Unraveling Data Sharing Challenges to Improve Collaboration atGlobal Ford Powertrain

Unraveling Data Sharing Challenges to
Improve Collaboration at
Global Ford Powertrain

Sassan Khoubyari
Lead Program Manager
Global Powertrain C3PNG(PLM) Deployment
Digital Innovation Department
Ford Motor Company
skhoubya@ford.com

Gokul Venkatesan
Principle PLM Consultant
PLM Ford Program Office
UGS Corporation
gvenkate@ugs.com
1

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 tactical
and strategic efforts to support global collaboration.

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

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.

3
Source: http://www.ford.com

GLOBAL FORD POWERTAIN ACTIVITY

Asia-Pacific
I-Engines
Europe Manual Transmissions
North America Diesel Engines Aluminum & Iron Castings
V-Engines V-Engines Chassis Components
I-Engines I-Engines
N.A. Diesel Manual Transmissions
Automatic Transmissions & Driveline Transaxles
Continuously Variable Transmissions Iron Castings
Iron and Aluminum Castings & Forging

Africa
I-Engines

South America
I-Engines
Chassis & Engine Components
Iron Castings
Aluminum Castings Draft

4

Evolution of the
Ford Product Creation Process
Since
1985 1992 1993 1996 2005+

CTC WCT WCP FPDS GPDS
Global Product
Concept World World Ford Product Development
to Class Class Development System
Customer Timing Process System
An Enterprise-
wide process
MBJ#1* 72 MBJ#1 68 MBJ#1 65 MBJ#1 43 MBJ#1 built from Global Best
Practices

* <KO> equivalent timing for S4/P4 program

For Joint Programs
5

Key Business Drivers –
Commonality (Before C3PNG)
Manual

Requirements:
Processes and Current Situation:
Resources •Different PDM
•Common PDM
•Different Product Structure
•Common Product Structure
•Different CAD
•Common CAD
Manual Supplier Supplier FNA
Processes and
PDM CAD PDM CAD
Resources Metaphase IDEAS VPM CATIA V5

Volvo
Supplier Supplier FOE
PDM CAD PDM CAD
VPM CATIA V4 Metaphase IDEAS
Manual
Processes and
Resources

Supplier
Mazda
Supplier Jaguar
PDM CAD
PDM CAD
Metaphase IDEAS
Manual Metaphase IDEAS

Processes CAD
and GNC
Resources Supplier Land Rover
Manual
PDM CAD
VPM CATIA V4 Processes
and
Resources
Our current Methods/Tools/Data environment inhibits cross brand programs
6

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

7

Business Challenges (Contd.) – Learning
curve effects with a large scale technology
transformation
C3P Classic C3P NG
Teamcenter
Enterprise Teamcenter Engineering
ETS (Engineering
Translation Services)
IMI 2 •Migration to Single
CAD to JT
PDM
•Dual CAD Authoring
Managed in Team
Center Engineering
•Supplier Access via
Supplier Next Generation
TDM Environment
TDM
authoring

Supplier
I-Deas
CAD
I-Deas

CATIA V5

8

Business challenges (Contd.)
Powertrain suppliers are located in geographically
disparate locations (Europe, India, China) NA *

Suppliers are connected to the Tce sites which are in
their proximity. For eg. suppliers in Germany are
Europe
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

9

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

External Internal
TCe NG
C3P
ANX Classic for
Interop. IMI 2
FDX

TeamCenter Metaphase
TeamCenter Ford Engineering Digita
(G-iMAN) IMI
Suppliers Buck
OOtB Tool
JT data in
P/T position
TDM
Vehicle Digital
Buck
Unigraphics
NX 3 PDV Server
NX Unix
References NX
data, converts PC User
into I-DEAS

I-DEAS JT data
PD & Mfg Eng.
10

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.

11

Addressing the challenges

Main Objective:
Return on Assets
Approach
Productization approach, by standardizing operations on the
portfolio of tools available
Rearrangement of the configuration of physical assets and
processes in the value chain
Drivers
Maximize 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

12

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

13

Data sharing process for the Suppliers
PTO Program Transfer group
PT Supplier Supplier is needing the data ownership of the
sourced for an connected to the creates a placeholder to
Engine/Transmi proximal Ford- placeholder to the supplier
ssion program Tce installation share data

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

Send reference
data in the form
of a Design
Solution

Powertrain - Supplier designs
data sync setup
North America to multisite the components and Supplier utilizes
has the data data to sites adds the data to the data for
needed where data is the placeholder background info.
needed in the FOE site 14

Powertrain Supplier Place Holder

• Every Powertrain supplier has
a placeholder that is attached
030101
to an associated product
structure to store the data 030100
V
030102 MP (Carry Over Master Package)
030000
EBO
M
Node
PT
Prog VSS Node
ram Node

ECS

Node
Collaboration
Supplier
PDN Deliverables _cad
GEN-PSS-PGM-
CAE Deliverables 1132100/1-supplier_x

15

Data transfer process with a supplier

Ford Environment
Background data
FNA Tce FOE Tce referenced Supplier 1
environment environment

Manual data
FNA FOE check-in
TCe TCe

Automatic data sync

16

Data sharing process with other Ford
Business Units
Receive
reference data in PTO
Vehicle team The site that the the form of a Program
needing the CBG is Design
connected to is Solution
providing the
data contacts
PTO identified for positioning data creates
the powertrain a placeholder
components

Multi-site the
PT-external
placeholder to
the site to
which the
other CBG is
connected

Other CBG data sync setup PTO designs
has the data to multisite the components and
data to sites adds the data to
needed
where data is the placeholder
needed in the FOE site 17

Ford Business Unit Place Holder

• Every CBG to which
Powertrain is providing data
030101
has a placeholder that is
attached to an associated 030100
product structure 030102
V
MP (Carry Over Master Package)
030000
EBO
M
Node
PT
Prog VSS Node
ram Node

ECS

Node
Collaboration
Node
PT-
PDN Deliverables external
PT-
CAD
CAE Deliverables
GEN-PSS-PGM-
1132100/1-CBG_x
18

Data transfer Process with Other
Business Units
Background data
referenced
Automatic data sync

FNA Tce
FOA TCE

Automatic data sync

PTO positions components in
the context of vehicle data

CATIA V5
I-Deas

and attaches it to the
placeholder

19

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

20

Data Flow (Synergy)

1. Create Work Assy 1. Analyze Data 1. Design in Context
2. Export Data 2. Import Data 2. Save to TC2005

PTO 2005
C3PNG Exchange
SR1 Client
Client Manager

C3PNG Exchange PTO 2005
Client Manager SR1 Client

1. Evaluate Design from 1. Export Data 1. Design review
PTO 2. Analyze Data
21
3. Import Data

The Raw Data

JT: Roughly 10% of CAD data
Double precision NURB geometry included
Single PLMXML structure file

22

Solution Architecture
Teamcenter Teamcenter
Rich Client Rich Client

Ford Supplier
C3P-NG Teamcenter
Tce 9.1.3.4 2005 SR1
Exchange Manager
Server
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 Exchange
Manager
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
23
database Unraveling Data Sharing Challenges to Improve Collaboration at Global Ford Powertrain

Solution Architecture
Teamcenter Teamcenter
Rich Client Rich Client

Ford Supplier
C3P-NG Teamcenter
Tce 9.1.3.4 2005 SR1
Data Exchange
Server

Exchange Manager support both in process as
well as batched transfer, and structure only vs.
structure with geometry
Supplier Teamcenter’s OOTB data model – Exchange
key metadata is mapped to the proper location Manager

based on configurable intelligent table

24

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.
25

Benefits to Ford

1. No need to upgrade to a new release.
2. Eliminates load on the ETS server to tessellate supplier data
3. Jt reduces the disk space required for supplier data
4. Greatly reduces the time a supplier needs to go from source to
productively supporting the program
5. Throughput increase as supplier data no longer needs to be:
Staged
Translated, Cleaned and Re-validated prior to delivery
6. Decreases the scope/risk involved with each C3PNG upgrade
7. Broadens the supplier market with more entrants in both
infrastructure and geography

26

Results

improved collaboration and increased utilization of the fixed cost
components (PLM systems, hardware) and
Shortened 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 equation
Taken together it shows the management team's decision to improve
return by optimizing the logistics and the collaboration processes.

27

Q&A

28

Appendix

29

Synergy Pilot at Powertrain

Data Sharing (PLMXML)
Item can be replicated only with JT
Load into CAD with JT only components
Load IDEAS assembly containing parts that have JT only datasets
Load CATIA v5 assemblies containing parts that have JT only datasets
Load UG-NX assemblies containing parts that have JT only datasets
Load IDEAS assemblies containing sub assemblies that have JT only for components
Load UG-NX assemblies containing sub assemblies that have JT only for components
Load CATIA v5 assemblies containing sub assemblies that have JT only for components
Save in CAD with JT only components
Save IDEAS assembly containing parts that have JT only datasets
Save UG-NX assembly containing parts that have JT only datasets
Save CATIA v5 assembly containing parts that have JT only datasets
Save IDEAS assembly containing sub assemblies that have JT only for components
Save UG-NX assembly containing sub assemblies that have JT only for components
Save CATIA v5 assembly containing sub assemblies that have JT only for components

30

Synergy Pilot

NG Actions on Hybrid Assemblies
Freeze New Revision on a Item that has only JT dataset
Create New Revision on a Item that has only JT dataset
Freeze on Hybrid I-DEAS assembly with components that contain only JT
Freeze on Hybrid CATIA v5 assembly with components that contain only JT
Create New Revision on Hybrid IDEAS/Catia V5 assembly with components that
contain only JT
Constrain assembly in I-DEAS/CATIA V5 using JT created from UG-NX
Working on Hybrid assembly in the publication workflow

ETS Handling of an Hybrid Assembly
Sending Hybrid IDEAS assembly for on-demand JT tessellation
Sending Hybrid CATIA v5 assembly for on-demand JT tessellation
Sending Hybrid IDEAS assembly for on-demand CAD2CAD translation
Sending Hybrid CATIA v5 assembly for on-demand CAD2CAD tessellation

31

Synergy Pilot

Working with Workflows
Establish 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 Configurations
Identify limitations of JT only usage
Identify any business requirements related to geometry requirements
Log any issues / concerns Identify any improvements required

Working with Positional / Motion Files
Complete a transfer of JT data in and out of Ford TcEng with Position
Identify any limitations of Positional data received from 6F/6F-Mid
Identify any limitations of Positional data sent to 6F/6F-Mid supplier
Define assembly constraints and save into TcEng for reuse
Identify any improvements required for Positional data
Identify any limitations of Motion data received from Engine
32

Unraveling Data Sharing Challenges to Improve Collaboration atGlobal Ford Powertrain

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