MITIGATING!WASTE,!DELAY!AND!RISK!

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1 MITIGATINGWASTE,DELAYANDRISK INTODAY SDESIGNREVIEWS: FINDING&ANSWERS&IN&RENEWED&DESIGN&VISUALIZATION& Respondents)in)the)2014)Design) Validation)and)Review)study)stated)they) averaged)20.5)design)reviews)a)month,) essentially)one)per)working)day.) Executed)poorly,)this)high)volume) activity)siphons)productivity)into) overcoming)barriers)to)the)process) instead)of)the)design)cycle. Published&by:&

2 2 PAGE MITIGATINGWASTE,DELAYANDRISKINTODAY SDESIGNREVIEWS Introduction Today'sstreamofnewtechnologyisendless.Everyday,some newsoftwareapplicationthatpromisestorevolutionize productdevelopmentisintroducedtogreatfanfare.yetwhen itcomestoimprovingqualityandmeetingdeadlines, companiesstillrelyonslow,manual,paper>basedreviews. WithmanysupplychainparticipantsusingdifferentCAD applications,loadingmulti>cadassembliestocheckfor interferencesisproblematic.thereisastrongneedtogetnon> engineeringparticipantsinvolvedinthedesignefforteven thoughmostmodelscan'tbeaccessedoutsidecad.mostrely on ,anincrediblyunsecuremeansofsharingdata,topass designmodelsbackandforth. Whyistheneedtoaddressthisissuesoacutenow?Recent researchhasshownthattheirimpactmayhavepreviously beenunderestimated.respondentsinthe2014&design& Validation&and&Review&studystatedtheyaveraged20.5design reviewsamonth,essentiallyoneperworkingday.inlarge companies,thataverageshootsupto57designreviewsa month,roughlyequatingto3perworkingday.thisisahigh volumeproblemthataffectsengineersandnon>engineers alike.executedpoorly,itsiphonsproductivityintoovercoming thesebarriersinsteadofintothedesigncycle.thegoodnews isthatthereareexistingsolutionsthathavebeenenhancedin newreleasestoaddresstheseproblems. ThereinliesthepurposeofthiseBook.Inthefollowingpages, morefindingsfromthe2014&design&validation&and&review& studyandthe2013&3d&collaboration&and&interoperability& studyaresharedinthecontextofdesignreviewchallenges. Furthermore,theevolutionoftheenhancedexistingsoftware applicationsisdetailed.lastly,theimpactontheorganization isreviewed.inall,itismeanttoprovideguidanceonhowto addressthislongstandingandseeminglyforgottenproblem. Newtechnologieswillcontinuetoemerge.Yetthatdoesn t meanthehighvolumeissueswithdesignreviewsshouldbe forgotten,especiallywheneasyandpragmaticsolutionsare availablenow. The)2014)Design)Validation)and)Review)study,)conducted)by) PTC,)collected)responses)from)over)280)participants)on)the) practices)and)technologies)related)to)effective)design) validation)and)design)reviews)processes)in)engineering.) Results)of)the)study)can)be)reviewed)in)a)published) infographic.) The)2013)3D)Collaboration)and)Interoperability)study,) conducted)by)lifecycle)insights,)collected)responses)from) over)800)participants)on)the)practices)and)technologies) related)to)interoperability,)modelkbased)initiatives)and)the) use)of)3d)in)the)enterprise.)

3 3 PAGE MITIGATINGWASTE,DELAYANDRISKINTODAY SDESIGNREVIEWS Terminology:DesignReviews,Design ValidationandDFX Ifthereisonethingthatmostpeopletrackingnew technologiescanagreeupon,it sthattheterminologycanbe terriblyconfusing.beforewelaunchdeeperintodesign reviews,itmakessensetodefinesometerms. DesignReview Adesignreviewisaprocesswhereengineeringpeerevaluate anindividual sdesignagainstitsform,fitandfunction requirements. Thismayincludeareviewofthemethodologiesandpractices usedduringthedesignprocess.thisactivitycanincludea rangeofdeliverables,including3dmodels,2ddrawings, documentsandmore.furthermore,thisactivityincludes differentwaystointerrogatethedesign,including measurements,interferenceorclashchecks,animations, requirementstraceabilityaswellassimulationandanalysis. Itisaclosedloopprocesswherethefeedbackisalways providedtotheindividualwhoownsthedesign. DesignValidation Designvalidationisaprocedurewhereotherproduct developmentparticipantschecktheimpactofadesign. Thiscouldoccurinadesigncontext,whereanotherengineer verifiesaneighboringdesigndoesnotnegativelyaffecttheir design.italsoincludesnon>engineeringscenarios,wherenon> engineeringparticipantsexaminetheviabilityofdownstream activitiesincludingmanufacturability,serviceabilityandmore. Amachinistmaychecktoseeifcuttingtoolscanreach undercuts.aserviceplanningmayseeifcomponentscanbe physicallyremovedtocompleteaserviceprocedurewithout clashesorinterferences. Incontrasttodesignreviews,thisisanopenloopprocess, wherefeedbackisonlyprovidedtotheindividualwhoowns thedesignifproblemsareencounteredorasacollaborative effortamongstanentireteam,whetherthatbeinsideor outsideengineering. DesignforX(DFX) DFXprocessesareamixtureofdesignreviewanddesign validationwherenon>engineeringparticipantsprovide feedbackonthefeasibilityofdownstreamactivities. Furthermore,itisdifferentinthetimingoftheactivity,where DFXprocessesareconductedearlierinthedesigncyclesothe engineercanbeaccommodatedchangesmoreeasily. Thisisaclosedloopprocesswherethefeedbackisalways providedtotheindividualwhoownsthedesign.

4 MITIGATINGWASTE,DELAYANDRISKINTODAY SDESIGNREVIEWS TheTroublewithDesignReview Findingsfromthe2014&Design&Validation&and&Review&study showthatdesignreviewsarehighvolumeactivities,butdoes thismeantheycauseproblemsforindividualsandthe organization?thissectionprovidesdetailedanswerstothat questionbysharingcriticalfindingsfromthe2014&design& Validation&and&Review&studyaswellasthe2013&3D& Collaboration&and&Interoperability&study,showingthereis seriouswasteandriskintheseprocesses,astheyexisttoday. GettingtheEnterpriseInvolvedinDesignReviews Traditionally,designreviewshavebeenaveryengineering focusedactivity.that,however,haschangeddramatically. Today sdesignsmustbedevelopedtakingcompany>wide factors,notjustform,fitandfunction,intoaccount.a product scommercialviabilitymustbeverified.partsmustbe purchasedatcompetitiveprices.aproduct smanufacturability mustbevalidated.serviceproceduresmustbecertified. Manufacturingengineersandmachinistsmustplanbillsof processorcheckmanufacturabilityofadesign. Theissueinthiscircumstanceisthatpracticallynoneofthese rolesusethehighlytechnicalcadapplicationsneededtowork withdesigndata.findingsfromthe2014&design&validation& and&review&studyshowthattheratioofcaduserstonon>cad usersinvolvedindesignrevieweffortsis100:123.soforevery 100CADusers,thereare123participantsthatdonotuseCAD. Thisbecomesproblematicasthecontextfortheseactivities are3dmodelsand2ddrawings,whichtraditionallyrequire CADapplications. Therearemanyissuesasaresult.Deliverablesthatareused forthebasisofdesignreviewsexistinmanydifferentforms, includingmodels,drawings,ecaddataanddocuments.togain accesstodesigndataandfiles,non>engineeringparticipants requestcustomizedscreenshotsfromengineers,distracting bothfromtheirday>to>daywork.additionally,non>engineering participantsthendocumenttheirfeedbackinformats,like images,documentsandspreadsheets,thatcan tbeopenedin CADapplications,whereengineerswouldmakemodifications tothedesign Insummary,aCAD>reliantprocessrequirestoomuchfrom participantsonallsides.non>engineeringrolesneedtoolsto letthemworkwithdesigndataautonomously. PAGE 4

5 MITIGATINGWASTE,DELAYANDRISKINTODAY SDESIGNREVIEWS TheMultiSCADComplexityofSupplierInvolvement Designreviewsareneverrunsolelywithinasinglecompany. Theyoftenshootoutintoothersuppliers,partnersand customers.infact,perthe2014&design&validation&and&review& study,4outof5respondentsstatedthattheyincludedata fromsuppliersaspartoftheirdesignreviewprocesses.that,in turn,meansthatthe3dmodels,2ddrawings,documentsand otherdeliverablescomeinanarrayofformats.evenifan organizationcanconsolidatetheircadapplications,theywill stillneedtoworkwithdesigndatainavarietyofformats. Workingwithdataandfilesinanumberofformatsisn t problematicperse.therealissueliesinthetranslationofthe datawhenitgoesfromoneapplicationtoanother.findings fromthe2013&3d&collaboration&and&interoperability&study showedthat50%oftoday sengineersspendatleast4hoursa weekfixing3dgeometry.justtobeclear,that snottime interrogating,analyzingorverifyinganything. Forengineers,thatistimespentfixingamodelordrawingjust tostartthatwork.thattimefixingdataisutterlylostandnon> valueadded.butfurthermore,engineershavetodraw togetherdesigndatafromamultitudeofsupplierstomockup thefullproductforclashdetection,interferenceandmore. Overall,alotoftimeisspentfixingorpullingtogethertheright dat.findingsfromthesamestudyfoundthat50%ofengineers workatnightsortheweekendstocatchup. Whilefixingandpullingtogetherdesigndatapaintsanugly pictureforengineers,theproblemsareactuallyworsefornon> engineers.machinists,serviceplannersandothernon> engineeringroleslackthetechnologyaswellastheknowledge andskillstofindtherightdataorevenfixthesetranslation problems.inthosescenarios,thedesignreviewprocessstops deadinitstracks.ifclosingthatfeedbackloopisimportantto thecompany,thenthisissuerepresentsasignificantdelayorit iscapturedoutofcontextinscreencaptures,documentsor spreadsheets.ifitisnotcritical,thentheloopisn tclosedand feedbackisn tprovided,resultinginerrorsthatproceed downstream. Allinall,dataexchangeandworkingwithmulti>CADdatain thesupplychainisaseriousissue,forengineers,the organizationaswellaseveryoneelseparticipatingindesign reviews.improvedcapabilitiestoread3dmodels,drawings anddocumentsinawidevarietyofformatsareneededto addressthisissue. PAGE 5

6 MITIGATINGWASTE,DELAYANDRISKINTODAY SDESIGNREVIEWS TheRisksofOutdatedDesignSharingPractices It'sanalltoofamiliarscenario.Aworkemergency,adesign failureatacustomer,landsonyourdeskat3pmfriday afternoon.youstaylatethatnight,improvisingafixtothe problem.youknowthedigitalsecurityprocedures,including theoneaboutnot ingdesigndata.yetthetechnical centeroverseasthatneedstoreviewitwillstarttheirshiftina fewhours.you itanyway. Ifyou'vedonethat,thenyou'renotalone.Infact,findings fromthe2013&3d&collaboration&and&interoperability&study showthatover70%oftoday sengineerssharedesigndata externallyvia ,afrighteninglyinsecurewayto collaborate.obviously,thatrepresentsabigintellectual propertyprotectionissueforthecompany.ifacompetitorgets aholdofthedesign,thenitcanbereplicated,perhapseven fasterthanyourcompanycanbringittomarket. Ofcourse,therearealternativestosharingdesigndeliverables via .someorganizationsareturningtowardsgeneric cloud>basedsharingspaces.thisprovidesameansofsharing individualfiles,butcadapplicationdataisn tsosimple. Assemblymodelsincludetensifnothundredsofindividual files.unfortunately,cloud>basedsharingtoolsdon t understandthestructureofcaddesigns,forcingusersto manuallydeterminewhichfilestouploaded. Overall,designreviewparticipantshavefewchoicesinterms ofsharing3dmodels,drawingsanddocuments.theyeither exposethemselvesandthecompanytoriskwhenusing orhavetomanuallymanagegreatercomplexitywhenusing genericcloud>basedsharingservices. PAGE 6

7 MITIGATINGWASTE,DELAYANDRISKINTODAY SDESIGNREVIEWS TheRenewalofDesignVisualizationandCAD Findingsfromthe2014&Design&Validation&and&Review&study andthe2013&3d&collaboration&and&interoperability&study showthattherearebigchallengesindesignreviewstoday. DesignVisualizationapplications,whichhavebeenavailable formorethanadecade,havebeenimprovedwithnewand enhancedcapabilitiesthatdirectaddresstheseissues.this sectiondetailsthatfunctionality. CapabilitiesEnablingNonSEngineers Highlytechnicalsoftwareisgreatfortheengineering organization,whoseparticipantsoftenhavemore sophisticatedskillsandknowledge.butastheseprocesses haveexpandedoutsideofengineering,newtoolsareneeded fornon>engineers.moderndesignvisualizationapplications includecapabilitiesthataddresstheproblems,including: Ease&of&Use:Manyoftheparticipantsindesignreviews willbecasualusers.theymayusethedesign Visualizationapplicationonceoneweekandthenevery daythenext.thesetoolshavebeenredesignedfor easynavigation,providingdiscoverableandeasytofind functionality. Right&Functionality&for&the&Job&at&Hand:Justbecause processparticipantsmightbecasualusersdoesn t meantheydon tneedcapabletools.theywillneedto markupdesignswithtextandsymbols,takecomplex measurements,validatetheaccuracybetweenpairsof deliverableslikemodelsanddrawings,checkfor interferencesandclashes,exposeproductand manufacturinginformation(pmi),createanimations andfarmore.designvisualizationapplicationsinclude thesecapabilitiestoenableallparticipantstoexecute theirtaskswhilemakingthemeasytouseand discoverable. Improved&Performance:DesignVisualization applicationsarealsoverylightweightintermsof footprintandperformance.theycannowhandlelarge assembliesandcomplexgeometrymodels,eliminating lagissuesthathaveplaguedsuchactivitiesinthepast. PAGE 7

8 MITIGATINGWASTE,DELAYANDRISKINTODAY SDESIGNREVIEWS CapabilitiesEnablingRiskSFreeDesignSharing Designreviewprocessesaren tjustaboutparticipantsinside thefourwallsofamanufacturer.italsoincludesanumberof criticalparticipantsinthecustomers,suppliersandpartnersin thedesignchain.assuch,sharingdesigndatafortheprocess inasecuremanneriscritical.onthisfront,several advancementshavebeenmade. Existingprojectandproductsharingspaceshavemadethe movetosomecombinationofpubliccloud,privatecloudand on>premiseconfigurations.thesesystemsunderstandcad applicationdata,allowinguserstoavoidthemanual managementoffileswhilestillmaintainingtheeaseofsharing toexternalpartiesovertheweb. CapabilitiesAddressingDataFormatsandExchange Designreview,becauseoftheinvolvementoftheentiredesign chain,isinherentlyamulti>cadactivity.inrecentyears,design exchangecapabilitieshaveincorporatedanumberofcritical capabilitiesthataddressthisreality. Opening&a&Variety&of&Data&Types:Designdataexistsin awidevarietyofformats.designvisualization applicationscannowopenthefullrangeoffilesthat casualandexpertuserswillencounterindesign reviews,makingsuretheprocessdoesn tstopdeadin itstracks. Opening&Native&Formats:Acriticalfirststepinanyof theseprocessesistoaccess3dmodels,2ddrawingsor documentsinarangeofformats.designvisualization andcadapplicationshaveexpandedtheircapabilities toopensuchfilesintheirnativeformats.thiscuts downonthelikelihoodofbrokengeometryor inaccuratedrawingsinthefirstplace. PAGE 8

9 9 PAGE MITIGATINGWASTE,DELAYANDRISKINTODAY SDESIGNREVIEWS TheImpactofNewTechnologies Theadoptionofthepracticesandtechnologiescoveredinthis ebookimplysomeadvantagesandbenefits.however,itis importanttospecificallyprojectaswellasmeasurethesuccess thatsuchchangesbring.thefollowingprovidesguidancein termsofexpectationsaswellasmetricstotrackinthoseareas. ShorterCycles,ReducedDownstreamErrors ThecapabilitiesofthelatestversionsofDesignVisualization andcadapplicationsallowmanydifferentparticipantstorun theseprocessesmoreaccurately,smoothlyandefficiently.one typeofconsequenceisareductionintheamountoftimeit takestoexecutetheseactivities,reducingthechancesthat importantmilestonesaredelayed.anotheroutcomeisthat criticalissuesarecaughtpriortodesignreleaseinsteadof downstreamwheretheybloomintooutrightemergencies. Metricstotrackincludethecycletimetoexecutethese processesaswellasthenumberofchangeorders,boththat occurbeforeandaftercustomerdelivery.bothmeasures shouldgodownovertime. ReducedDistractions,IncreasedAutonomy Anotherbenefitofadoptingnewpracticesandtechnologiesis thereductionintheamountofassistanceanyparticipant needsduringdesignreviews.forexample,amachinistcan startanddocumenttheirmanufacturabilityfeedbackonhisor herowninsteadofwalkingtoandwaitingatanengineer s desk.theengineercandedicatemoretimetodesignwork insteadofopeningupa3dmodelincadandshowingittothe machinists.bothemployeesavoiddelaysanddistractions. Metricstowatchwouldbeemployeeefficiency,which representsthepercentoftheirdayspentoncore responsibilitiesinsteadofnon>valueaddedactivitieslike walking,waitingandopeningmodelsforothers.those measuresshouldgoupovertime. HigherRetainment Anotherimportantareaofimprovementistheunplanned extratimethatanyemployeespendsatwork.thereductionof emergencyactionandprojectreprioritizationthatleadsto overtimehassomehardcostadvantages.overtimewages, whereapplicable,canbeavoided,translatingintobottomline costsavings.buttherearehumancapitalretainment advantagesaswell.engineersandotheremployeesthatwork expectedhoursaremorelikelytostay.giventoday'sshortage ofengineersandotherskilledtechnicalworkers,thatisan advantagethatshouldnotbeoverlooked. Metricsrelevanthereincludethenumberofextraorovertime hoursworkedperweek.thesemeasuresshouldgodownover time.

10 10 PAGE MITIGATINGWASTE,DELAYANDRISKINTODAY SDESIGNREVIEWS SummaryandRecommendations Thereareseriouschallengesfordesignrevieweffortstoday. However,improvementstoDesignVisualizationandCAD applicationspromisetohaveabigimpact,forboth organizationsandindividuals. TheTroublewithDesignReview Perthe2014&Design&Validation&and&Review&study,4outof5 respondentsincludedatafromsuppliersintheirdesign validationandreviewprocesses.findingsfromthe2013&3d& Collaboration&and&Interoperability&studyshowedthat50%of today sengineersspendatleast4hoursaweekfixing3d geometry.thisisanon>valueaddedtimesinkforengineers. Butfornon>engineers,itisanoutrightshowstopper. Reviewsofdesignsareincreasinglybecominganenterprise activity.findingsfromthe2014&design&validation&and&review& studyshowthattheratioofcaduserstonon>cadusers involvedindesignrevieweffortsis100:123.thisbecomes problematicasthecontextfortheseactivitiesare3dmodels and2ddrawings,whichtraditionallyrequirecadapplications, evenfornon>engineers. Gettingdesigndatatotherightparticipantsisnoeasytask. Findingsfromthe2013&3D&Collaboration&and&Interoperability& studyshowthatover70%oftoday sengineerssharedesign dataexternallyvia .newcloud>basedsharingappsdon't understandcadfiles,forcinguserstomanuallymanage complexdata.withthefirst,employeesareputtingthe company'sintellectualpropertyatrisk.withthesecond, participantsspendmoretimeonnon>valueaddedtasks. TheRenewalofDesignVisualizationandCAD DesignVisualizationapplications,whichhavebeenavailable formorethanadecade,havebeenimprovedwithnewand enhancedcapabilities,including: DesignVisualizationtoolscanopennativefilesfrommanyof today'scadapplications,practicallyeliminatingtheneedtofix geometry.suchapplicationscanalsoexchangedesignswith CAD,allowingengineerstoopenmarkupsinCAD. DesignVisualizationtoolsareeasytousefornon>engineers, yetofferadvancedfunctionalityliketheabilitytotake measurements,createcross>sectionsandmuchmoreforthem toparticipateintheseprocesses. Projectandproductsharingspacesunderstandinherently understanddesigndata,reducingrisktointellectualproperty withoutburdeninguserswithtechnicalknowledgeofcadfiles. Thesetoolshavesignificantlyprogressedrecently,warranting closerconsideration.theyrepresentarealopportunityto addressthelongstandingchallengesofdesignreview. For)more)information)on)this)topic,)visit)PTC s)site.)ptc)has) licensed)this)ebook)for)distribution.)all)concepts)and)ideas)were) developed)independently.) )2014K2015)LCKInsights)LLC) ChadJackson,thePrincipalAnalystof LifecycleInsights,isarecognizedauthority ontechnologiesthatenableengineering, includingcad,simulation,pdmandplm. Contact/Follow: