Altair Process Manager Lean Methodology. FEM Process Automation and Optimization Using Lean Methods

Transcription

1 FEM Process Automation and Optimization Using Lean Methods Philipp Salomon, Markus Gfrörer, FEA Analyst, Tenneco Inc. European Emission Control R&D Center Edenkoben, Germany Account Manager, Altair Engineering GmbH Niederlassung Böblingen Abstract This presentation is to show the reorganization of FEA processes inside the FEA department of the European Tenneco emission control R&D center. Guidance to this reengineering has mostly been given by lean methodology. This Toyota invented approach gains productivity by identification and avoidance of non- value adding steps. Beyond process wait states, lean methodology also focuses on variance as well as on rework efforts. The introduction of lean at Tenneco has been accompanied by the University of Michigan. Altair engineering was involved in the automation of FEA specific processes by using the Hyper Works Process Manager.

2 Purpose accelerate work make reports right first time force a common understanding of analysis purpose for all participants establish clean and stable link between external supplier and FEA department free resources for advanced work keep on - site product know - how make task suitable for outsourcing increase supplier s capabilities outsource portion of repetitive process parts

3 Navigation Lean product development misunderstandings about Lean general overview on Lean methodology application example in the Tenneco FEA department Initial state current state analysis identification of process waste definition of future state deduction of target metrics Tools & Technology Altair HyperWorks ProcessManager Process overview in sketches Skilled people linking Tenneco and it s suppliers together Conclusion and outlook Discussion

4 What is Lean some very common misunderstandings of LEAN : appling LEAN means to sack lots of people they ll take away your last pencil reducing the staff to 50% by increasing the load to 150 % is LEAN

5 Focus of LEAN methodology Altair Process Manager RFQ - Start Concept Design Review Quote Waiting Rework Gateway A Design Rework design mitigation Wait for CFD Gateway Review Concept CAE CAE CAE Value added parts of the process are the traditional focus of cost saving activities LEAN focuses on NON value adding items

6 Identification of product development waste categories redundant tasks multiple inspection points Stop and go tasks Re- set up each time after process disturbance Unsynchronized concurrent tasks seems like the right thing to do, but is often the root cause of a great deal of waste large batch sizes cycle times increase with batch size, time waiting for huge data dumps Lack of system discipline lack of scheduling discipline causes arrival variation, which drives excessive queue times Reinvention waste re-creating or rediscovering knowledge Transaction waste time and effort in arranging the work to be done (administration overhead) Waiting waiting for data, answers, decisions, review events and available capacity System over utilization a system, loaded more than 80% of ist capacity reacts with dramatic effects on small changes External quality enforcement effort and expense expended to collect data that is never used High process and arrival variation variations in processes and arrival are two of the three primary contributors to long queues Hand offs transferring data from one party to another

7 Lean the three aspects Altair Process Manager skilled people High Performance Tools & Technologies Process

8 Application of value stream mapping 1K W 2KW Customer 3KW Customer 4K W Cus tomer 5KW 6KW 7KW Customer Customer Customer Team (SI) FEA Data list I Repo rt Data list I new data -Engine data -Hot End data -RW 1-2 P 80 h Info Info CCDes ign P 40 h CAD preparation Data list II CAD prep. -RW 1-2 Erros Data list II FEA order Review CCDurability (BI) FEA P 40 h P+D 40 h Check & assemble data Check of batch data P 24 h R FEM RW 8 OT FEA 8 OT FEA 8 OT 80% LCC resources Customer Customer FEA Customer Team (SI) Data list I S AP/PDM -Engine data -Hot End data Meeting - CCDes ign CAD preparation & Data list II Data Warehous e SDM Information Data Warehous e CCDurability (BI) FEA Kickoff Meeting -P resent P lan -Reques t Data FEA order Customiz ing TT: 1 h Check & assemble data Check of batch data FEM Cus tom. FEA Standard KAIZEN: due to Checklist Standards Workflow FE A work recording to TA -Standards

9 Navigation Lean product development misunderstandings about Lean general overview on Lean methodology application example in the Tenneco FEA department Initial state current state analysis identification of process waste definition of future state deduction of target metrics Tools & Technology Altair HyperWorks ProcessManager Process overview in sketches Skilled people linking Tenneco and it s suppliers together Conclusion and outlook Discussion

10 Current state analysis and identification of process waste 1KW 2KW Customer 3KW Customer 4KW Customer 5KW 6KW 7KW Customer Customer Customer T eam (SI) FE A Data list I Data list I new data -Engine data -Hot End data -RW 1-2 P 80 h Info Info CCDesign P CAD preparation Data list II CAD prep. -RW h Erros Data list II FEA order Review CCDurability (BI) FEA P 40 h P+D 40 h Check & assemble data Check of batch data P 24 h R FEM RW 8 OT FEA 8 OT FEA 8 OT 80% LCC resources Types Customer Eigenmode Static Vibration Roadload Thermal total no. of report formats required 2 '' '' '' '' '' '' repeated format 4 '' '' '' no specification 6 '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' '' 12 '' 1 '' '' 1 21 different report formats

11 Definition of future state Customer Customer Customer Team (SI) FEA Data list I SAP/PDM -Engine data -Hot End data Meeting - CCDesign CAD preparation & Data list II Data Warehouse SDM Information Data Warehouse CCDurability (BI) FEA Kickoff Meeting -Present Plan -Request Data TT: 1 h FEA order Check & assemble data Check of batch data product know - how FEM Custom. FEA work recording to TA-Standards FEA Standard Customiz ing keep on - site KAIZEN: due to Checklist Standards Workflow make task suitable for outsourcing increase supplier s capabilities outsource portion of repetitive process parts

12 Navigation Lean product development misunderstandings about Lean general overview on Lean methodology application example in the Tenneco FEA department Initial state current state analysis identification of process waste definition of future state deduction of target metrics Tools & Technology Altair Hyper Works Process Manager Process overview in sketches Skilled people linking Tenneco and it s suppliers together Conclusion and outlook Discussion High Performance skilled people Process Tools & Technologies

13 Altair Process Manager guided application collects tacit knowledge to well defined processes open architecture, TCL interface, plugin of 3rd party products is possible arbitrary level of user guidance can be designed into the processes interactive changes possible during workflow operations

14 Navigation Lean product development misunderstandings about Lean general overview on Lean methodology application example in the Tenneco FEA department Initial state current state analysis identification of process waste definition of future state deduction of target metrics Tools & Technology Altair Hyper Works Process Manager Process overview in sketches Skilled people linking Tenneco and it s suppliers together Conclusion and outlook Discussion High Performance skilled people Process Tools & Technologies

15 Correlation process (core part) Altair Process Manager FEA HVA Compare running modes spectra Measurement HVA Operational Modal Analysis Running Mode Correlation HZ H Z MAC Running Modes MAC Eigenmodes

16 Correlation process Correlation of Running Modes Correlation Table

17 Correlation process correlated stress evaluation Deformations Response spectra comparison HZ 1 HZ MAC quantifiable Quality

18 Navigation Lean product development misunderstandings about Lean general overview on Lean methodology application example in the Tenneco FEA department Initial state current state analysis identification of process waste definition of future state deduction of target metrics Tools & Technology Altair Hyper Works Process Manager Process overview in sketches Skilled people linking Tenneco and it s suppliers together Conclusion and outlook Discussion High Performance skilled people Process Tools & Technologies

19 skilled people two main impacts of the Process Manager driven result evaluation: new staff members can be trained in less than one day established staff members can invest their time in detail evaluations, new methodologies to return new skills.

20 Navigation Lean product development misunderstandings about Lean general overview on Lean methodology application example in the Tenneco FEA department Initial state current state analysis identification of process waste definition of future state deduction of target metrics Tools & Technology Altair Hyper Works Process Manager Process overview in sketches Skilled people linking Tenneco and it s suppliers together Conclusion and outlook Discussion

21 Target metrics 16 standa rdization clu ste rupda te, re start XP / Linu x on com mon platform comm on datam odel on cluster / wo rks ta tion automatization spectral processing parallel work / India LEAN EVENT III [Stunden] prove stability of solution standard FEA batch processing of complete workflow 0 Feb. 05 Mrz. 05 Apr. 05 Mai. 05 Jun. 05 Jul. 05 Aug. 05 Sep. 05 Okt. 05 Metric: types standardiza tion clusterupdate, restart XP / Linux on comm on platfo rm Anzahl Module Target real com mo n datamod el on cluster / workstation automatization spectral processing parallel work / India LEAN EVENT III batch processing of complete workflow 5 5 [Stunden] correlated FEA Jul. 05 Feb. 05 M rz. 05 Apr. 05 M ai. 05 Jun. 05 Aug. 05 Sep. 05 Okt. 05 Monat 0 Feb. 05 Mrz. 05 Apr. 05 Mai. 05 Jun. 05 Jul. 05 Aug. 05 Sep. 05 Okt. 05

22 keep on - site product know - how make task suitable for outsourcing increase supplier s capabilities outsource portion of repetitive process parts

23 Bibliography / references Altair Process Manager Garcia, Patrick, Tenneco - Heinrich Gillet GmbH, Drogosz, John, Optiprise - University of Michigan: Lean Engineering Best Practice in the Automotive Industry, Conference Efficient Development processes and process orientated structures, Axel Schröder & Partner, 2006 Garcia, Patrick, Tenneco - Heinrich Gillet GmbH, Drogosz, John, Optiprise - University of Michigan: Schlanke F+E Von der Strategie bis zum Einzelprojekt, 3. Lean Management Summit, Aachen, 2006 Jeff Liker (Editor): Becoming Lean : Inside Stories of U.S. Manufacturers, Productivity Press, Portland, Oregon, 1998 Morgan, J. M., Liker, J. K: The Toyota Product Development System, Productivity Press, Oregon, 2006 Morgan, J. M., Liker, J. K: Lean Product and Process Development, 2006 Pantleon, Thomas, Weyrich, Michael - DaimlerChrysler Research and Technology India: Captive Offshore-Services from India presentation on DC CAE / EDM Forum 2007 Stuttgart Ohno, T., : The Toyota Production System: Beyond Large Scale Production, Productivity Press, Oregon, 1988 Womack, J. P., Jones, D. and Roos, D.: The Machine That Changed The World, Harper Perennial, 1988