) - exported from the native CAD system - inserted by a product data management (PDM) system - probably the most widely used 3D visualization format
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Product Lifecycle Management with SAP PLM Data Formats for Archiving: TIFF
TIFF (Tagged Image File Format) file format for storing images
ISO 12639:2004 (Second edition) standard for TIFF/IT
2D
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Product Lifecycle Management with SAP PLM Data Formats for Archiving: PDF / 3D PDF
PDF (Portable Document Format) file format to represent documents independent of application software Hardware operating systems encapsulates a complete description of a fixed-layout document (text, fonts, graphics)
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Product Lifecycle Management with SAP PLM Data Formats for Archiving: 3D PDF
3D PDF (3D Portable Document Format) file format to represent 3D documents independent of application software Hardware operating systems encapsulates a complete 3D model including additional information
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Group Techniques
Integration
Data conversion
Data Replication
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Product Lifecycle Management with SAP PLM Definition of PDM: Master Data to describe an item
Characteristic master data Description - semantic meaning - makes searching easier Identification (material-no.) - clear in the system - classification Function specific data - status, revisions level, responsible dept. Other master data - Specific information like e.g. weight
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Product Lifecycle Management with SAP PLM Classification for items
Classification
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Definition of terms Object: Material: Is a classifiable item (e.g. material, vendor, work centre) All objects of the company Procures produces stores Sells For these objects (materials) a material master is created. These objects can be parts (components) raw materials groups(assemblies) operating supplies appliances (products) machine spares packaging materials production resources/tools technical process data which are virtually entered as a part with a process number
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Definition of terms Material type: Is a grouping of materials having identical properties. The material type has important controlling functions. Is a group of objects (in this case material) having identical or similar properties. Key for the object to be classified
Class:
Class type:
Characteristic: Describes the property (e.g. length, weight, (raw) material) of an object. Value of characteristic: Value of characteristic (e.g. 10 cm, 15 kg, copper).
(Raw) material group: Grouping key for a (raw) material is a characteristic in the classification system.
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Product Lifecycle Management with SAP PLM Classification for items: Example 1
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Product Lifecycle Management with SAP PLM Classification for items: Example 2
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Product Lifecycle Management with SAP PLM Classification for items: Characteristics
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Product Lifecycle Management with SAP PLM Product Structure
Product Structure
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Product Lifecycle Management with SAP PLM BOM: Bill of material: Engineering- / Manufacturing-BOM
BOM Bill of material A bill of material is a list of: raw materials sub-assemblies intermediate assemblies sub-components parts the quantities of each needed to manufacture an end product used for communication between manufacturing partners A BOM can define products as designed (engineering bill of materials) as ordered (sales bill of materials) as built (manufacturing bill of materials) or as maintained (service bill of materials).
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BOM Bill of material
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General Bill of Material (BOM) The BOM is a list of all parts and/or assemblies required to produce a composite object (product or assembly). Engineering Bill of Material (= E-BOM) This BOM represents the view of the Design department and includes all parts and assemblies, which belong to a productThe structure can deviate from the M-BOM. Manufacturing Bill of Material (= M-BOM) This BOM represents the view of the Production Dept. There must be a BOM available for every part (or assembly) that has is produced in the plant and has routing. The structure of this BOM is adapted to the production sequence. If necessary, the M-BOM contains additional items such as raw materials, operating supplies as well as packaging material for finished products.
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PreBOM (early BOM) Bill of material for quotation phase and early concept phase (until creation of E-BOM), which is available as a new function of SAP PLM/ Part (Component) A part (component) is an object that cannot be taken apart without it being destroyed. Assembly An assembly is an object consisting of two or more parts and/or assemblies (of lower order). Product A product is a usable or saleable object resulting from production. Device Is a specific term for a product with complete function (no service part). A device is a product consisting of a number of parts and/or assemblies.
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E-BOM M-BOM
Device (FERT)
E-BOM / M-BOM deviations Raw materials, packaging etc. Parts in purchasing assemblies subassemblies (more than one component) Quantities in LED selection groups E-BOM position split into multiple M-BOM positions Assemblies with only one positions warning
Device (HALB) P1 P2 P3 P4 P5 GR 1 P6 P7 GR 2 P8 P9
VERP VERP LEER Device (HALB) P1 P2 P3 P4 P5 GR 1 P6
P10 GR 2
Purchasing assembly
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PLM with SAP PLM at UPT 2012

Product Lifecycle Management with SAP PLM

Product Lifecycle Management with SAP PLM Agenda

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Introduction of Hella KGaA Hueck & Co. Company profile

People Counter Interior Lighting systems

Product Lifecycle Management with SAP PLM Agenda

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

Source: Feldhusen, RWTH Aachen

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Sold units [mio]

Time on market [years]

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

Communication Information Engineering work

Source: VPE, M. Eigner

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

Product Lifecycle Management with SAP PLM Product complexity 1980

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Product Lifecycle Management with SAP PLM Product complexity 2009

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

http://www.youtube.com/watch?v=lVxIB84 ETNE&list=UUTuzRa0kw5iMhsZRNA3AL QA&index=7&feature=plcp

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

Product Lifecycle Management with SAP PLM Willingness to pay

What the customer wants...

What the customer is willing to pay...

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

Product Lifecycle Management with SAP PLM Past: Sequential processes

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Product Lifecycle Management with SAP PLM Today: Concurrent engineering

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

Product Lifecycle Management with SAP PLM Customer Requirements Documents

terms of delivery technical & quality specifications

customer requirement documents

... ... ...

project specific requirements

company specific conditions

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

PEP Product Engineering Process

Introduction to PEP Product Engineering Process

Prodcut Lifecycle Management | Dr. E. Slaby | Hella | Timisoara, October 2012

PLM with SAP PLM at UPT 2012

F qualify product & process

G stabilize operation & quality

A develop draft & create quote