magna steyr

Magna SteyrAUTODESK UNIVERISTY

Las Vegas – November 15, 2018

Robert Ostermann

Digital Factory – Factory DNA

Personal Introduction

15 November 2018 2Author: Robert Ostermann Disclosure or duplication without consent is prohibited

Robert Ostermann

• Factory designer

• At Magna Steyr Fahrzeugtechnik

AG & Co KG, Graz since 2000

• Mechanical engineer for factory design and

expert for factory models in different OEM

projects

Agenda

Company Presentation

Digital Factory

Factory DNA

15 November 2018 Author: Robert Ostermann Disclosure or duplication without consent is prohibited 3

Reflects the real world

Agenda


Digital Factory

Factory DNA



Management


VEHICLE ENGINEERING &

MANUFACTURING

Karl StrackePresident

COMPLETE VEHICLES

Mike BissonPresident

SEATINGEXTERIORS

Grahame BurrowPresident

BODY & CHASSIS

John FarrellPresident

BODY EXTERIORS & STRUCTURES SEATING SYSTEMS POWER & VISION

ELECTRONICS

Kelei Shen

President

POWERTRAIN

Swamy Kotagiri

President

MECHATRONICS,

MIRRORS, LIGHTING

John O’HaraPresident

Tom Skudutis Swamy Kotagiri

Don Walker Chief Executive Officer

Tom Skudutis Chief Operating Officer

Jim Tobin Chief Marketing Officer, President Magna Asia

Swamy Kotagiri Chief Technology Officer

Günther Apfalter President Magna Europe

Mike Sinnaeve VP Operational Improvement & Quality

Chief Financial OfficerVince Galifi

Mark Dong President Magna China

Günther Apfalter

Management

6

VEHICLE ENGINEERING &

MANUFACTURING

Karl StrackePresident

COMPLETE VEHICLES

Mike BissonPresident

SEATINGEXTERIORS

Grahame BurrowPresident

BODY & CHASSIS

John FarrellPresident

BODY EXTERIORS & STRUCTURES SEATING SYSTEMS POWER & VISION

ELECTRONICS

Kelei Shen

President

POWERTRAIN

Swamy Kotagiri

President

MECHATRONICS,

MIRRORS, LIGHTING

John O’HaraPresident

Tom Skudutis Swamy Kotagiri

Don Walker Chief Executive Officer

Tom Skudutis Chief Operating Officer

Jim Tobin Chief Marketing Officer, President Magna Asia

Swamy Kotagiri Chief Technology Officer

Guenther Apfalter President Magna Europe

Mike Sinnaeve VP Operational Improvement & Quality

Chief Financial OfficerVince Galifi

Mark Dong President Magna China

Guenther Apfalter

Author: Robert Ostermann Disclosure or duplication without consent is prohibited15 November 2018

Magna Steyr – Range of Services


EngineeringComplete Vehicle

ManufacturingFrom systems and modules

to complete vehicle engineering Flexible world-class solutions from niche to

volume production

Flexible and global solutions, customized for OEMs

Complete Vehicle Manufacturing in Graz – Different CustomerPrograms at one location

Hall 1

Hall 12

Hall 2

Hall 8

Custom

Manufacturing

Mercedes-Benz G-ClassBody-In-White (Hall 2), Assembly (Hall 12)

BMW 5 Series

BMW Z4

New Program, SOP 2019(Hall 3, 81, 82)

Jaguar E-PACE

Jaguar I-PACE

(Hall 1, 2, 3, 39, 71)

Paint Shop

(Hall 8, 14)

Engineering

Hall 14

Hall 39

Engineering

Center

Hall 81

Hall 3

Hall 82

Hall 71Jaguar

I-PACE

since 2018

Jaguar

E-PACE

since 2017

New program

start in 2019

Test Track

Apprentice Training

CenterPrototype Build

15 November 2018 8

New Mercedes-

Benz G-Class

since 2018BMW Z4

since 2018

BMW 5

since 2017

Author: Robert Ostermann Disclosure or duplication without consent is prohibited

Audi

V8L

1990 – 1994

VW Transporter

T3 4x4

1984 – 1992

VW

Golf Country

1990 – 1991

Voiturette

1906

Alpenwagen

1919

Puch

500 / 650 / 700c / 126

1957 – 1975

Haflinger

1959 – 1974

Pinzgauer

1971 – 2000

3.3 Million Automobiles Made in Graz

BMW X3

2003 – 2010Saab

93 Cabrio

2003 – 2009

Chrysler

300 C

2005 – 2010

Jeep Grand Cherokee

WH

2005 – 2010

Jeep

Grand Cherokee

ZG/WG/WJ

1994 – 2004

Mercedes-Benz

E-Class

1996 – 2002

Mercedes-Benz

M-Class

1999 – 2002

Chrysler

Voyager

2002 – 2007

Mercedes-Benz

E-Class

2003 – 2006

Peugeot

RCZ

2010 – 2015

Jeep

Commander

2006 – 2010

Aston Martin

Rapide

2010 – 2012

Mercedes-Benz SLS

Aluminium body

2009 – 2014

MINI

Countryman

2010 – 2016

MINI

Paceman

2012 – 2016

Jaguar E-PACE

since 2017

JaguarI-Pace

since 2018

BMW 5 Seriessince 2017

New Programstart 2019

Mercedes-Benz G-Class

since 1979

BMW

Z4since 2018


Agenda


Digital Factory

Factory DNA



Volatile markets Political and regional market changes

New technologies and increasing

complexity

What’s the Challenge?


Reflects the real worldEfficient processes

Better quality and reduced

start-up costs

Shorter start-up phase to

reach the production peak

Reduction of investment

and production costs

Real vehicle

Virtual factoryVirtual vehicle

Real factory

12

Digital Factory

15 November 2018 Author: Robert Ostermann Disclosure or duplication without consent is prohibited

Serial productionRamp upDevelopment[t]

[#]

Shortened

product-development process

Reach

production peak

faster

Reach

operating points faster

Modifications during

shutdown

TA SOP PS

Faster speed, lower costs, higher efficiency and increased quality

13

Digital Factory – Objective: Maintaining a Competitive Advantage


Agenda


Digital Factory

Factory DNA



VIDEO

../../../CAD/TH/81/VP_GJ29/FM/H81-GJ29-DWF-Animator-04c.mp4

Digital Standards

• Every click can be converted into monetary units

• Digital Standards are required for Magna’s efficient

workflows in addition to our established technical

and visual standards

• Successful implementation of the Digital Factory

needs a shift in historical structures and mindsets


Digital Standards

• Describes a “digital code” focusing on meta data in a:

- Factory model

- CAD-system

- Data management

• Value and purpose:

- Improves the overview and structure

- Connection between different data

- Inheritance of data properties

- Enables a mapping of standards

- Sets a basis for change management

- Enables an interface to other systems

Factory

DNA15 November 2018 Author: Robert Ostermann Disclosure or duplication without consent is prohibited 17

Digital Standards


Systems for Model Generation and Data Management

Data Management

Factory Layout

Production Facilities

Model

Factory

Model

Building

Model

Author: Robert Ostermann Disclosure or duplication without consent is prohibited 1915 November 2018

Factory Model

Data Management

Building Model

Production Facilities Model

Digital Standards

Data Structure

Lifecycle

Data Properties


Data Management

Standards

• Buildings

• Documentation

• Templates

• Change history

• Standard structures

• Project structures

• Supplier structures

Data Management Standards


Data structure



Data structure Lifecycle



Data Structure Lifecycle Data properties



Flexible data structure and filtering

Building evaluation

Data properties

Level of detail

Phase of change


Building Model

Standards

• Authority management

• Project management

• Execution plan (fine)

• Factory integration (middle)

• Analysis (rough)



• Data links

• Structural analysis

• Structural physics

• Energy analysis

Building Model Standards


Data properties

26


Data managementFactory model/layout

CAD-model/layout

Data properties

MS_Resource: 02-04-04-03

MS_Resource: 02-04-04-03




Feine Detaillierung im Maßstab 1:50 Mittlere Detaillierung im Maßstab 1:100 Grobe Detaillierung im Maßstab 1:200

Data properties Level of detail

High level of detail – Scale 1:50 Mid level of detail – Scale 1:100 Rough level of detail – Scale 1:200



Red lines: NEW

Yellow lines: DEMOLISHED

Black lines: EXISTING

Data properties Level of detail Phase of change



Data properties Level of detail Phase of change Building evaluation



Building model and technical building equipment

Data properties

Level of detail

Supplier integration


Production Facilities

Standards

• Handoff library

• Return and audit

• Coordination model

• Detailed construction

• Factory integration

• Rough planning



• Data links

Defined

type-properties

Predefined

instance-properties

Production Facilities Standards


Reduced part (Level of detail)Highly detailed construction

Library part Layout/model partCase 1: Individual construction

Defined

type-properties

Via data management

“inherited”

Defined

type-properties

Defined

instance-properties

“inherited”

Data properties

Defined

type-properties

Predefined

instance-properties



Library part Layout/model partCase 2: Parametric part

Defined

type-properties

Via data management

“inherited”

Defined

type-properties

Defined

instance-properties

“inherited”

Data properties



Data properties



Data managementFactory model/layout

CAD-model/layout

Data properties



Detailed model Factory integration

Data properties Level of detail



Data properties Level of detail Supplier integration

1. Stock datain the PDM-System

(layouts, libraries, etc.)

2. As-built data and library handoff

to suppliers

3. Factory layout planningby suppliers

4. Data returns to Magna

5. Coordination-model –audit process

6. As-built model(Factory BOM)

Plant reference system

Virtual reality

Factory integration


Factory Model

Standards

• Model integration

• Coordination model

• Faceting

• Geometry transformation

• Plant base point

• Building base point

• Production facilities base point

Factory Model Standards


H81/H83

Building base pointX = 381490 mm

Y = 326085 mm

Z = 5555 mm

Plant base point

X=0; Y=0; Z=0

Plant reference system



Faceting factor and geometry transformation

Plant reference system Virtual reality

100 0.01



Model integration – Clash detection

(green vs. red)

Coordination model – Change planning

within integrated CAD-model

Plant reference system Virtual reality Factory integration

Live Presentation with Q & A

15 November 2018 43

Virtual factory model

360° views

Live factory model

Author: Robert Ostermann Disclosure or duplication without consent is prohibited

../../DARWIN/UA/Doku/H81_83-GJ29-DWF-02b.nwf_2017-Nov-21_11-44-09PM_Current View.html




../../DARWIN/UA/Doku/H81_83-GJ29-DWF-02a.nwf_2017-Nov-21_11-46-30PM_Current View.html

../../DARWIN/UA/Doku/H81_83-GJ29-DWF-02a.nwf_2017-Nov-21_11-46-30PM_Current View.html

../../DARWIN/UA/Doku/H81_83-GJ29-DWF-02c.nwf_2017-Nov-22_08-11-41AM_Current View.html

../../DARWIN/UA/Doku/H81_83-GJ29-DWF-02c.nwf_2017-Nov-22_08-11-41AM_Current View.html

Preview “Factory DNA” video


A Closer Look – Production Facilities Standards

17. Oktober 2018 Autor: Robert Ostermann Disclosure or duplication without consent is prohibited 46

• Standard Inventor Properties:

E.g. Part Number,…

• User Defined Properties:

E.g. Category, Manufacturer,…









• Instance Properties:

E.g. Building No., Level,

Equipment Number from an

EPR System

Family DNA:

Data Properties



Grandmother

• Case 1:

Assembly (with Any-CAD

reference) of a unique

construction

3D Representation

Level of Detail

• Case 2:

Part of a parametric

construction

3D Representation

Different Parameters

(Geometry, Visibility,…)

• Type Properties:

Standard Inventor Properties

Custom Inventor Properties

Mother

• Case 1:

Library Part

Meshed Object

2D/3D Representation

“Factory Design Utilities”

Parameters

• Case 2:

Library Part

Boundary Representation Part


“Factory Design Utilities”

Parameters



Standard FDU Properties


• Predefined Instance Properties:

Standard FDU Props (empty)

Custom FDU Props (empty)

Child

• Case 1:

Model/Layout Part

Meshed Object


Specified “Factory Design

Utilities” Parameters

• Case 2:

Model/Layout Part

Boundary Representation Part


Specified “Factory Design

Utilities” Parameters





• Instance Properties:


Custom FDU Properties

Data Properties



Grandmother

[Any-CAD reference]

Assembly

L.O.D. - Substitute (Shrinkwrap)

* 1: Batch-File for VAULT-Add-On

(Import Object Properties)

Automated CSV

Excel Template with Type

Properties:

Child

• Model/Layout Part

• Meshed Object

• 2D/3D Representation

• Specified “Factory Design Utilities”

Parameters

• Case 1

Mother

• Library Part

• Meshed Object


• “Factory Design Utilities”

Parameters

*2: FDU – Convert to Asset:

• Transfers Type Properties:

Inventor Standard Properties

AND

Inventor Custom Props

• Create Instance Properties:

FDU Standard and Custom Props

in Library Part

*2 *3

*3: FDU – Place from Library:

• Type Properties

• Instance Properties

are passed to every “Child”

in a model or layout

*1

Data Properties

A closer look – Production Facilities Standards


Grandmother

[Any-CAD reference]

Assembly




Automated CSV


Properties:

Child


• Meshed Object



Parameters

• Case 1

Mother

• Library Part

• Meshed Object



Parameters




AND


• Creates Instance Properties:


in Library Part

*2 *3


• Type Properties




*1 CAD/PDM Manager User

Data Properties



Grandmother

[Any-CAD reference]

Assembly




Automated CSV


Properties:

• Case 1

*1

Step *1: VAULT-Add-On (Import Object Properties) – AUTODESK Consulting Tools

Data Properties



• Case 1

Mother:

Prepare for step *2:

Place substitute (shrinkwrap) in

factory layout

Check Inventor custom properties

in bill of material properties are

moved forward into library parts

Data Properties



• Case 1

Mother

• Library Part

• Meshed Object


• No “Factory Design Utilities”

Parameters




AND


• Creates Instance Properties:


in Library Part

*2

Data Properties



Step *2:

Start <Convert to Assets>

functionality

Create representative Asset Name

Use “Coarse” simplification

Define <Default Publish Location>

Define <Default Asset Properties>

BE AWARE THAT: All input and

values are not saved temporarily.

A pending “Save Status” of an

element won’t let you convert

• Case 1

Mother

Data Properties



Step *2:

Use Factory Asset Properties

Category and Keywords to help

you find items in the library

Check Part Number and Create

Date time stamp

Use a simple representative

Descriptor

ATTENTION: iLogic Rules and

Function are “cut off” during

<Convert to Assets> process

• Case 1

Mother

Data Properties



Step *2:

Define Instance Properties

Use standard layer definitions

BE AWARE THAT: No standards or

templates for instance properties are

possible with this method

• Case 1

Mother

Data Properties



Step *2:

Generates your Factory Model, if

you use the “Replace models in

layouts with converted assets”

ATTENTION: Use “Save as” or a

copy, if you don’t want to lose

model for the asset creation

process

Use <Sync to AutoCAD> to create

your Factory Layout

Otherwise continue with Step *3

• Case 1

Mother

Data Properties



Child


• Meshed Object


• No “Factory Design Utilities”

Parameters

• Case 1

*3


• Type Properties




Data Properties



• Case 1

Step *3:

Use the <Search assets> function

or your explorer structure

Place your assets in AutoCAD or

Inventor

Child

Data Properties



Grandmother

Parametric Construction Part

* 1: iLogic Rules:

to control Type, Geometry and

Visibility Properties:

Child


• Boundary Representation Part



Parameters

• Case 2

Mother

• Library Part




Parameters

*2: FDU – Create Asset:

• Uses iLogic Rules for:


AND



FDU Standard and Custom Properties

in Library Part

*2


• Type Properties




*1

*3

Data Properties



Grandmother


* 1: iLogic Rules:



Child





Parameters

• Case 2

Mother

• Library Part




Parameters




AND



FDU Standard and Custom Properties

in Library Part

*2


• Type Properties




*1

*3

CAD/PDM Manager

Data Properties



• Case 2

Grandmother


* 1: iLogic Rules:



*1

Data Properties



• Case 2

Step *1:

Use iLogic Global Form for Standard

Type Properties to get standard Values

out of an Excel List e.g. Resource

Code (MS_Resource)

Grandmother


* 1: iLogic Rules:



*1

Data Properties



• Case 2

Grandmother


* 1: iLogic Rules:



*1

Step *1:

Use iLogic Global Form for Standard

Type Properties to get standard Values

out of an Excel List e.g. Resource

Code (MS_Resource)

Use iLogic Rules to control variable

parameters (e.g. Part Number)

Publish value to Inventor standard

property

Publish value to Inventor custom

property and to “functional parameter”

for the reuse in a factory property to

make sure the properties are

published correctly by placing a

“child” in a layout/model

Data Properties



• Case 2

Grandmother


* 1: iLogic Rules:



*1

Step *1:

Reuse “functional parameter” in

factory properties <Asset Properties>

for correctly published parameter-values

when placing a “child” in a layout/model

Data Properties



• Case 2

Grandmother


* 1: iLogic Rules:



*1

Step *1:

Define Instance Properties

Use standard layer definitions

Set parameter alias (Factory Name)

and Factory Tooltip

ATTENTION: No standards or templates

for instance properties

Data Properties



• Case 2

Mother

• Library Part




Parameters



Inventor Standard Prop

AND




in Library Part

*2

Step *2:

Start <Publish Asset> functionality

Create representative Asset Name

Define Publish Location

Define 3D/2D Options

Data Properties



• Case 2

Step *3:

Use the <Search assets> function

or your explorer structure

Place your assets in AutoCAD or

Inventor

Child

Data Properties

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