PLM & the Management of Complex Product Structures

Lehrstuhl für Virtuelle Produktentwicklung

Complexity Management and PLM

Martin Eigner

© 14.3.2011 Eigner VPE Folie: 1


Complexity Management and PLM 2011

Agenda …

1 | Complexity based on Multidisciplinary Products
2
1 | Solutions for Variant Handling: Neutral and Generic BOM
3 | External and Internal Variance
4 | Simplexity – Symplify the Things
5 | Strategic Product Planning and Architecture

© 14.3.2011, Eigner VPE Folie: 3

Complexity based on more function and higher variation

Example Cayenne
Interior Modules:
660
Pipes:
1.200 - 1.500
Pins:
600 bis 2.000
length of pipe:
approx..:
2.800 m, 60-70 kg
32 Vehicle-specific
Cable Ducts

Source: Porsche AG


Shift Variance to Software and Electronic

Example BOSCH
 From 1 engine to 2 engines
 No Kinematic based on
electronically reverse
Dashboard space free

Example BMW

 All variants based on the same
116 2 liter engine
 Differentiation based on
118 different SW calibrations

120


Software Becomes a Dominant Factor of the Product

□ Mechatronic…

Mecha-
tronic

Mechanic IT
Mechanik
Mecha- Mechanic
tronic IT

Source: vgl. [me] 2.2010 Electronic
Electronic

…yesterday (1968) …tomorrow ???
□
When Software and Electronic becomes stronger, why should we use methods from
Mechanic & Hierarchical Requirements and Function Structure?


Software/Electronic becomes stronger….. Example: Adaptive Cruise Control

□ Mechatronic Elements
electronic components
Sensor and Control Unit ECU

mechanics
software

control
HIL simulation testing

testing / diagnosis
Quelle: BOSCH


Interdisciplinary Product Design based on an Extended V-Model

Anforderungs- Produkt- Prozess-
Entwicklung Produktion Betrieb Recycling
definition Planung planung

Eigenschaftsabsicherung

A/R
Modellbildung, Beschreibung
(z.B. in SysML, ModelicaML virtuelle Tests
physische Tests

F Integrierte Funktions- und
(Model Based Design)
Modellbildung und Simulation
(Simulink, MATLAB, Modelica)

Dienst- hybride Tests
L leistung (z.B. HIL)

Mechanik
Disziplinenspezifische
E/E
Modellbildung
(M-CAD, E-CAD, CASE)
Software A/R: Anforderung/Requirements
P
Modellbildung- und Simulation F : Funktion
L : logische Lösungselemente
… P : physikalische Elemente


Model based Design for Mechatronic Design

 Interdisciplinary Product Design requires new Design
Methodologies
(„Pahl/Beitz and Rodenacker for Multidisciplinary Design“)
 Functions should move into the foreground instead of
Mechanics and Geometry.
 Model Based Design as part of Systems Engineering (SE)
should be established as an integrative Methodology and a
bridge between the different engineering disciplines.
 PLM should be the Backbone of the SE approach





A/R
Modellbildung, Beschreibung
(z.B. in SysML, ModelicaML virtuelle Tests
physische Tests



Mechanik
E/E
P


Systems Modeling becomes Part of the Engineering

□ Supporting Systems Modeling multidisciplinary E-BOM
ASURO
- Combined structures in the
early phases of product development
Left drive

motor

gear

pinion 1
multidisciplinary Multidisciplinary Requirements , Function,
requirements modeling Behavior and Building Block Modeling
pinion 2

Original statement pinion 3

pinion 4
360
rotation
wheel
360 rotation
around point
optic rotation
measurement

max speed LED

opt. sensor
collision
detection

Systeme: Doors, Requisit Pro, XML SE Systeme (SysML, ModellicML) PLM-Systeme


Example: Requirements for a MicroRobot

□ Engineering of a requirement structure with linked elements

System /Functional BOM

Extracted requirements

Engineering BOM

Satisfied by a component
Satisfied by a function


Example for concept models (Architecture)

□ System structure
- Block definitions
- Internal structure

Internal structure of the control Engineering BOM

<<electronic>> MircoRobot

…

electronics

Circuit board

Controller

Sensor

…

Internal structure of the drive mechanics
<<mechanic>> Drive chassis

motor

gear

wheel
…


SE as an integrated part of a PLM concept

Plan Concept Design …

Engineering (authoring systems in concept design, M-CAD, E-CAD, CASE)
Requirements structure System /Functional BOM (e.g. SysML) Engineering BOM

Requirements management tools System requirements System structure CAD/CASE authoring systems

4XX_200.ASM

L224_300_200_HS.ASM
System behavior
F1_300_200_G.ASM

F3_300_211_B.PRT

F3_300_238_F.PRT

…

Deriving hierarchicalManagement (PLM)
Product Lifecycle structure information
(e.g. via XML)
Requirements structure System /Functional BOM Engineering BOM
System requirements System structure

System requirements model
System structure model
All data in one PDM system System behavior model


Product and Process Backbone Mechatronic

Plan Concept Design Validate Production Support

Requirements BOM System /Functional BOM Engineering BOM Simulation/Testing BOM Manufacturing BOM Service BOM

Product Lifecycle Management Production Systems
(PLM) (ERP/MES)





A/R

virtuelle Tests
physische Tests

Modellbildung und Simulation
(Simulink, MATLAB, Modelica)


Mechanik
E/E
P


Tools Modelling and Simulation


Multidisciplinary modeling and simulation

 Programming language for simulation
- Programming language of 4th generation
and easy to use
- Textual
 For example Matlab, Modelica, …

 Graphical modeling
- Modeling graphs with blocks and signals
- Calculation in background
 For example Matlab/Simulink, LMS
AMESim, …

 Component based modeling
- Component view with energy flows
- Model multidomain problems
- Reuse of library elements
 For example Matlab/Simulink Simscape,
Modelica Standard Library, …


Description of the inverse pendulum in simulation model

 Behavior of components is described in simulations
e.g. in Matlab/Simulink
- pendulum and drive kinematics
- Actuators and sensors
- Controler
- Boundary conditions





A/R

virtuelle Tests
physische Tests



Mechanik
Disziplinenspezifische
E/E
Modellbildung
(M-CAD, E-CAD, CASE)
P


Discipline specific models for example software

 Object oriented system and detailed Design (OOD)
 Coding and Integration
- Automatic deriving of an skeleton for
class definition
- „Programming by pressing a button“ is not realistic




Agenda …

1 | Design Methodology 2.0
2


The Solution: Neutral or Modular BOM

Whiteboard for System Engineers

 Environment to define possible
neutral structures of a product

 Split BOM into a neutral/generic structure,
options and an instantiated structure

 To make complexity visible

 To reduces the BOM´s 1020-27
down to round about 5000!!! BOM´s


Modular (Generic) BOM

 Modular BOM
- Define options (option categories)
- Create a modular BOM
 Define the multi-level hierarchy
 Assign Items to the modular BOM
 Define product logic
- Create an order
 Assign specification
 Derive order specific BOM
- Instantiated BOM´s only on the low level


Generic Product Structure in Automotive

Machine Industry can use the same principles to simplify the Product Structure

Product Family A

Seats

Cockpit

Dashboard 3004000751 3-spoke Steering Wheel

Meters/gages

Dashboard upper part
(default/standard)
Dashboard lower part

Steering column compl. 2015700309 3-spoke Steering Wheel w/Cruise
CRUISE=YES
Distance tube

Steering wheel
CRUISE=YES & NAVI=YES
…
3005600333 4-spoke St. Wheel w/Cruise & Navi
Airbag Legend
… Product Family
… Component in GPS
Position Variant with Rule
…
Item (Assembly or Part)




Agenda …

2


Solution for Product Configuration

Solution Space

Product Configuration Sales
(Search for valid Solutions) Engineering
Manufacturing

Order
Prod. Variants Configuration
Options Customer
Car Type
Smith
BMW 320i

Constraints Color
Extras
Convertible
Black

- Radio X25

1132 Backrest, Sport shape
Vachette leather, Heating
Vehicle
7451 Structure
Vehicle
0810 Foam
Car body
8786 Trim cover Car body
Attach. parts ext.
1891 Backrest, Normal shape Attach. parts ext.
… Alcantara
1820
Seat cushion, Normal shape
7451 Structure Alcantara
…
7452 Structure
Seats 0812 Foam
0813 Foam
9700 Trim cover Seats
Seat, front left 2700 Trim cover
… Seat, front left
Seat cushion ... 1891
Backrest, Normal shape
1990 Backrest, Normal shape Seat cushion Alcantara
Textile
Backrest 7451 Structure
7451 Structure
Backrest
0812 Foam
Headrest 0812 Foam
Headrest 9700 Trim cover
Armrest 6541 Trim cover
Armrest
Recliner 2001 Headrest, Alcantara
4431 Armrest, Vachette leather Recliner ... …
Seat rail ... …
Seat rail 4530 Armrest, Alcantara
...

Deriving
… 4530 Armrest, Alcantara
... …
... … …
… …
… 4502 Recliner
8887 Armrest, Textile
0912 Seat rail
... …

Product Structure
0912 Seat rail

individual BOM


External Variance

Product Configuration
(Search for valid soltions))
1027

Order 8037
Selected Options
Solution Space Customer Smith
Car Type Z41
Color Black
Extras
- Radio X25
- AirCondition Basic
- Crypton Light LC0

 Variance from the customer perspective  External Variance
 Selection of options leads to individual order-oriented solutions
 Constrains determine valid combination of options


Internal Variance

Product Configuration
(Search for valid soltions))
1027

Order 8037
Selected Options
Solution Space Customer Smith
Car Type Z41
Color Black
Extras
- Radio X25
- AirCondition Basic

Options, Rules/Constrains - Crypton Light LC0

Color = Black, Creme, Grey
AirCondition = Basic, Comfort

Vehicle
1132 Backrest, Sport shape
Vachette leather, Heating
Vehicle
7451 Structure Car body
0810 Foam
Car body Attach. parts ext.
1820
Seat cushion, Normal shape
8786 Trim cover Alcantara
Attach. parts ext. …
7452 Structure
1891 Backrest, Normal shape
… Alcantara
0813 Foam
7451 Structure Seats
2700 Trim cover
Seats 0812 Foam Seat, front left
1891
Backrest, Normal shape
9700 Trim cover Alcantara
Seat, front left Seat cushion
… 7451 Structure
Seat cushion ... Backrest
1990 Backrest, Normal shape
0812 Foam
Textile
Backrest Headrest 9700 Trim cover
7451 Structure
Headrest Armrest
0812 Foam 2001 Headrest, Alcantara
Armrest 6541 Trim cover Recliner ... …

Recliner Seat rail 4530 Armrest, Alcantara
4431 Armrest, Vachette leather
... …

…
Seat rail
...
... …

4530 Armrest, Alcantara
... …
Analysis …
…

4502 Recliner

0912 Seat rail
… …
8887 Armrest, Textile
Rules/Constrains
...

0912 Seat rail
…

Orderoriented
Rule based Variant-BOM
Derivation BOM
Definition



Agenda …

2


Simplexity

 Symplicity means to reach the largest effect with the
smallest effort…..
- Albert Einstein

 There is no justification for complexity if things could be
easy.
- Leonardo Da Vinci

Ora Ito, Designer


Jeffrey Kluger Symplexity

Simplexity: Why Simple Things Become Complex (And
How Complex Things Can Be Made Simple)
By Jeffrey Kluger

WHY are the instruction
manuals for cell phones
incomprehensible?

WHY is a truck driver’s job
as hard as a CEO’s?

HOW can 10 percent of
every medical dollar cure
90 percent of the world’s
disease?

WHY do bad teams win so
many games?

Complexity, as any scientist will tell you, is a slippery idea. Things
that seem complicated can be astoundingly simple; things that
seem simple can be dizzyingly complex. A houseplant may be
more intricate than a manufacturing plant. A colony of garden
ants may be more complicated than a community of people. A
sentence may be richer than a book, a couplet more complicated
than a song.


Simplexity in Art and Design

 Ora Ito (born 1977)



 Optimization
Reducing External Variance


Stückzahl
Quantity by Variant

0
10.000
20.000
30.000
40.000
50.000
60.000
70.000
80.000
l, Textil, (keine), Manuell

xtil, (keine), El. Memory

Leder, Heizung, Manuell

extil, (keine), Elektrisch

© 14.3.2011 Eigner VPE
der, Heizung, Elektrisch

ntara, Heizung, Manuell
 Reduce Variance

Textil, Heizung, Manuell
commercial success

til, Heizung, El. Memory

antara, (keine), Manuell

tara, Heizung, Elektrisch

, Leder, (keine), Manuell

extil, Heizung, Elektrisch

Leder, Heizung, Manuell

ntara, Heizung, Manuell

ntara, (keine), Elektrisch

er, Heizung, El. Memory

Product Variants
ra, Heizung, El. Memory
- Eliminate product variants not contributing to

antara, (keine), Manuell

eder, (keine), Elektrisch
 Varying demand for individual product variants

ara, (keine), El. Memory

der, Heizung, Elektrisch

tara, Heizung, Elektrisch

ntara, (keine), Elektrisch

, Leder, (keine), Manuell

der, (keine), El. Memory

eder, (keine), Elektrisch
The inevitable Long (Thin) Tail

0

Accumulated Quantity
50.000

without heating
100.000
150.000
200.000
250.000
300.000
350.000

Stückzahl kummuliert
Example: leather seat

Folie: 35

The inevitable Long (Thin) Tail

 Technical constraints
- Exclude combinations
that don’t work
 Marketing/product management
constraints
- Exclude/enforce combinations
to “guide” customer

Picture: Mathias Zagel


Reduce Variance with Constraints

 Reduce possible ARMREST
ARM_DRV (Arm rest Driver)
combinations of option values ARM_none (none)

- Enforce desired combinations COL_IN
- Avoid undesired combinations CLI_BLK (Black)
CLI_CRM (Beige)
CLI_GRY (Gray)
- Reduced external variance of
Car Seat, front left: DOORS
2DOOR (2 Door)
864  576 (-33%) 4DOOR (4 Door)

- Likewise reduced SEAT_ADJUST
internal variance SAD_ELM (El. Memory)
SAD_ELE (Electrical)
of all affected assemblies SAD_MNL (Manual)

SEAT_CVR
SAD_VACH (Vachette leather)
SAD_ALCN (Alcantara)
SAD_TXTL (Textile)
enforce
SEAT_HEATING
exclude SEA_HEAT (Heating)
SEA_none (none)

SEATS
SEA_SPRT (Sport)
SEA_NORM (Normal)

STEERING
STEER_R (RHD)
IT Tool: CONFIGIT STEER_L (LHD)



 Optimization
Reducing Internal Variance


Reduce internal Variance

 Assume external variance is fixed
 Leverage reuse of parts/assemblies
- “Multi functionality”, oversize it
- Utilize symmetry
- Standardize geometry elements
- Decouple interfaces
- Remove functionality
- Relocate functionality
- Shift variation from Mechanic to Electronic and Software


“Multi Functionality” – Oversize it

Picture: Mathias Zagel


Utilize Symmetry


The new VW modular transverse product platform
1 2 3

Examples for characteristic elements
Technical length Unified engine positioning Standardized fixtures
for rear axle

bond
control bar
axle
Multi control bar
axle

Standardized position of engine, Reduction of combinations of tilt
Standardized fixtures for different
gearbox, suspension, air angle and geometric distance from
types of axles
conditioning unit and pedals axle from 36 to 2

Source: Volkswagen Sachsen GmbH


Decouple Interfaces


Decouple Interfaces

Dock connector


Decouple Interfaces




Agenda …

2


Strategic Product Planning

Platform Strategy
E
....... D
C Synergie
B
A

Modul Strategy
Variant Strategy (Reuse of Parts and Components
across Plattforms)
E
....... D
C Synergie
B
A


Cost and Benefit of Variants

Turnover
Cost
Cost / Turnover

Optimum

Variation

Quelle: Prof. Dr. Schuh, University of Aachen


Contact

Thank you

Martin Eigner

Institute for Virtual Product Development (VPE)
University of Kaiserslautern
Postfach 3049
D-67653 Kaiserslautern
T +49/172/1524406
F +49/631/205-3872
eigner@mv.uni-kl.de

vpe.mv.uni-kl.de


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