Closed-Loop Engineering Integrated Product Development at a Vehicle Manufacturer

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1 Closed-Loop Engineering Integrated Product Development at a Vehicle Manufacturer Dr. Stephan Kohlhoff Geschäftbereich Automotive SAP Deutschland AG & Co KG

2 Agenda Motivation Closed-Loop Engineering Vehicle Development Process Parts Progression Test and Validation Plan Vehicle Usage an Build Plan Prototype Build (Shop Floor Planning & Control, Procurement & Logistics) Vehicle Usage (Testing) and Results Documentation Summary SAP AG 2003, Title of Presentation, Speaker Name / 2

3 Validation Loops in the Vehicle Development Process Development Path Validation Disruption Disruption Disruption Concept & Analysis Prototyping & Development Integration & Validation SAP AG 2003, Title of Presentation, Speaker Name / 3

4 Agenda Motivation Closed-Loop Engineering Vehicle Development Process Parts Progression Test and Validation Plan Vehicle Usage an Build Plan Prototype Build (Shop Floor Planning & Control, Procurement & Logistics) Vehicle Usage (Testing) and Results Documentation Summary SAP AG 2003, Title of Presentation, Speaker Name / 4

5 Process Overview Rohkaros. Karosserie Verkleidung Projekt B42 B42 Motor Antriebsstrang Getriebe Project structure according product and organisational aspects. Project master timing for major components 1. Vehicle Development Process 6. Vehicle Usage (tests) & Results Documentation After delivery prototypes are tracked according to the vehicle usage plan. Planned & unplanned rebuilds are kept in the vehicle history and test results are documented with reference to the product structure Fahrw. 2. Parts Progression Parts Progression for all parts and their usage are connected to the vehicle development plan. Bench A-Tafel Assy 1 Assy 2 B I W Türen Eng Ass Dress Up Getriebe 5. Prototype Build Vehicle usage provides delivery requirement dates for the prototype shop. This triggers capacity requirements for the shop floor and material requirements for procurement. Vehicle usage for prototypes are build up from vehicle test requests which are derived from test and validation plans 4. Vehicle Usage & Build Plan 3. Test & Validation Plan Test and validation plans for all development phases are derived from the vehicle development plan SAP AG 2003, Title of Presentation, Speaker Name / 5

6 Process Overview Rohkaros. Karosserie Verkleidung Projekt B42 B42 Motor Antriebsstrang Getriebe Project structure according product and organisational aspects. Project master timing for major components 1. Vehicle Development Process 6. Vehicle Usage (tests) & Results Documentation After delivery prototypes are tracked according to the vehicle usage plan. Planned & unplanned rebuilds are kept in the vehicle history and test results are documented with reference to the product structure Fahrw. 2. Parts Progression Parts Progression for all parts and their usage are connected to the vehicle development plan. Bench A-Tafel Assy 1 Assy 2 B I W Türen Eng Ass Dress Up Getriebe 5. Prototype Build Vehicle usage provides delivery requirement dates for the prototype shop. This triggers capacity requirements for the shop floor and material requirements for procurement. Vehicle usage for prototypes are build up from vehicle test requests which are derived from test and validation plans 4. Vehicle Usage & Build Plan 3. Test & Validation Plan Test and validation plans for all development phases are derived from the vehicle development plan SAP AG 2003, Title of Presentation, Speaker Name / 6

7 Derivation of Test & Validation Plan from Master Plan Project Project B42 B42 Body Body Powertrain Powertrain Vehicle Vehicle Test Test B.I.W. B.I.W. Interior Interior Engine Engine Transmission Transmission Vehicle Build Vehicle Build Testing Testing Test Test & Validation Validation Plan Plan Test Test & Validation Validation Plan Plan Test Test & Validation Validation Plan Plan Test Test & Validation Validation Plan Plan SAP AG 2003, Title of Presentation, Speaker Name / 7

8 Context of the Validation Plan Product Structure Requirements / Goals Test Standards Validation Plan Durability Program 21 (Compr. Factor 1,5) Run: km Duration: 6 Months Simulation Laboratoty Vehicle Part (Ser.Nr) (System) Failure Mode 1 Failure Mode 2... Mesurement km Hrs Cyc Validation Activity Validation Object SAP AG 2003, Title of Presentation, Speaker Name / 8

9 Derivation of the Validation Plan Projekt B42 Projekt B42 Body Body Overall Project Structure Requirements / Goals B.I.W. B.I.W. Interior Interior Durability: > km Component Plan Validation Plan Bad Road Test Programm 21 SAP AG 2003, Title of Presentation, Speaker Name / 9

10 Vehicle Request derived from Validation Plan Durability Drivability Sommer Test Brake Test Winter Test Pass-by Noise Emission Test SAP AG 2003, Title of Presentation, Speaker Name / 10

11 Process Overview Rohkaros. Karosserie Verkleidung Projekt B42 B42 Motor Antriebsstrang Getriebe Project structure according product and organisational aspects. Project master timing for major components 1. Vehicle Development Process 6. Vehicle Usage (tests) & Results Documentation After delivery prototypes are tracked according to the vehicle usage plan. Planned & unplanned rebuilds are kept in the vehicle history and test results are documented with reference to the product structure Fahrw. 2. Parts Progression Parts Progression for all parts and their usage are connected to the vehicle development plan. Bench A-Tafel Assy 1 Assy 2 B I W Türen Eng Ass Dress Up Getriebe 5. Prototype Build Vehicle usage provides delivery requirement dates for the prototype shop. This triggers capacity requirements for the shop floor and material requirements for procurement. Vehicle usage for prototypes are build up from vehicle test requests which are derived from test and validation plans 4. Vehicle Usage & Build Plan 3. Test & Validation Plan Test and validation plans for all development phases are derived from the vehicle development plan SAP AG 2003, Title of Presentation, Speaker Name / 11

12 Test Plan & Vehicle Usage/Test Plan Test Plan Durability Drivability Sommer Test Brake Test Winter Test Pass-by Noise Crash MVSS 208 Crash MVSS 214 Emission Test Vehicle Test Plan P1 P2 P3 C1 C2 P Different Option Codes 6 Rebuild 5 SAP AG 2003, Title of Presentation, Speaker Name / 12

13 Vehicle Usage Plan Extension of Pool Car Solution Available Prototypes Vehicle Requests Plan per drag & drop Planned SAP AG 2003, Title of Presentation, Speaker Name / 13

14 Validation Plan in the Project Planning Board SAP AG 2003, Title of Presentation, Speaker Name / 14

15 Prototyp Planning Board Result of Validation Planning SAP AG 2003, Title of Presentation, Speaker Name / 15

16 Effect of Appling Vehicle Request Option Codes SAP AG 2003, Title of Presentation, Speaker Name / 16

17 Warning Configuration Conflict SAP AG 2003, Title of Presentation, Speaker Name / 17

18 Dispatching Filter SAP AG 2003, Title of Presentation, Speaker Name / 18

19 Process Overview Rohkaros. Karosserie Verkleidung Projekt B42 B42 Motor Antriebsstrang Getriebe Project structure according product and organisational aspects. Project master timing for major components 1. Vehicle Development Process 6. Vehicle Usage (tests) & Results Documentation After delivery prototypes are tracked according to the vehicle usage plan. Planned & unplanned rebuilds are kept in the vehicle history and test results are documented with reference to the product structure Fahrw. 2. Parts Progression Parts Progression for all parts and their usage are connected to the vehicle development plan. Bench A-Tafel Assy 1 Assy 2 B I W Türen Eng Ass Dress Up Getriebe 5. Prototype Build Vehicle usage provides delivery requirement dates for the prototype shop. This triggers capacity requirements for the shop floor and material requirements for procurement. Vehicle usage for prototypes are build up from vehicle test requests which are derived from test and validation plans 4. Vehicle Usage & Build Plan 3. Test & Validation Plan Test and validation plans for all development phases are derived from the vehicle development plan SAP AG 2003, Title of Presentation, Speaker Name / 19

20 Agenda Closed-Loop Engineering Vehicle Development Process Parts Progression Test and Validation Plan Vehicle Usage an Build Plan Prototype Build (Shop Floor Planning & Control, Procurement & Logistics) Vehicle Usage (Testing) and Results Documentation Summary SAP AG 2003, Title of Presentation, Speaker Name / 20

21 Summary Validation is a very important and integral part of the vehicle development process and is very often characterized by numerous system disruptions Closed-Loop Engineering integrates the areas of product documentation, design, validation & test, and quality management. To implement it several prerequisites need to be fulfilled: 1: Integrated validation, prototype build, and prototype test schedule planning 2: Validation planning and prototype build as a configurable Engineering order process 3: Closed Loop: Design protoytpe build test & development design via system integration SAP AG 2003, Title of Presentation, Speaker Name / 21

22 Prerequisite for Closed-Loop Engineering Configurable Engineering BOM for Prototypes Maintenance of configuration parameter (option codes) early in the development phase Development steps along a defined development path with fixed design stages used as effectivity parameter for configuration Prototype test sequence documentation (rebuild, problem notifications) System integration as prerequisite for avoidance of Information loss Product Structure & Configuration Validation and Prototype Planning Prototype Build Test Execution Quality Management SAP AG 2003, Title of Presentation, Speaker Name / 22

23 Thank you for your attention!

24 Copyright 2004 SAP AG. Alle Rechte vorbehalten Weitergabe und Vervielfältigung dieser Publikation oder von Teilen daraus sind, zu welchem Zweck und in welcher Form auch immer, ohne die ausdrückliche schriftliche Genehmigung durch SAP AG nicht gestattet. In dieser Publikation enthaltene Informationen können ohne vorherige Ankündigung geändert werden. Die von SAP AG oder deren Vertriebsfirmen angebotenen Softwareprodukte können Softwarekomponenten auch anderer Softwarehersteller enthalten. Microsoft, WINDOWS, NT, EXCEL, Word, PowerPoint und SQL Server sind eingetragene Marken der Microsoft Corporation. IBM, DB2, DB2 Universal Database, OS/2, Parallel Sysplex, MVS/ESA, AIX, S/390, AS/400, OS/390, OS/400, iseries, pseries, xseries, zseries, z/os, AFP, Intelligent Miner, WebSphere, Netfinity, Tivoli, Informix und Informix Dynamic ServerTM sind Marken der IBM Corporation in den USA und/oder anderen Ländern. ORACLE ist eine eingetragene Marke der ORACLE Corporation. UNIX, X/Open, OSF/1 und Motif sind eingetragene Marken der Open Group. Citrix, das Citrix-Logo, ICA, Program Neighborhood, MetaFrame, WinFrame, VideoFrame, MultiWin und andere hier erwähnte Namen von Citrix-Produkten sind Marken von Citrix Systems, Inc. HTML, DHTML, XML, XHTML sind Marken oder eingetragene Marken des W3C, World Wide Web Consortium, Massachusetts Institute of Technology. JAVA ist eine eingetragene Marke der Sun Microsystems, Inc. JAVASCRIPT ist eine eingetragene Marke der Sun Microsystems, Inc., verwendet unter der Lizenz der von Netscape entwickelten und implementierten Technologie. MarketSet und Enterprise Buyer sind gemeinsame Marken von SAP AG und Commerce One. SAP, SAP Logo, R/2, R/3, mysap, mysap.com und weitere im Text erwähnte SAP-Produkte und -Dienst-leistungen sowie die entsprechenden Logos sind Marken oder eingetragene Marken der SAP AG in Deutschland und anderen Ländern weltweit. Alle anderen Namen von Produkten und Dienstleistungen sind Marken der jeweiligen Firmen. SAP AG 2003, Title of Presentation, Speaker Name / 24

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