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© Copyright 2016Slide 1 CONFIDENTIAL

Right First TimeDevelopment Process Improvement

Dr. Alfred R. Boulos

Strategic Global Account Manager


Introduction

• Businesses constantly have a need to improve their processes

• Market trends• Competition threats• General need to increase efficiency throughput

• Six-Sigma, Kaizen, Lean Manufacturing etc… all rely on

• Optimum Process Performance and • Continuous Process Improvement

• Processes will constantly need to adapt to new business demands and emerging technology


Toyota President in May 2013 said “We are also making progress in reforming manufacturing technologies and vehicle development processes…”.

He added “By competitiveness, some may think of low labor costs, favorable foreign exchange rates […] the longer-term “true competitiveness” entails, to name a few, a capability to develop human resources, a culture to pursue quality and productivity…”

PWC see in the challenges ahead for the automotive industry that:

“The demand for customer centric focus, end to end integrated operations and optimal cost management has never been greater.”

Time to be a leader in engineering process improvement ?


People

ProcessProduct

3Ps of Virtual Product Development


People

ProcessProduct

Correct data entry and availability

Better collaboration

Responsive simulation results to business needs

Expert simulation knowledge/data capture, share and re-use

Data flow between users, departments and applications

Implementing best practice simulation methods

Simulation process turn-around

Repeatability of simulation process



People

ProcessProduct

Reduce duplication of data

Reduce design cycle iterations

Improved product quality through increased simulation

Efficient workflow process

Constantly improving and evolving workflow

Variability and product configuration Optimization



People

ProcessProduct

Availability of skilled resources to drive analysis

Market positioning of products

Market delivery demands

Responsiveness to in-service product issues (recalls)

Faster decision making and design sign-off

Empower engineers with advanced simulation capabilities



People

ProcessProduct

Au

tom

atio

n


• Optimization: • Selection of key system parameters that can be

varied within a specific range, to meet a specific resulting objective or to find an optimum configuration

• Automation:• Removal of redundant/repetitive tasks, whilst

capturing expert knowledge to build, modify or adapt a model, by defining a simulation process and/or a base abstract model

• Democratization:• Provision of analysis tools and sharing of expert

knowledge, easily and at no compromise via a guided web-based interface


Driveline Development Process Improvement

Optimization Automation Democratization

O A D

Services

Software



O A D

Driveline Development Process ImprovementProcess Improvement and Integration from within Romax Technology to be covered in more

detail at 13:30

“Process Automation and Integration Using Romax Software Suite - Examples and Success Stories”

- Michael Platten, Noise and Vibration Specialist, Romax Technology



O A D



Development Process Improvement - Deliverables

• Understand strategic objectives and goals

• Map the current Process or “Value Stream”

• Identify key process stakeholders, leaders and decision makers

• Highlight data silos and process times (cycle, wait and waste)

• Scope areas of improvement

• Agree priority areas of improvement, and establish potential gains

• Demonstrate and map new process

• Qualify new process gains

• Setup deployment plans


Step 3: Define improved process

Step 1: Interviews & observation

In parallel: Identify key issues

Step 2: Create existing process flowchart

Step 4: Run pilot project

Interviews with key stakeholders to create a process map which reflect the various users understanding

Group session with engineers to create/validate the process flowchart(s) & communicate goals to the team to obtain full commitment

Define the root causes and define improved flowchart fixing any issues or inefficiencies & validate with stakeholders

Support engineering team with pilot project to make sure implementation is efficient

Step 5 Deployment phase

Support deployment of new process to maximise benefit to clientand focus/optimise process communication based on pilot project

5 Step Process Improvement Approach


Customer Engagement Resources

• Executive Sponsor• Authority over Process/VS• Accountable for results• Influential and can mandate process change

• Champion/s• Oversees portion/s of Process/VS• Involved in process workflow strategies• Manager that accept the need to adapt/change current process

• Facilitator• External to company• Knowledge in process and VS mapping, and engineering CAE

workflows• OTB thinker


Executive Summary

• Client Challenges:

• Client wanted to optimise its transmission design process and reduce cost by 20%

• Romax Scope:

• Romax performed a 5 weeks audit interviewing 20 employees from technical director, managers and engineers to build a process map and highlight improvement opportunity

• Romax create an implementation plan which was run on a pilot project for manual transmission

• Achievements:

o 60% process improvement for transmission concept design

o Implementation of process all transmission concept engineering

o Cost reduction £0.5Million per design

Customer Case Study: Japanese Auto OEM


Executive Summary• Client Challenges:

• Build up a world class design process using a combination of the best practice of engineering and powerful simulation tools;

• Romax Scope:

• Use a real pilot project to assess the client process and and resolve their specific issues (ie. the gear whine / sideband noise performance of client’s automatic transmissions)

• Develop a process which can be used by the client independantly, and train engineering team

• Achievements:

• Successful pilot project lead to 10 week time saving compared to existing process

• Implementation of process to the complete transmission engineering

• Cost reduction $1,2Million over 2 years

Customer Case Study: Korean Auto OEM


Executive Summary

• Client Challenges: • Client wanted to optimise its transmission integration process and reduce

need for prototyping by 20%

• Transmission NVH issue appearing when supplier design is integrated into vehicle require the CAE team at the OEM to remodel the complete transmission leading to cost and time wasted

• Romax Scope:• Romax performed a 1 weeks audit at the OEM and 3 days audit at the transmission

supplier interviewing the Design, CAE and Driveline integration teams to identify the opportunity for process improvement and inter-company (OEM/Transmission Supplier) process improvement

• Romax create an implementation plan which was run on a pilot project for manual transmission

• Achievements: • Successful pilot project lead to 10 weeks time saving

• Implementation of process to the complete transmission engineering

• Cost saving: ~590,000Euros*

• Engineering man power saving = 90,000Euros per driveline configuration

• Testing validation cost reduction due to improved model/simulation = 500,000Euros

• * excluding potential sales increase due to early release of vehicle to market

Customer Case Study: European Auto OEM



Automation DemocratizationOptimization

O A D


Optimization – (Micro vs. Macro)

• Micro Level• Single Discipline• Executed from within a specific program• Limited parameter specification• Ideal for narrowing variable range• Most efficient after parameter Sensitivity

Analysis or Design of Experiments

• Macro Level• Multi-Discipline• Executed as part of a process• Unlimited parameter specification• Most efficient after micro level parameter

range reduction

Parameters

CAD/CAE

Objectives

Objectives

CAD/CAE 1

CAD/CAE 2

CAD/CAE X

Global Parameters



Optimization Democratization

OAutomation

A D


Gear

Clutch

Bearing

Shaft

Requirements of A CAE Process Automation Solution

• Functional representation of product systems• System & product Intent

• Functional requirements

• Design variables

• System constraints

• Operating conditions

• Performance metrics

• Tool-agnostic engineering automation • CAD, FEA, MBD, Gearbox, math tools

• Automation that is robust acrossdesign changes and Product Families

• Automated mixed-fidelity modeling

Structural FEA & LifeIn-house

tools

FE MesherCAD

Gear/BearingSystem Analysis

AcousticsAnalysis

Comet Template


CAE Knowledge Capture

Product Evaluation Using Simple “Engineering Calculators” (SimApps)

• Embed expert knowledge• In robust, reliable, easy-to-create templates• Minimal or no scripting• Experts Tools – Your CAD, Your CAE

• Automate repetitive modeling & analysis work• Using Abstract Modeling, they work

across the entire Family of Products that share a basic architecture

• Deploy Anywhere!• Web-based, cloud-enabled

• Run by Anyone!• Easily, Rapidly & Automatically analyze

and optimize design variants• Within a discipline or across multiple

disciplines

CAD in

Report out

Template

True Virtual Test Rigs


Comet WorkspaceParametric, Multi-Fidelity, Multi-Source, Multi-Discipline

Abstract Engineering Model™

Adaptors to External Tools

Mesh Models

Systems Models

CAD Models

Product Representations

Analysis Models(Auto-Generated)

IsightOptimization Tools

MBD ToolsSystems ToolsFEA Tools

ANSA Mesher

CODE V Optics

Automating Product Development ProcessesIntegrating Tools & Data Across All Design Phases


750K engineers

worldwide of this type today already using

CAE

8M engineers who aren’t benefiting

from the use of simulation tools today

Target End Users of Comet SimApps

• Simulation Experts: Multi-Disciplinary Processes• Create and validate best-practice analysis processes• Run the most complex simulations

• Design Engineers: Standard, Repetitive Processes• Run well-defined standard analyses safely & consistently• Use web-deployable, role-based Vertical Applications that

drive Comet Templates (built and updated by the experts)

• Chief Engineers/Program Managers/Systems Engineers• Run multi-fidelity systems analyses from the dashboard• Conduct design reviews effectively, without needing

presentations

• Ultimately, “Anyone asking Performance Questions”• Run actual simulations through a simple web interface to

quickly ascertain the performance and cost of customized engineered products


Benefits of Automation

• Enable Engineers and Teams of Engineers to perform Rapid & Robust Design Space Exploration early & often

• Significantly reduce the cycle time of each design iteration (>80-90%)

• Explore the design space more accurately and automatically• Evaluate more concepts

• Better utilize limited resources:human experts & non-experts, time/schedule, program cost

• Capture knowledge of scarce and dwindling number of experts in an executable/reusable form using Comet’s Templates

• Facilitate the spread of “Systems Thinking” across the multi-disciplinary team of product development engineers

Significantly increase the ROI of your simulation investments over the entire product development lifecycle

Gear

Clutch

Bearing

Shaft



Optimization Automation

O ADemocratization

D


Democratization - Overview

• Companies often have a goldmine of underutilized value

within their CAE investments (including Excel, MATLAB and

legacy software)

• These existing tools are often under-exploited because:

• Usage is limited to expert or experienced (“elite”) users only

• Time is wasted by excessive manual processes

• Sub-optimal designs due to insufficient time for design space

exploration

• Inefficient usage of expensive software licenses

• Organization is unaware of them (e.g. Excel and legacy), access

limited

• Unreliable execution across IT infrastructure


EASA Overview

• EASA is an appification and deployment platform that

democratizes software

• Takes nearly any existing software such as Excel,

MATLAB, CAE, legacy and in-house codes and

• Enables an “author” to create a custom fit-for-

purpose GUI, with error trapping and design or

business rules embedded

• Transform it into a web app – a URL accessible

application that authorized users can run from any

connected device

• Couple multiple programs into a single app,

simplifying and automating work processes


Benefits of Democratization

• Ease of use

• Access management – control who can see, use, update

• Version control

• Auditability

• Intellectual Property protection

• Reliability – run anywhere, regardless of local

infrastructure, e.g. mobile devices, different local Excel

version, OS, etc.

• Integration/automation – databases, Salesforce,


Romax is a preferred choice over a “pure management consultant”:

• Experienced engineering company who run complex projects

• Understand highly complex systems and methods of engineering

• World specialists in bearings/gears/drivetrains and mechanical system

• Used to organising technical people & project manage efficiently

• Able to find out the real technical-based problems and their consequences

• Need to be the best & more efficient to keep client interested in our offering -> tried and tested a number of solutions to problems in engineering projects

Romax has a proven track record of delivering savings to clients:

• Reduced by 80% in process duration for US OEM for Transmission NVH

• Saved 500kGBP/transmission design for Japanese automotive OEM

• Saved 10 weeks and an estimated 590k Euros for transmission integration for a EU automotive OEM & supplier through inter-company data exchange protocol

• Project delivered for Korean, US, Japanese and European Clients across industries from automotive, off-highway to wind.

Executive Summary: Proven Track Record


Romax has delivered up to 80% time saving through process improvement with return on investment within 1 year

Overall Romax has enable it clients to save several million £ (GBP).

Our offering is targeted at our areas of expertise transmission, gearbox and bearings design, analysis, NVH, Optimization, cost reduction, assembly and manufacturing processes

Romax is independent and has a proven worldwide track record in delivering high quality design in record time

Romax has developed tools and techniques which are recognised as world class

Automotive market competitive intensity has risen over the years and require to deliver product faster and reduce cost.

Romax experience and track record can enable you to achieve both targets !

Summary & Conclusions

right first time - romax technology · • minimal or no scripting ... ansa mesher code v optics...

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