Systems Driven Product Development

Transcription

1 Systems Driven Product Development UMTRI Focus on the Future September 15, 2010 David Taylor Sr. Director, Automotive Marketing

2 The process of building vehicles has never been more complex ENVIRONMENT INFORMATION GLOBALIZATION SAFETY Emissions Infotainment Emerging Markets Active/Passive Propulsion Driver assistance Global Development Telematics Energy efficiency V2X Global sourcing Connection based Materials ELV Service Global manufacturing Sensor based Page 2

3 Software Usage in Vehicles Innovation by source Contribution to revenue SOFTWARE 60% SOFTWARE 70% SOFTWARE 4% ELECTRONICS 16% MECHANICAL 80% SOFTWARE 15% ELECTRONICS 25% MECHANICAL 60% Electronics 20% Electronics 20% Source: McKinsey 2006 Page 3

4 Is the problem getting bigger? Lin nes of Code (Millions) Automotive Embedded Software Lines of Code Industry Projection Software Development Capability Metrics NASA: defects per KLOC Average Supplier: 4-6 defects per KLOC Poor supplier: 6-10 defects per KLOC Model Year Overall automotive software complexity is growing exponentially Number of Lines of Code is growing exponentially Number of distributed software-system solutions growing rapidly Number of system dependencies (coupling) growing Number of Customer input signals growing exponentially Page 4

5 Electronics cs failures Pandemic? a Chrysler: recalls for brake computer systems BMW 754i: Software error leads to recall Ford: 3.6M vehicles recalled for cruise control Mercedes-Benz: $30M recall... Drive-by-wire problem Toyota Prius: recall due to software in Hybrid Engine Mercedes-Benz: Useless electronic features dumped 60%-90% of electronic failures in vehicles are because of mechanical issues - say due to vibrations and introduce a crack in the multi- module chip Failure Modes and Mechanisms in Electronic Packages By Puligandla Viswanadham and Pratap Singh Page 5

6 Is this an organizational issue? Design Engineer Mechanical Engineer Software Engineer Electrical Engineer Management D&R Engineer CAE Engineer Suppliers Electronic Engineer Platform Engineer Advanced Vehicle Engineer Page 6

7 Is Systems Engineering the answer for Automotive? Systems Engineering - an interdisciplinary field of engineering that focuses on how complex engineering projects should be designed and managed. Holistic View Multidisciplinary Interdisciplinary Well Defined Manage Complexity Or does it create more complexity? Behavior Systems Thinking Interdependency Interaction Page 7

8 Requirements Distillation & Decomposition Veh hicle definition Customer requirements PROGRAM DEFINITION Ideation Vehicle requirements PROGRAM Plant, process INITIATION Theme requirements development System requirements SYSTEM DESIGN SYSTEM VALIDATION Concept design Engineer ring definition Sub-system requirements Component requirements SUB- SYSTEM DESIGN COMPONENT DESIGN SUB-SYSTEM VALIDATION COMPONENT VALIDATION Preliminary design Component detailing Page 9

9 V-Model Automotive Systems Engineering Cross-Domain Veh hicle definition CUSTOMER VIEW Customer Vehicle Plant, Process Ideation Theme development Engineer ring definition ENGINEERING VIEW System Sub-system Component Mechanical Electrical Electronics Software Process Plant SYSTEM DESIGN SUB- SYSTEM DESIGN SYSTEM VALIDATION SUB-SYSTEM VALIDATION Concept design Preliminary design Component detailing Implementation COMPONENT DESIGN COMPONENT VALIDATION Page 10

10 Key PLM Requirements to Deliver Systems-Driven Product Development Page 11

11 Requirements, Company Standards, Regulations Standard vehicle functional model Vehicle Technical Spec Targets Vehicle Integration Areas Vehicle Integration Areas Vehicle Integration Areas Fuel Economy System-level Functional model System-level VTS Sub-system Functional Sub-System ModelTechnical Spec Calculated Component Functional Model Component Technical Spec Behavioral Models Physical Models Page 12

12 Vehicle-level functions driving design process Requirements and Functional network, allocation to logical structure Vehicle Integration Area Fuel Economy Engine Parameters Trans. Parameters Torque Conv. Parameters Driveline/ Final Drive Parameters FEAD Loads Chassis Loads VIA Mass VIA Aero Drag Gross Torque Induction Losses Exhaust Losses Rotating Intertia Fuel Map Gearing & Shift Schedule Trans. Losses Rotating Inertia Torque ratio/stiffness Rotating Inertia Torque Conv. Losses Torque Conv. Locking schedule Rotation Inertia Gearing Losses/ efficiency Power Steering Loads Compressor Loads Alternator Loads Fan Loads Brakes/ bearings Tires Rotating inertia Drag Coef Frontal Area Lugging Limits Idle Speeds Page 13

13 System Integration Architecture and Physical Architecture make complexity manageable System Integration Architecture Physical Architecture Fuel Economy Engine Parameters Exhaust Losses Function Behavioral Model Wire Harness CAD part Page 14

14 Architecture facilitates reuse Page 15

15 Key PLM Requirements to Deliver Systems-Driven Product Development Systems Engineering Page 16

16 Key PLM Requirements to Deliver Systems-Driven Product Development Configuration Systems Engineering Page 17

17 System-based design with consistent configuration management across all domains FW A B C Manuals F Variant A A Master Product Configuration Platform D E G H SW HW HW K I L J System FW Variant B A FW B C F E G SW HW HW K I L D C HW HW K F I H L J FW Page 18

18 Key PLM Requirements to Deliver Systems-Driven Product Development Configuration Systems Engineering Page 19

19 Key PLM Requirements to Deliver Systems-Driven Product Development Configuration Systems Engineering Change, Issue and Schedule Management Page 20

20 Key PLM Requirements to Deliver Systems-Driven Product Development Page 21

21 Key PLM Requirements to Deliver Systems-Driven Product Development Configuration Systems Engineering Change, Issue and Schedule Management Page 22

22 Key PLM Requirements to Deliver Systems-Driven Systems Driven Product Development Open Foundation Systems Engineering Configuration Change, Issue and Schedule Management Page 23

23 Key PLM Requirements to Deliver Systems-Driven Systems Driven Product Development Open Foundation Systems Engineering Configuration Change, Issue and Schedule Management Page 24

24 Key PLM Requirements to Deliver Systems-Driven Systems Driven Product Development Open Foundation Configuration Traceability Systems Engineering Change, Issue and Schedule Management Page 25

25 Thank you! ありがとう! Merci! 고맙습니다! Dziekuje! Bedankt! 谢 谢! 謝 謝! Tack! Dêkuji! Danke! תודה Obrigado! Gracias! Page 26 Grazie! धन यव द!