© MAHLE
Scott Janowiak
Numerical Simulation Engineer
ENDES
Lead Time Reduction using Automatic
Reporting Director (ARD) fo...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
Agend...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
Quick...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
FEA a...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
Areas...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
The A...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
Chall...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
Speci...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
Speci...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
Speci...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
The R...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
Video...
MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015
Lead Time Reduction using ARD for MAHLE
© MAHLE
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Lead Time Reduction using Automatic Reporting Director (ARD) for MAHLE

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Lead Time Reduction using Automatic Reporting Director (ARD) for MAHLE

  1. 1. © MAHLE Scott Janowiak Numerical Simulation Engineer ENDES Lead Time Reduction using Automatic Reporting Director (ARD) for MAHLE 1
  2. 2. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE Agenda  Introduction of MAHLE  Background of FEA at MAHLE  Areas for Improvement  The Altair Connection  Challenges Faced  Special Developments  The Result  Video Demo  Questions 2
  3. 3. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE Quick Introduction of MAHLE  MAHLE is a Tier 1 automotive systems supplier  Based in Stuttgart, Germany – Over 64,000 employees – 10 R&D centers around the world – Over $13 Billion in sales globally in 2014  North America – Over 10,000 employees in 29 locations – Over $2.6 Billion in sales – N.A. Headquarters located in Farmington Hills, MI  All light vehicle and truck OEM’s with production operations in NA are supplied by MAHLE  Business Units include: – Engine Systems and Components – Aftermarket and Motorsports – Filtration and Engine Peripherals – Thermal Management (Previously Behr) 3
  4. 4. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE FEA at MAHLE  Finite Element Analysis has become a major tool in the development process – Multiple design variants – Several load and test cycles considered – This leads to a lot of results to report!  Globally, MAHLE has a standard process for doing FEAs, but no official reporting process  In FH, there are several engineers doing FEAs – Pistons represent a bulk of the work – Several engineers could work on the same engine program – Reports can take several hours to create 4
  5. 5. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE Areas for Improvement  Standardized reports – Each engineer has a slightly different way of presenting the same results  Hard to compare variants if layout is different  Speed / Cutting down wasted time – A lot of the reporting time is spent doing non-engineering work  Setting up the HyperView session  Cropping/aligning pictures  Picking nodes  Results Organization – Summary tables require extra work  Picking nodes and changing results 5
  6. 6. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE The Altair Connection 6  MAHLE has been using HyperWorks for over 6 years – Good relationship with Altair team  Altair’s Product Development (PD) team approached MAHLE with the concept of Automated Reporting – MAHLE brought several reports for reference at the kick- off meeting – Also brought a wish-list of functions for an automated tool  Table generator  View Flexibility  MAHLE Master Template – Altair PD quoted a 4-6 week lead time for customized solution  Project started January 2014
  7. 7. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE Challenges Faced 7  Some of the challenges that we encountered: – MAHLE has some unique files and results types  Internal Lifetime/Fatigue Calculation program  Needed special consideration for the table maker – The first program created skewed pictures  Image had white space all around  Aspect ratio not locked in PowerPoint interface – The hot spot finder was rounding the results  Found minimum, but not necessarily in correct location  Working together with the Altair PD team, the issues were able to be solved and great tool was created Boundary Box in PPT Template Correct Skewed Correct Min=4.71 Rounded Min=4.74 Absolute Min=4.71
  8. 8. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE Special Developments 8  HyperView Automation – Takes model and all result files – Creates a 15 page HyperView session  Special MAHLE page layout – Custom legends applied – Some pages left blank for text – Session can be saved/reopened later – Director Window is easy to navigate
  9. 9. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE Special Developments  Hotspot Finder – Finds local hot spot of selected nodes  User selects Max or Min  Note created in HyperView – Adds Lifetime/Fatigue result to summary table  Also gathers stress and temperature results for the node – Also can be used for other results like Pressure or Temperature  Results not added to summary table – Exports results in a table in PowerPoint  Table can be edited 9
  10. 10. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE Special Developments  Some of the other customized features are: – A special high resolution image of our the mesh – A picture cropping tool that automatically crops the white space  Separate Legend Picture – Automatic Notes for Temperature – A special interface with PowerPoint to properly insert the pictures and ensure the best quality image – Ability to run in Batch-mode 10 High Resolution Std. Resolution
  11. 11. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE The Result  Working with Altair PD, the Automatic Reporting Director was developed and customized to fit MAHLE’s needs – 5 weeks for delivery of final solution  The estimated reduction in lead time for a report – From over 4 hours – Down to less than 1 hour  Some of the other benefits are: – Less wasted time of engineers – Standardized layouts – More details of the results with the automatic table generator  The ARD tool was developed and is currently being used in the US office, but is planned to be deployed to the other MAHLE offices globally 11
  12. 12. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE Video Demo 12
  13. 13. MAHLE Industries, Incorporated, ENDES, Scott Janowiak, 15-April-2015 Lead Time Reduction using ARD for MAHLE © MAHLE 13 Questions?

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