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Laboratory conference
Concept specification for a prototype and test information system (PaTIS) for OSS Europe
Leipzig 2008
Emanuel Sideras in copr. with Klaus SchaalOSS / Alfdorf
© TRW Automotive Inc. 20082
Background
The product design and validation process needs to be transparent. Product information (E-BOM) has to be linked with the generated testing information in order to allow cost efficient test planning and performing.
General Requirements:
• Standardized and automated linkage between part status and test result• Standardized and automated handling of the E-BOM• Automated / integrated workflow (Engineering- Prototype Shop-
Laboratory)• Avoidance of multiple inputs of data• Possibility for automated searches over different projects, locations
regarding failure modes, parts,....• Standardized and automated reporting
© TRW Automotive Inc. 20083
Shirley Czestochowa
Areas to be involved
PaTIS
26 MilesBricherasioAschau
Airbag Component TestsSystem Tests
Seatbelt Component TestsMath. Simulation
Airbag TestsSteering wheel Tests
System TestsMechatronik Tests
Math. Simulation
Airbag TestsSteering wheel Tests
System TestsMechatronik Tests
Bag (Fabric) TestsMath. Simulation
VilanovaPortugalVigoSpainValladolidSpain
Alfdorf Germany
Aschaffenburg Germany
Shanghai
Location‘s
Design EngineerApplication Engineer
Sample Shop
Validation EngineerTest Laboratory
Testing group‘s Department‘s
Prio 1
Prio 2
Integration Priority
© TRW Automotive Inc. 20084
High Level Process Overview
Part PhaseCustomer
PartsTest
FixturesReDefineSamples
Additional Parts
Assemblefixtures
Build Test Samples
Deliver Test Samples
Prepare Test Samples
Analisis & Docum. PhaseRecherche prev. Tests
Analyse Results
Test Report Archive
Definition
Test PhasePrepareTests
PerformTests
Test Documentation
Store testedParts
DVP&RE-BOM Parts
Parts DocumentationRaw Data
EXTERNAL
EXTERNAL
COP COP
DVP&R: Design Verification Plan and Report
Cost estimation
Define Test samples
Define Testingprocedures
© TRW Automotive Inc. 20085
Workflow & Data managementWorkflow PaTIS
DefineParts / Tests
BuildParts
Test Parts
AnalyseParts / Data Archive
Process Phase
Reports
Testresults
Part
Orders
DVP&R
E - BOM
Drawing
Testplan
Raw Test Data
Dat
a Fl
ow Assebly Fixture
Machine Data
Test Fixture
© TRW Automotive Inc. 20086
Drivers for good quality
Good quality specification
Acceptance from Stakeholder
Consideration of TRW-requirements
Consideration of supplier-requirements
© TRW Automotive Inc. 20087
Questions to start off
• How can WE get an overview of the entire process?
• How can we collect and restructure the needs of our users?
• How can we collect all the relevant requirements?
• How can we give the vendors sufficient insight / overview of the total processes?
• What information is relevant for the vendors in order to understand our concerns and/or to make an offer?
• Involvement of the supplier during the concept specification
© TRW Automotive Inc. 20088
Measure (What do we have ?)
Description of the current processes in order to get all important activities which has to be considered for the concept specification.
BB Project BB06152007003Concept specification for a prototype and test information system (PaTIS) for OSS Europe
Define (What should be done ?)
The product design and validation process needs to be more transparent. Product information (BOM) has to be linked with the generated testing information via PaTIS to allow cost efficient test planning and performing.
Problem:How to make a concept specification which covers the needs of the several departments and plants in order to use it for the offering process of a PaTIS.
Control (Check if complete !)
• Meeting with all suppliers and exchange of information's and ideas, expectations • Internal customers checked the draft of the specification and make their additions• Offering process -> replay of the suppliers
Analyze (What do we additional need ? – find the gaps)
Development of the „Hot Spots“ – Issues which has to be considered, described and specified in order to have a specification for PaTIS, based on the activities of the SIPOC.
Affinity Diagram out of the SIPOC:
Improve (Close the gaps !)
A workshop was set up:• Description of the future state activities• Generating possible concepts for the “Hot Spots”• Identify potential improvements• Generating benchmark criteria
• Consolidation with specification of Aschaffenburg
• Writing of the specification & assessment lists• Business case (preliminary)
© TRW Automotive Inc. 20089
Description of the existing processes
Instructions to describe the current processes
List up for each process group each necessary information:• Name of the document / Information• Is the document/Inf. an Incoming and / or Outgoing • From Whom / To Whom• Information System (Paper, E-Mail, File, ….) • Kind of test: Design Verification / COP / Math. Simulation• Place of Test: External, Intercompany, Plant (Internal)• Functional Group• Store existing example template or screen hardcopy
© TRW Automotive Inc. 200810
Current state -> Future state
SIPOC
Realization / Priorization
Information handling
Files / metadata
Release / change processes
Current problems
Potential improvement
Functional issues
Storage / Warehouse
DVP&R
Capacity planning
Other Functional Modules
Data structure
Ordering
E-BOM
Interfaces to other systems
© TRW Automotive Inc. 200811
Interfaces (Example)
© TRW Automotive Inc. 200812
Modules of PaTIS
Capacity/Resource
planingStorage
WarehouseTest FixturesPrüfvorrichtung
Assembly Fixtures
Montage Werkzeug
SAP-BOM-Netzplan-SAP Order-SAP Project
Web - Portal
Customer/Supplier/OthersWeb – GUI (TRW Internal)A
pplic
atio
nsSu
bsys
tem
sEx
tern
al
Syst
ems
PDF Viewer
Digital Archive
Ixos
Gasgenerator
DB
X-Crash/
PulseDBCOPS
Maschines
Prüfmittelüber
wachung GQDOORS
SAP-Maschinendaten
-Leistungskatalog
Lessons
Learned DBClarity
CAD Viewer
2D / 3D
Movie Viewer
Falcon
MS-Office
Applications
Barcode
Scanner
Label
Parts / Boxes
Windchill-Rel Drawing-Lastenheft-ERDs-GIs
Launch
List
Test
Analyse
-Diadem
-QS-Stat
-Minitab
Inspection devicesPrüfmittel
Ker
nel
Workflow
ManagementReport Generator
Order
Management
Release/Change
Management
BOM
Management
Document
Management
People and
Organisation
Test Data
Management
Cost
Estimation
Web Services (D)VP & (R) ODBC
Inte
rface
s
© TRW Automotive Inc. 200813
Specification of PaTIS
Specification
• Functional assessment
• Technical assessment
• Commercial assessment
Templates for supplier benchmark:
• Risk assessment
Outcomes of the workshops were consolidated with the specification
© TRW Automotive Inc. 200814
Assessments process - plan
Comercial
Assessment
+
Technical
Assessment
+
EstimatedTotal Cost
of Ownership
Short
listed
Vendors
(3 ?)
Functional
Assessment
+
ReferenceCustomerInterview
+
ComercialNegotiation
Winner !18 Vendors
© TRW Automotive Inc. 200815
Obstacles and Surprises
• Common definition of terms
• Presentation of facts which should SOMEHOW be resolved
• Different concepts of vendors
• Weighting of assessment lists
• Corporate IT-strategie
• Who should / should not be included (Pro – Contra) Scope
© TRW Automotive Inc. 200816
Current status
© TRW Automotive Inc. 200817
Current status
© TRW Automotive Inc. 200818
Remaining Topics
• Open points / go through the assessment lists
• Elaborate / Present concepts
• Weighting
• References
• Contracts / Negotiation
• Decision
© TRW Automotive Inc. 200819
Thank you for your attention!