unraveling data sharing challenges to improve collaboration atglobal ford powertrain

1

Unraveling Data Sharing Challenges to Improve Collaboration atGlobal Ford Powertrain

Sassan KhoubyariLead Program ManagerGlobal Powertrain C3PNG(PLM) DeploymentDigital Innovation DepartmentFord Motor [email protected]

Gokul VenkatesanPrinciple PLM ConsultantPLM Ford Program OfficeUGS [email protected]

mailto:[email protected]

2Unraveling Data Sharing Challenges to Improve Collaboration at Global Ford Powertrain

Introduction

Product Lifecycle Management is a key enabler in achieving operational efficiency and plays a pivotal role in achieving economical and fast-to-market solutions.

Powertrain Organization partners with Global Supplier base to design, assemble and manufacture products, globally and to delivers to the Ford vehicle teams across the world.

Implementation of a PLM solution, which helps grapple with the challenges by managing a multi-CAD, multi-PIM environment, broad-based visualization, regimented workflows and BOM authoring to maximize its collaboration success in a global environment.

This presentation shares the insights of Powertrain’s tacticaland strategic efforts to support global collaboration.


Ford Motor Company

Ford Motor Company, a global automotive industry leader based in Dearborn, Mich., manufactures and distributes automobiles in 200 markets across six continents. With about 300,000 employees and 108 plants worldwide, the company’s core and affiliated automotive brands include Ford, Jaguar, Land Rover, Lincoln, Mazda, Mercury and Volvo. Its automotive-related services include Ford Motor Credit Company.

Source: http://www.ford.com


GLOBAL FORD POWERTAIN ACTIVITY

EuropeDiesel EnginesV-EnginesI-EnginesManual TransmissionsTransaxlesIron Castings

South AmericaI-EnginesChassis & Engine ComponentsIron CastingsAluminum Castings

Asia-PacificI-EnginesManual TransmissionsAluminum & Iron CastingsChassis Components

AfricaI-Engines

North AmericaV-EnginesI-EnginesN.A. DieselAutomatic Transmissions & DrivelineContinuously Variable TransmissionsIron and Aluminum Castings & Forging

Draft


Evolution of theFord Product Creation Process

Evolution of theFord Product Creation Process

CTCCTC WCPWCP FPDSFPDS GPDSGPDS

43 MBJ#143 MBJ#1

WCTWCT

19851985

Conceptto

Customer

Conceptto

Customer

19921992

World Class

Process

World Class

Process

Global Product Development

SystemAn Enterprise-wide process

built from Global Best Practices

World Class

Timing

World Class

Timing

19931993Since 1996Since 1996

72 MBJ#172 MBJ#1 68 MBJ#168 MBJ#1 65 MBJ#165 MBJ#1

Ford Product Development

System

Ford Product Development

System

MBJ#1*

** <KO> equivalent timing for S4/P4 program<KO> equivalent timing for S4/P4 program

2005+2005+

For Joint Programs


PDM Metaphase

CADIDEAS

Supplier

PDM VPM

CADCATIA V4

Supplier

PDM Metaphase

CADIDEAS

SupplierVolvo

FOE

PDM VPM

CADCATIA V4

Supplier Land Rover

Jaguar

Manual Processes

and Resources

Manual Processes

and Resources

Manual Processes and

Resources


Resources

Manual Processes

and Resources

Manual Processes

and Resources

PDM Metaphase

CADIDEAS

Supplier FNA

PDM VPM

CADCATIA V5

Supplier

PDM Metaphase

CADIDEAS

SupplierMazda

CADGNC


Resources


Resources


Resources


ResourcesCurrent Situation:•Different PDM•Different Product Structure•Different CAD

Requirements:•Common PDM•Common Product Structure•Common CAD

Key Business Drivers –Commonality (Before C3PNG)

Our current Methods/Tools/Data environment inhibits cross brand Our current Methods/Tools/Data environment inhibits cross brand programsprograms


Business Challenges

Ford Global Powertrain Operations serves the following organizations & Joint ventures

North America• VEE• ATO• Mfg

Europe• IGEE• EU Diesel• FFA / R&A• GFT


C3P Classic

CAT

IA V

5I-D

eas

IMI 2IMI 2

Business Challenges (Contd.) – Learning curve effects with a large scale technology transformation

Business Challenges (Contd.) – Learning curve effects with a large scale technology transformation

Teamcenter Engineering Teamcenter Enterprise

CA

D

auth

orin

g

CAD to JT

ETS (Engineering Translation Services)

I-Dea

s

•Migration to Single PDM•Dual CAD Authoring Managed in Team Center Engineering•Supplier Access via Next Generation Environment

Supplier

SupplierTDM TDM

C3P NG


Business challenges (Contd.)

Powertrain suppliers are located in geographically disparate locations (Europe, India, China)

Suppliers are connected to the Tce sites which are in their proximity. For eg. suppliers in Germany are connected to Tce in Merkenich / Cologne depending on their proximity to these sites.

New PLM tools seem to be bringing the suppliers closer to the OEMs ….. but need reasonable amount of process changes for seamless data sharing

NA *

Europe


Business challenges (Contd.) :Process of Data SharingFord/GM Transmission Joint Venture Example

TeamCenter(G-iMAN)

UnigraphicsNX

TeamCenterEngineering

OOtB

NX 3Unix

TDM

I-DEAS

Metaphase

ANX FDX

External

IMI

PC UserJT data

PD & Mfg Eng.

Vehicle DigitalBuck

ServerPDV

DigitaBuck Tool

C3PClassic for

Interop.

References NX data, converts into I-DEAS

JT data in P/T position

Internal

Ford Suppliers

TCe NG

IMI 2


Technical Challenges

Suppliers located in Europe, China, India are connected to the Tce sites in their proximity

Vehicle teams of other brands, needing data from FNA powertrains are connected to Tce sites in their geography.

Data that these teams need from other sites need to be imported or replicated at their sites in a timely fashion.

Manually importing large assemblies is a tedious task and is also subject to latency issues due to data traffic.

Data from suppliers need to be staged

Supplier data has to be tessellated

Data translation from OOTB NX to Ideas so that it can be shared with the vehicle teams that are using C3PNG.


Addressing the challenges

Main Objective:Return on Assets

ApproachProductization approach, by standardizing operations on the portfolio of tools availableRearrangement of the configuration of physical assets and processes in the value chain

DriversMaximize value creation and minimize costs

increase the utilization of the fixed cost components (PLM systems, hardware)Improve dividends (returns) from the capital already invested in the PLM solution


Tactical and Strategic measures

Tactical measures (Interim)

Automated data transfer processes to better utilize the systems (fixed cost components) and minimized manual data pull and push (variable cost components)

to improve data flow with suppliers and other CBGs for the interim and also to

to be positioned to scale up to cater to the data demands until a strategic solution is launched

Strategic measure (for the future)

‘Synergy’ Project


Data sharing process for the Suppliers

PT Supplier sourced for an

Engine/Transmission program

Supplier is connected to the proximal Ford-Tce installation

PTO Program needing the data

creates a placeholder to

share data

Transfer group ownership of the

placeholder to the supplier

Multi-site the placeholder to the site where the supplier is

connected

Send reference data in the form

of a Design Solution

Supplier utilizes the data for

background info.

Supplier designs components and adds the data to the placeholder in the FOE site

Powertrain -North America has the data

needed

data sync setup to multisite the

data to sites where data is

needed


Powertrain Supplier Place Holder

PT Program

VSS Node

Node

Node

Supplier_cad

Collaboration

PDN Deliverables

CAE Deliverables

Node

ECS

030100

EBOM

030102

030101

MP (Carry Over Master Package)V

030000

• Every Powertrain supplier has a placeholder that is attached to an associated product structure to store the data

GEN-PSS-PGM-1132100/1-supplier_x


Data transfer process with a supplier

FNA Tce environment

FOE Tce environment

FNA TCe

FOE TCe

Supplier 1

Automatic data sync

Ford Environment

Manual data check-in

Background data referenced


Data sharing process with other Ford Business Units

Vehicle team needing the

data contacts PTO

The site that the CBG is

connected to is identified

PTO Program

providing the data creates a placeholder

Multi-site the PT-external

placeholder to the site to which the

other CBG is connected

Receive reference data in the form of a

Design Solution

for positioning the powertrain components

PTO designs components and adds the data to the placeholder in the FOE site

Other CBG has the data

needed

data sync setup to multisite the

data to sites where data is

needed


Ford Business Unit Place Holder

PT Program

VSS Node

Node

Node

PT-external

Collaboration

PDN Deliverables

CAE Deliverables

Node

ECS

030100

EBOM

030102

030101

MP (Carry Over Master Package)V

030000

• Every CBG to which Powertrain is providing data has a placeholder that is attached to an associated product structure

GEN-PSS-PGM-1132100/1-CBG_x

PT-CAD

Node


Data transfer Process with Other Business Units

Automatic data sync

Background data referenced

CAT

IA V

5

I-Dea

s

FOA TCEFNA Tce

PTO positions components in the context of vehicle data

and attaches it to the placeholder

Automatic data sync


Piloting New Approach

The mentioned implementation has now equipped us with lessons and provides us the opportunity to scale up gradually to enable data sharing with other CBGS and other suppliers in this data sharing approach

Additionally, Powertrain organization is looking into a new approach called ‘synergy’ project, based on jt-only data sharing


Data Flow (Synergy)

1. Create Work Assy2. Export Data

1. Analyze Data2. Import Data

1. Design in Context2. Save to TC2005

C3PNGClient

PTO 2005SR1 ClientExchange

Manager

C3PNGClient

PTO 2005SR1 Client

ExchangeManager

1. Design review1. Export Data2. Analyze Data3. Import Data

1. Evaluate Design from PTO


The Raw Data

JT: Roughly 10% of CAD data

Double precision NURB geometry included

Single PLMXML structure file


Solution Architecture

TeamcenterRich Client


FordC3P-NG

Tce 9.1.3.4Exchange Manager

Server

SupplierTeamcenter

2005 SR1

ExchangeManager

Exchange Manager leverages the existing infrastructure with no required changes to the current C3P-NG certified solution

Exchange Manager client can be run form anywhere within the supplier LAN while still leveraging the most efficient high bandwidth connection to the OEM

6F/6F-Mid Teamcenter is OOTB data model –key metadata is mapped to the proper location based on configurable intelligent table

2005 SR1 will be connected to 6F/6F Mid database


Solution Architecture



FordC3P-NG

Tce 9.1.3.4Data Exchange

Server

SupplierTeamcenter

2005 SR1

ExchangeManager

Exchange Manager support both in process as well as batched transfer, and structure only vs. structure with geometry

Supplier Teamcenter’s OOTB data model –key metadata is mapped to the proper location based on configurable intelligent table


Benefits to Ford Suppliers

1. Provides local data management solution

Unlimited

Comprehensive

Multi-CAD capable

Latest generation

2. Enables asynchronous data transfer work flow enhanced with JT (Data Manager/Release Analyst Role)

3. Provides platform for supplier internal PLM processes and workflows

4. Greatly reduce costs related to bandwidth for OEM connectivity.


Benefits to Ford

1. No need to upgrade to a new release.2. Eliminates load on the ETS server to tessellate supplier data3. Jt reduces the disk space required for supplier data4. Greatly reduces the time a supplier needs to go from source to

productively supporting the program5. Throughput increase as supplier data no longer needs to be:

StagedTranslated, Cleaned and Re-validated prior to delivery

6. Decreases the scope/risk involved with each C3PNG upgrade7. Broadens the supplier market with more entrants in both

infrastructure and geography


Results

improved collaboration and increased utilization of the fixed cost components (PLM systems, hardware) andShortened time needed to collaborate data between suppliers and the powertrain programs shorter setup times to prepare data that has to be shared along the value chain Improved operational efficiency and increased throughput with out the need for huge resource requirements.Utilization of down time by making sure these automated processes are scheduled during low load on the servers (physical assets)Reduced operational complexity from automation of the data transfer (using data sync and data lists)Increased flexibility while lowered costs.Directly affects profits by controlling the cost side of the equationTaken together it shows the management team's decision to improve return by optimizing the logistics and the collaboration processes.


Q & A


Appendix


Synergy Pilot at Powertrain

Data Sharing (PLMXML)Item can be replicated only with JTLoad into CAD with JT only componentsLoad IDEAS assembly containing parts that have JT only datasetsLoad CATIA v5 assemblies containing parts that have JT only datasetsLoad UG-NX assemblies containing parts that have JT only datasetsLoad IDEAS assemblies containing sub assemblies that have JT only for componentsLoad UG-NX assemblies containing sub assemblies that have JT only for componentsLoad CATIA v5 assemblies containing sub assemblies that have JT only for componentsSave in CAD with JT only componentsSave IDEAS assembly containing parts that have JT only datasetsSave UG-NX assembly containing parts that have JT only datasetsSave CATIA v5 assembly containing parts that have JT only datasetsSave IDEAS assembly containing sub assemblies that have JT only for componentsSave UG-NX assembly containing sub assemblies that have JT only for componentsSave CATIA v5 assembly containing sub assemblies that have JT only for components


Synergy Pilot

NG Actions on Hybrid AssembliesFreeze New Revision on a Item that has only JT datasetCreate New Revision on a Item that has only JT datasetFreeze on Hybrid I-DEAS assembly with components that contain only JTFreeze on Hybrid CATIA v5 assembly with components that contain only JTCreate New Revision on Hybrid IDEAS/Catia V5 assembly with components that

contain only JTConstrain assembly in I-DEAS/CATIA V5 using JT created from UG-NXWorking on Hybrid assembly in the publication workflow

ETS Handling of an Hybrid AssemblySending Hybrid IDEAS assembly for on-demand JT tessellationSending Hybrid CATIA v5 assembly for on-demand JT tessellationSending Hybrid IDEAS assembly for on-demand CAD2CAD translationSending Hybrid CATIA v5 assembly for on-demand CAD2CAD tessellation


Synergy Pilot

Working with WorkflowsEstablish workflow with 6F/6F Mid supplier Items containing JT only

Follow workflow process for at least one complete cycle

Log any issues / concerns

Working with End Item ConfigurationsIdentify limitations of JT only usage Identify any business requirements related to geometry requirementsLog any issues / concerns Identify any improvements required

Working with Positional / Motion FilesComplete a transfer of JT data in and out of Ford TcEng with PositionIdentify any limitations of Positional data received from 6F/6F-MidIdentify any limitations of Positional data sent to 6F/6F-Mid supplierDefine assembly constraints and save into TcEng for reuseIdentify any improvements required for Positional dataIdentify any limitations of Motion data received from Engine

unraveling data sharing challenges to improve collaboration atglobal ford powertrain

Business

global collaboration

global environment

seamless data sharing

global bestpractices

powertrain suppliers

business challenges

global supplier base

ford vehicle teams