engineering process innovation - ibm · volvo construction equipment korea ltd engineering process...

VOLVO Construction Equipment Korea LTD

Engineering Process InnovationWith New IT Solution

Volvo Construction Equipment Korea

Engineering Process InnovationWith New IT Solution

Volvo Construction Equipment Korea

• EPI History• Target• Integration Strategy• VPM Function Analysis and Data Migration• Applications• Implement to Development Process• Keys to a Successful Implementation


�� History of Engineering Process InnovationHistory of Engineering Process Innovation

● EPI (phase 0) Consulting Project : Jul. ’96 ~ Feb. ’97– Analysis AS-IS and Exhibit TO-BE Vision– Present Implementation Plan

11. . The 1st StepThe 1st Step (Consult with ITI)

22. . The 2nd StepThe 2nd Step

33. . The 3rd StepThe 3rd Step

● Set up EPI Master Plan : Apr. ’97– Consider the resource of SHI

● E-CIM & Technical Support Team Organization : Jul. ’97● Modify EPI Master Plan : Jan. ’98● E-CIM Center of Daeduck R&D move to Changwon : Jun. ’98● Merge to VOLVO : Jul. ’98

● Set up IT Master Plan : Sep. ’98● Set up VPM Implementation Plan : Oct. ’98


● Organized VPM Project Team : Sep. ’98● Prepared Project : Dec. ’98● VPM Function Analysis : Feb. ’99● VPM User’s Scenario : Mar. ’99● Data Base Design : Apr. ’99● Investment for Infrastructure(2 Billion won) : Apr.’99● Data Conversion & Migration Method : May. ’99● Applications : Jul.’99

✧ Part Master Management✧ Approval & Drawing Support✧ VPM Web✧ Engineering Change Reporting✧ SAP & COLS Interface(~on going)✧ Multi Model Effectivity Validation(~ on going)✧ Cost & Weight Summation (~ on going)

● Education & Training : Jul.’99✧ Super User :20 persons✧ Engineer : 100 persons✧ Manager : 30 persons✧ Casual User :100 persons✧ General User(WWW) :All Volvo User (on going)

● Current Data Conversion & Migration :~Dec.’99

�� VPM Project HistoryVPM Project History


�Target••ProcessProcess••OrganizationOrganization••Information TechnologyInformation Technology


AdvancedEngineering

(CAB)

AdvancedEngineering

(CAB)ProductPlanningProductPlanning

ConceptDesign

ConceptDesign

Prototyping/Test

Prototyping/Test

DetailDesignDetail

Design

ProcessPlanningProcessPlanning

Prepare forMass/salesPrepare forMass/sales

��

•Strategic Suppliers•CAD/M/ID

•QFD•S.E•Design for Quality

•CAPP•Predict Performance•Reliability Growth

•CAD/E/M•CAPP•Cost Modeling

•Generative Technical Publishing •Reliability Monitoring

● Advanced develop in Core technology & Family design● Product planning & Concept design C.E ● Detail design & Process planning C.E● Prototyping with Mass Process● Commence reliability before pilot parts are available

Self Managing Team / Data Share/System Interface

SAVING23

● Encourage empowerment● Integrate information

•��

ProductPlanningProductPlanning

ConceptDesign

ConceptDesign

ProtoDesignProto

DesignPrototyping

/TestPrototyping

/TestProcessPlanningProcessPlanning

Prepare forMass/salesPrepare forMass/sales

36

•• ProcessProcess


•• OrganizationOrganization

Functional MatrixFunctional Matrix

• Difficult cross functional communication• Absence of Continuous Improvement culture• Task Oriented not Result Oriented• Results are not owned• Responsibility can be avoided

Current

Balanced MatrixBalanced Matrix

Transition

Self Managing TeamSelf Managing Team

● Project based organization ● Basically full-time and co-located● Follows throughout its life cycle● Result Oriented Project Management ● Responsibility for product development● Empowerment

Vision


•• Information TechnologyInformation Technology

External AccessWWW

DataInterface

M-BOM

BOM

ECM

DocumentManagement

PDM

PARTMASTER

Internet orTCP/IP

SAP/R3

Mfg.Asm

QualityData

Simul.Data

TestData

QMS/FMECA

CAPP

��

��

��

ForecastCost

Cost Modeling

SEDB

Test

ArchiveData

DesignHistory

Step 1Step 2

STEPIGES

M-BOM,Part,ECN,Price

ForecastPrice

ProductPart info.

DesignAlternative

CompareData

Report

Report


�Integration Strategy••System IntegrationSystem Integration••BOM IntegrationBOM Integration••Product Data Flow Over ViewProduct Data Flow Over View


Single System for:Single System for:••Data Consistency &AccuracyData Consistency &Accuracy••Remove non valued double ActivityRemove non valued double Activity••earlier Communicationearlier Communication

Part Part master

EBOM Engineering Bill of Materials

MBOM Manufacturing Bill of Materials

SBOM Part Planning

ECN Engineering Change Notices

PP Process Planning

VPMVPM

R/3Client / Server

ABAP/4

COAM

PS

WFIS

MM

HR

SD

PP

QM

FI

PMInterface

Production Bill of Materials

Production Change Notices

Routing

InterfacePart Catalogue

Generation

Process Plan Sheet

••System IntegrationSystem Integration


••BOM IntegrationBOM IntegrationSingle-BOMSingle-BOM

ValueValue

E-GroupE-Group

RCVRCV KnobKnob

C/FrameC/FrameS/FrameS/Frame

BushingBushing

Framewa

FramewaCABCAB

BoomBoom

EngineAssy.

EngineAssy.

LeverAssy.LeverAssy.

BoltBolt

BracketBracketPlatePlate

FrameFrame

PlatePlateGlassGlass

S/DoorS/Door

Boomassy

Boomassy

Process PlanProcess Plan

ProcessProcess

PP_ValuePP_Value

LowMaterial

LowMaterial

SectionSection

Part PlanPart Plan

CS_ValueCS_Value

Cyl. HeadCyl. Head CamshaftCamshaft

Boomassy

Boomassy

GearGear KeyKey

EngineeringServiceManufacturing

Effectivity(Machine Serial No)QuantityEffectivity(Machine Serial No)QuantityIllustration Fig noEffectivity(Component Serial No)QuantityIllustration Fig noEffectivity(Date)QuantityProcess OrderTact no

VPMVPMR/3

Client / ServerABAP/4

COAM

PS

WFIS

MM

HR

SD

PP

QM

FI

PM

M-BOMM-BOM

ValueValue

Boomassy

Boomassy

Framewa

Framewa CABCABEngine

Assy.EngineAssy.

LeverAssy.LeverAssy.

C/FrameC/FrameS/FrameS/Frame

BracketBracketPlatePlate

Interface


Model & DrawingsModel & DrawingsPrototype, E, M, A/S BOMPrototype, E, M, A/S BOM

Std. Configuration by Country Std. Configuration by Country Configuration & parts by Machine Configuration & parts by Machine EngEng., ., MfgMfg. & Service Part Master. & Service Part Master

Engineering Change NoticeEngineering Change NoticePart & Process PlanningPart & Process Planning

IllustrationIllustrationSupplier, Cost, Weight...Supplier, Cost, Weight...

Sales ConfigurationConfigured DMU

Part MasterE-BOM, DrawingEffectivity & ECN

Data interfaceWEB Viewing

Next stepExportExportImport

Production-BOMPart Master

Sales ConfigurationECN

Configuration byCountry & machine

EC Result

Part MasterModel & Drawings

ECNSupplier & Cost

Single-BOMPart Master & ECNProcess Plan SheetModel & Drawings

3D Product Models3D Die Models

Service Part MasterA/S BOM

Part Catalogue

Service Part MasterA/S BOM, DrawingEffectivity & ECN

Service Part MasterDrawing

Effectivity

••Product Data Flow Over ViewProduct Data Flow Over View


�VPM Function Analysis and Data Migration••Part Master ManagementPart Master Management••BOM ManagementBOM Management••Drawing, Model & ECN ManagementDrawing, Model & ECN Management••Configuration ManagementConfiguration Management••Design History Control & ManagementDesign History Control & Management

VOLVO Construction Equipment Korea LTDPart CategoriesPart Categories

PNS WebPNS Web

•• Part Master ManagementPart Master Management

Part nameStandardization

(about 10,000 Part name---> 803 Part name)

Old pname New pname C-code FGI C/S Eng0501209270 DW2 SHIFT LEVER LEVER-SHIFT DW2 2302 Y Y050370000 U/JOINT ASSY PROPELLER SHAFT-ASSY 2204 4510 Y100B-91301 BALL V/V 10K VALVE-DRAIN 8220 Y Y1010-11350 B DATA PLATE DECAL-DATA PLATE 8460 8970 Y1015-02670 RAD.TOTAL ASS'Y RADIATOR-ASSY TOTAL 0530 2611 Y Y1020-03460 H/LIGHT&T/S-RH HEADLIGHTS-RH TURN SIGNAL 1400 3500 Y Y1022-00640 H/LIGHT&T/S-RH HEADLIGHTS-RH TURN SIGNAL 1400 3500 Y Y1023-00770 CONTROL-W/AMP INSTR PANEL-WITH AMP 1100 8810 Y Y1023-00780 B CTRLR-W/AMP CONTROL UNIT-WITH AMP 1190 Y Y1023-03890 A CTRLR-W/AMP CONTROL UNIT-WITH AMP 1190 Y Y1072-03980 L BOOM BEARING ARM-WA 4580 Y Y1090-90781 NAME PLATE DECAL-CAB 8460 8970 Y Y1091-01530 STRIPE-FUEL DECAL-STRIP 8460 8970 Y Y1123-00460 END PIECE PLATE-END PIECE 4274 Y Y1123-02990 SW A'Y-ST.&FUEL SWITCH-ASSY FUEL AND START 1137 Y Y1123-03180 R/S-ROOM LAMP SWITCH-ROOM LAMP 8460 3870 Y Y

pno

Conversion

Migration

••Recommendation GradeRecommendation Grade••Old-New Part RelationOld-New Part Relation••Function Group IndexFunction Group Index••……......

••176,353 176,353 Part noPart no

VPMVPMDATABASEDATABASE

Unique PartUnique PartInformationInformation

••MaturityMaturity••VersioningVersioning••……......


VPMVPM

•• Drawing, Model & ECN Information ManagementDrawing, Model & ECN Information Management

Engineering Change Notice

2D Drawings 3D Models


••BOM ManagementBOM Management

VPMVPMDATABASEDATABASE

Strong System ConstraintStrong System ConstraintUnique BOM StructureUnique BOM Structure

Easy to useEasy to use

•Weak System Constraint•No Configured BOM support•Text Based BOM

••About 1,100,000 recordsAbout 1,100,000 records

P NO Version P NO Version QTY start end Model1115-03760 1115-00021 1 1 9999 EC2101115-03760 1115-00110 1 1 9999 EC2101115-03760 1115-00160 2 1 9999 EC2101115-03760 1115-00373 1 1 9999 EC2101115-03760 1115-00410 1 1 9999 EC2101115-03760 1115-00420 1 1 9999 EC2101115-03760 1115-00430 1 1 9999 EC2101115-03760 1115-00440 1 1 9999 EC2101115-03760 1115-00620 1 1 9999 EC2101115-03760 1115-01010 --A 1 1 9999 EC2101115-03760 1115-03780 1 1 9999 EC2101115-03760 1115-03870 1 1 9999 EC2101115-03760 2022-02350 3 1 9999 EC2101115-03760 9011-10803 11 1 9999 EC2101115-03760 9011-10804 16 1 9999 EC2101115-03760 9011-11006 8 1 9999 EC2101115-03760 9011-11007 4 1 9999 EC2101115-03760 9011-11207 8 1 9999 EC2101115-03760 9035-10602 2 1 9999 EC2101115-03760 9211-08000 27 1 9999 EC2101115-03760 9211-10000 12 1 9999 EC210

Parent Child EffectivityC

onve

rsio

n

Migration

Error Check Error RateBOM Structure Error 1.7%Quantity Error 3.2%Assembly Part Structure Error 0.1%Part Name Error 8.0%Non Standard Part Usage Error 0.6%Part Revision Error 1.1%Drawing Information Error 4.3%Sub Engieer Group Code Error 9.0%Engineer Group Code 3.1%Duplicate Part Information Error 25.5%Error Record Count 48.3%


DDEC210

DD00A001BASIC

DD04A002 ALTER 70DD04B002ENG W A.H

DD04J004F.F FUMP 50

DD08A001CAB FIXED

DD08B001SEAT FABDD08B003

SEAT W A.H

DD08A015CAB SLIDE

DD04J001NO F.F FUMP

DD04A001 ALTER 50

SAME

EU Variant

DD04B002ENG W A.H

NA Variant

VPMVPM

••Configuration ManagementConfiguration Management••Effectivity ManagementEffectivity Management -Range(Product Serial No.) -Option(Model Name or Value code)

DDEC210

DD00A001BASIC

DD04A002 ALTER 70

DD04B002ENG W A.H

DD04J004F.F FUMP 50

DD08A001CAB FIXED

DD08B001SEAT FAB

Configuration Handler ManagementConfiguration Handler Management•Pre-defined Configuration -Engineering Standard Configuration -Standard Configuration by Country -Actual Configuration by Model

EC210 Serial No.78

Compare EUwith NA

DDEC210

DD00A001BASIC

DD04A001 ALTER 50

DD04B002ENG W A.H

DD04J001NO F.F FUMP

DD08A015CAB SLIDE

DD08B003SEAT W A.H

DDEC210

DD00A001BASIC

DD04A002 ALTER 70

DD04B002ENG W A.H

DD04J004F.F FUMP 50

DD08A001CAB FIXED

DD08B001SEAT FAB

DD-51-1201-001-AA

>>>

>>>

>>>

>>>

>>>

1112-00010BRACKET F1112-00020BRACKET F1112-00030BRACKET R1112-00070COUPLING

1112-00770INSERT

1112-00200HUB SPLINE

1112-00760ELEMENT

1112-00780INSERT

EU Standard NA Standard


•• Design History Control & ManagementDesign History Control & Management••Design Action ControlDesign Action Control••Part Structure Status ControlPart Structure Status Control••Engineering Change Status ControlEngineering Change Status Control•Engineering Change Notice Generation•Effectivity Management


�Applications•Part Master Accuracy•Approval & Drawing Support•Engineering Change Notice Generation•Engineering Data Web Searching•Part Catalogue Technical Publication•SAP Interface(part & BOM)


••Part Master AccuracyPart Master Accuracy

Part MasterPart Master

Part Name Reference TablePart Name Reference Table

FGI Reference TableFGI Reference TableAccuracy CheckAccuracy Check

Part No

Generation

Service Usage GenerationService Usage GenerationCategory Reference TableCategory Reference Table

Fixed FGI GenerationFixed FGI Generation

Fixed Category GenerationFixed Category Generation

Accuracy CheckAccuracy Check

Accuracy CheckAccuracy Check

Product & Dangerous Code GenerationProduct & Dangerous Code Generation


Draw the StandardDrawing Formatfrom CADAMSymbol Library

••Approval & Drawing SupportApproval & Drawing Support

Make up theProductStructure(BOM)in VPM DB

Register/ Save theDrawing in VPM DB

ApproveUsing ActionFlow in VPM


••Engineering Change Notice GenerationEngineering Change Notice Generation


••Engineering Data Web SearchingEngineering Data Web SearchingR&D WebR&D Web

VPM WebVPM Web

••Part InformationPart Information - Part Master- Part Master - Drawing Information - Drawing Information - Suppler Information - Suppler Information - Where Used - Where Used••Product StructureProduct Structure - Configured Part Structure - Configured Part Structure - Parent-Child Link Information - Parent-Child Link Information (Effectivity, Quantity) (Effectivity, Quantity) - Part Information - Part Information••Engineering Change NoticeEngineering Change Notice

PNSPNS

••ABC SearchABC Search••Conditional SearchConditional Search

VPM StandardVPM Standard

••Bulletin BoardBulletin Board••IntroductionIntroduction••VPM DataVPM Data - Sales Configuration Code - Model Master - Value Master - Engineering Group Master - Part master - VPM Management - Code Table - Trigger & Constraint•Engineering Change•Interface•Data Migration•User’s Scenario

Web DocWeb Doc

••Document SearchingDocument Searching - Engineering Report - Engineering Report - Technical standard - Technical standard - Engineering Change Request - Engineering Change Request - Patents - Patents - Purchasing Information - Purchasing Information - General Standard - General Standard - Manufacturing Information - Manufacturing Information••UserUser’’s Manuals Manual••Bulletin BoardBulletin Board••Document Check InDocument Check In••Administrator FunctionAdministrator Function


Part & DrawingPart & DrawingVPM WebVPM Web

Part StructurePart StructureEngineering Change NoticeEngineering Change Notice


KOREA

SWEDEN

•Part Planning•Build Service BOM•Illustration

��

��

VPM

••Part Catalogue Technical PublicationPart Catalogue Technical Publication

•Image Generation

��

��

FrameMaker

•Add Data•Translation(Sweden,German,French,Spanish)

��

COLS

FTP

FTP

NFS

Parts Catalogue

Publishing

CD

PROSIS

CD

Publishing


�Next Applications•Process Plan Sheet Technical Publication•SAP Interface(Engineering Change & Routing)•Multi Model Effectivity Validation•Cost & Weight Summation


�Application to Development Process•Engineering Process•Engineering Change Process•Cab Development Process•Frame Design Process


••Engineering ProcessEngineering ProcessProduct Planning Prototyping Pilot Mass Product

••Generate VariantGenerate Variant ••Build Build ProtoProto BOM BOM

••Define RestrictionDefine Restriction ••Create Part MasterCreate Part Master

••Interface Material MasterInterface Material Master

••Fix Total BOMFix Total BOM••Fix Part MasterFix Part Master

••Add Service DataAdd Service Data

••Interface Manufacturing BOMInterface Manufacturing BOM••UpdateUpdate Material Master Material Master

••Fix Configuration by CountryFix Configuration by Country••Part Structure by ModelPart Structure by Model

R/3Client / Server

ABAP/4

COAM

PS

WFIS

MM

HR

SD

PP

QM

FI

PM

••BuildBuild Configurable Configurable BOM BOM


Participation of BOM user function in structuring BOM

EngineeringConfigurationEngineering

Configuration

AdvancedEngineeringAdvanced

EngineeringProductPlanningProductPlanning

ConceptDesign

ConceptDesign

DetailDesignDetail

DesignProto/Test

Proto/Test


Prepare forLaunching

Prepare forLaunching

PS I ED PD A

R&D S&

M

P/P

P/C

R&D

Proto BOMDrawing

Proto BOMDrawing Single BOM

Drawing&Illustration

Single BOMDrawing&Illustration

R&D

MFG

Purc

hasi

ng

P/C

R&D S&

M

P/P

P/C

S/P

LaunchingPackage

LaunchingPackage

ManufacturingConfiguration

ManufacturingConfiguration

R&D S&

M

P/P

P/C


Part PlanningPart Planning

Process PlanningSheet

Process PlanningSheet

Part CataloguePart CatalogueM

FG

MFG

S/P

Pub

SalesConfiguration

SalesConfiguration

R&D : Research & DevelopmentS&M : Sales & MarketingP/P : Product PlanningP/C : Production ControlMFG : ManufacturingS/P : Service PlanningPup : Publication

BOM Generation ProcessBOM Generation Process


••Engineering Change ProcessEngineering Change ProcessProposed In-Work Ch/Re/App/Agree Release Complete

••UpdateUpdate Material Master Material Master

••Engineering Change Order ControlEngineering Change Order Control

••Execution Engineering ChangeExecution Engineering Change

••ValidateValidateEffectivityEffectivity -Serial No-Serial No

••UpdateUpdateTarget dateTarget date

R/3Client / Server

ABAP/4

COAM

PS

WFIS

MM

HR

SD

PP

QM

FI

PM


••Cab development ProcessCab development Process

ConceptConceptDesignDesign

CAIDCAID

Manufacturing MuleManufacturing Mule

Advanced EngineeringAdvanced Engineering

CAICAI

RPRP

VPMVPM

CADCAD

CAPPCAPP

CAMCAM


••Frame Engineering ProcessFrame Engineering Process

VPMVPM

Weight 15% ReductionWeight 15% ReductionNo. of Items 15% ReductionNo. of Items 15% Reduction


�Key to a Successful Implementation•Project Team•Preparation at Just in Time•Education & Training


••Team Work Team Work ••Project Manager PowerProject Manager Power

••Product Development Experience Product Development Experience ••Process Design CapabilityProcess Design Capability••Current Data Gathering/Analysis/Conversion CapabilityCurrent Data Gathering/Analysis/Conversion Capability

••Data Base Design CapabilityData Base Design Capability••Software TechnologySoftware Technology••CooperationCooperation

••Project TeamProject Team


••Preparation at Just in TimePreparation at Just in Time

If NotIf Not……... ...

�� BPR Method BPR Method - 3 years ago! - 3 years ago!

�� New Process Design - New Process Design - 2 years ago! 2 years ago!

�� Volvo - 1 year ago! Volvo - 1 year ago!

�� Millennium - Millennium - this year! this year!


••Education & TrainingEducation & Training

••Who is the most Conservative Manager?Who is the most Conservative Manager?

••Who gets the most benefit?Who gets the most benefit?

••Who are Super-Users?Who are Super-Users?

engineering process innovation - ibm · volvo construction equipment korea ltd engineering process...

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