“ Assembly Planning & Validation ” Ninth ARC India Forum, Pune August, 2011 Achieving Operational Excellence Through

1. “Assembly Planning & Validation”Ninth ARC India Forum, Pune August, 2011Achieving Operational Excellence Through IT and Automation Solutions Kumar Batalada Business Consultants Siemens Industry Software (India) Pvt Ltd kumar.batalada@siemens.com

2. Siemens Answers for Automotive Industry

3. Siemens Automation and PLM portfolio integrated in one automotive suite CAD Factory design Automation design TIA Idea Digital Cooperation: Continuous knowledge-based information exchange in innovation networks thanks open communication standards PLM Totally Integrated Automation Production Product Lifecycle Management TIP Totally Integrated Power Digital collaboration Service Product design Production Production Sales Logistic Key benefits • SPEED (First to Market) • Achieve concurrent disciplines • Digitally analyze products and production • Re-use assets: knowledge, engineering, parts, manufacturing plans & resources • CONFIDENCE (Right to Market) • Simulate & validate to ensure results • Achieve closed-loop continuous improvement • Manage change throughout the lifecycle

4. Challenges Fe ed op ba Lo ck Product Planning Production Change Change 3 Change Change EWI Mfg BOM Work Instructions CAD Parts 1 CNC Change Change Change Change Quality Plan Process Drawing Product Structure 2 4 Feedback Loop MES

5. Challenges • If there are 100 ECR during a new product development, total time spent on the changes ~ 125 – 190 man days • Propagating a change into planning documents consumes 30-70 hours per change • 30 % of time spent in searching the data • Update information in multiple documents • Concurrencewith SOP Deadline

6. Managing Characteristics in Design Change Environment Example of the “Data Explosion” Engineering through Supply Chain Mfg BOM Typical Year of Changes: 600 Design Changes 200 Fixtures/Gauges 300 new additions 5M+ Characteristic Opportunities • 10000 engineering drawing • Avg. 500+ characteristics/part 5M X Characteristic Opportunities Work Instructions • 5 billion opportunities for error • Manual Process for Data input & Changes • Lack of Productivity • Repetitive Data Entry • Errors • NVA Process Drawing Quality Plan

7. Cost of Errors Proactive Vs Reactive 100 Exponential Cost Cost of ECN [$] 10 1 Product life cycle Field Recall Design Verification Production Drawing Prototype

8. Digital Manufacturing:An Integral Part of our PLM Strategy Typical Mfg. Engineering Scenario Point Solutions Project Mgmt PLM Vis Web Services TC Extensions (Application Interface) Web Services Configuration Mgmt Change Mgmt PLM XML PLM XML Features Structure Requirements Multi-CAD Geometry Process PMI GD&T Digital Manufacturing Supporting the Life Cycle from Planning through Production Mfg Execution Systems Digital Product Development

9. Manufacturing Engineer Workflow

10. Create mBOM by defining phantom assembly Assign parts from different functions in eBom to create a desired manufacturing assembly Make / Buy definition on the created manufacturing assemblies mBOM Creation in Teamcenter Manufacturing eBOM mBOM Top Level mBOM Cone Bearing Assembly Make Differential Assembly Make PI_ComAssy Buy CH Case Buy Engineering / Designer Manf / Manf Eng Phantom Assembly

11. Review Change Notice Parts added Parts deleted Parts modified Material changed Compare E-BOM and M-BOM Update changes in M-BOM Benefits Improved BOM accuracy Significant Reduction in change reconciliation processing time BOM Reconciliation / Change Management eBOM mBOM Top Level mBOM Cone Bearing Assembly Available in eBOM but not available in mBOM Differential Assembly PI_ComAssy CH Case Engineering / Designer Manf / Manf Eng Phantom Assembly

12. Create Bill of Process Assign Parts from mBom to process Generate Process Documents Bill of Process Management - BOP Process eBOM mBOM Top Level mBOM Cone Bearing Assembly Differential Assembly PI_ComAssy CH Case Engineering / Designer Manf / Manf Eng Phantom Assembly

13. Manufacturing Engineer Workflow – AS-IS Process Validation is carried out during the Proto Build stage Too many issues are identified at this stage Forced product design or tooling changes are required

14. Vehicle Program Management New Product Development Start of production Design Freeze Concept Freeze Market Launch Product Validation Concept Initiation ManufacturingValidation Start of production Planned Schedule Actual Schedule Schedule by Virtual Study

15. Virtual Studies • Business Challenge: • Non Conformance: Assembly fitment issues during proto build stage • Quality: manufacturing plans are not confirmed against latest engineering changes • Complexity: Variation of products manufactured Key Capabilities: • Simulation of assembly process and material flow • Integrated human modeling • The results of any simulation can be leveraged as visual work instructions

16. Benefits (Measured/Potential): • Continuous improvement in digital pre-assembly process yields to … • Issues at 1st physical build reduced by 80% from ’06 to ‘09