SECURISTYLEWindow producer benefits from CATIA and SMARTEAM

Monaco Yacht ShowSolutions for the luxury yacht market

MECHTOOLEnclosure maker streamlinesdesign process with PLM

INTERNATIONAL

UK AND IRELAND

11 20

05

1

ContactT h e V 5 P L M M a g a z i n e

mag

feature

Accelerating Transformation in the Automotive Supply Chain

DASSAULT SYSTEMES LTDSuite 9 -10 Riley Court

Milburn Hill RoadCoventry CV4 7HPUnited-Kingdom

Switchboard +44 (0) 2476 857400Fax: + 44 (0) 2476 857403

e-mail: info-solutions@ds-fr.comwww.3ds.com

3882-UK/Dassault 7/11/05 9:34 Page 28

Over the last couple of years, PLMhas come out of the design officecommunity and is increasingly

raised at the top level of companies whichoperate in various market segments. We used to discuss with our customers howthey could increase by 10-15% some speci-

fic process, how they could produce drawings more quickly, howCATIA data should be managed by some other PDM etc. IT used to lead the discussion and dictate some rules; Engineeringand Manufacturing people were asked to comply with those IT rules (whatever they could be) but still get strong enhancements(whatever IT decided).Only a minority understood that PLM had to be taken the reverse way:select the end-to-end processes to optimize or change, select newmethods, select PLM tools with IT then ask IT to drive integration.This minority has clearly won today! More and more PLM is owned by the Business and by the Management as PLM is fully understoodas the main leverage for strategic initiatives which will drive the companies in their next market position (… or out of the market ifthey are unable to lead change).There is a strong logic behind this ownership change: PLM servesto improve top line by enabling more innovative products launchedearlier and PLM also serves to improve bottom line by enablingcost reduction and managing diversity. No other initiative will havea larger footprint in the coming years!“V5 PLM Transformation” has become our motto to help you ourcustomers and business partners. We have also decided tochange to be better positioned with you. We have reshaped ourlong-time partnership with IBM so that the various teams ofDassault Systèmes are closer to you in your various countries,while retaining the recognized added value of IBM in the largeaccounts. Since this summer, many of you have already appre-ciated this change and we will continue to accelerate in thisdirection.

You have in your hands this new magazine that we will use 3times a year to report how customers, business partners,IBM and Dassault Systèmes work together to implement V5PLM… and share success ! Enjoy reading…

Internationalnews

• Dora Lainé reports live from ECF 2005

Solution spotlight• Solutions for the luxury yacht market• Powerful CATIA data exchange

based on SMARTEAM

feature• Accelerating transformation

in the automotive supply chain

success story• Meissner: CATIA, SMARTEAM and CADBAS-

PartExplorer to model tooling and molds• Toyota Motorsport: doubling design

productivity with V5 PLM

Product overview• Interview: Nordine Marouf, ENOVIA market

development manager

in practice• Generative Mechanical Design• Lawton stays ahead in the medical instrument market• Mechtool cuts time to market• Securistyle increases its edge• Blackflag Composite customises yachts

Editorial4

7

8

12

18

UK and Ireland

DENIS SENPÉRÉ

Vice-President PLM EuropeDassault Systèmes]

15

Contact magThe V5 PLM Magazine published by Dassault Systèmes - 9 quai Marcel Dassault - 92150 Suresnes - France • Publication Executive: Denis Senpéré• Chief Editor: Gilles Kircher • Editorial Board: Céline Pérès, Carole Genolhac,Philippe Bonnard, Achim Loehr, Mike Crow, Frédéric Lefebvre, Jean-Marc Galea,Steffi Dondit, David Treacher, Maria Ivanova • Photo credits: Dassault Systèmes’customers and partners • Design and Production: Images et Formes • Printed inFrance - “ISSN applied for”

3Contact mag | n°1

3882-UK/Dassault 7/11/05 9:34 Page 2

news

Amajor happening at this year’s ECFwere the more than 70 conferencesand workshops that took place giving

customers and partners a forum where theyshared their PLM experiences. All industrieswere represented and the topics that werecovered in the customer presentations high-lighted the transformation process in motionand the breadth of PLM solutions used. Here is the personal selection of Contact Mag: • Sennheiser, one of the world’s leading

electroacoustics companies, implementedCATIA V5 and SMARTEAM to meet therapidly growing pressure for shorter deve-lopment cycles, quicker responses to latedesign changes and the need for increasedcollaboration with external partners.

• Fissler, market leader in cookware, decidedto redesign their PLM processes by imple-menting CATIA V5 and SMARTEAM andrecorded a 20 - 25% global productivityincrease as a result.

• Volvo Construction Equipment’s “One Company Vision” required them to increasecollaboration within the group. They migratedto CATIA V5 from other CAD systems, imple-mented SMARTEAM and as a result created a full multi-site environment wherethey could “design anywhere, produceanywhere”.

• Bobst Group, leading supplier of complexequipment and services for the folding carton,corrugated board and flexible materialsindustries, reduced total development costsby 15% with ENOVIA V5 and CATIA V5.

• Volvo’s truck business area successfullyimplemented CATIA V5, ENOVIA V5 andDELMIA V5 for the development of their newtruck generation which will hit the marketunder the Volvo, Renault and Mack brands

• DaimlerChrysler explained in great detailshow CATIA V5 is now massively used in alltheir business areas for cars, trucks, bus andpowertrain under the Mercedes, Chrysler,Freightliner or Mitsubishi Fuso brands andhow they are accelerating the integration oftheir suppliers into this new environment

• BMW gave a very similar message to theirsuppliers, reinforcing the direction that the German automotive industry is takingwith CATIA V5.

“The addition of ABAQUS Inc., leader in advanced finite elementanalysis software, to the DassaultSystèmes family will bring real life simulation toour customers and make the virtual world real”,said Bernard Charlès, President and CEO, Dassault Systèmes. Mr. Charlès announced the addition of a new brand to the existing portfolio called SIMULIA, an open scientific platform for multi-physicsthat will enable the integration of all types of simulation applications thereby providing an accurate simulation of the product behaviourunder operational or extreme conditions.

Another major announcement was the acqui-sition of VIRTOOLS creator of software solu-tions that enable companies to bring 3D to life,a major driving force in Dassault Systèmesstrategy to democratize 3D. Virtools’ applica-tions allow users to quickly and easily add lifeexperience to any 3D object. For example,imagine being able to visualize what a driverfeels, in terms of ergonomics, while virtually driving his/her car. This is the future of productdevelopment. This is what PLM can do for you.

CAA V5 Corner

ECF 2005 Facts and Figures If you change the way you look at things, things change

New this year The Customer forum,an opportunity for customers to exchangeviews with Dassault Systèmes and IBM

representatives. Moderated by Alex Taylor,more than 160 customers participated,making this first edition a success.

Virtuous cycle of innovation

The rollout plan is in two phases, the first involvesapplications for the development of topology andgenerative systemsschematics for electrical and thesecond phase willbe an electrical diagrams offeringand generativeviews for publishing.“Our partnershipwith DassaultSystèmes will offerseamless integrationwith the V5 portfoliothereby helping ourcustomers save

time”, said Alain Di Crescenzo,Chairman & CEO,IGE+XAO. “Our customers havereacted positively toour partnership withDassault Systèmeswhere our solutionswill complement theDassault SystèmesV5 electrical PLMoffering. When twomarket leaders join

forces to bring theircustomers a complete end-to-endcomprehensive solution in electricalengineering, theadded value isimmediately perceived”.

CAA V5 Gold Software Partner IGE+XAO, software editor dedicated to electrical engineering and systemsdesign, unveiled their development plan for six new products fully based on CAA V5 technology for electricalmodeling and diagram generation.

Dassault Systèmes held a press conference onOctober 5th to announce the acquisitioncompletion of two majormarket players in the areaof product simulation.

Main SessionTransformation was the keyword of this plenarysession, describing the evolution of our‘Channel Management’ partnership with IBM,as well as the evolution of PLM to assist companies in their pursuit of the coveted title of market leader. For transformation to occur, companies needto constantly innovate to meet their customers’expectations. “Innovation, said Bernard Charlès,President and CEO, Dassault Systèmes, willdrive the future of the manufacturing business.PLM enables engineers to play a role from initial product requirements all the way to cus-tomer experiences.” Companies that integratein their product’s life cycle how this product willbe used in real life situations will have a clearlead over their competitors.Nick Donofrio, Executive Vice President,Innovation & Technology, IBM, explained, “Thevalue of PLM technology is to enable innovationby capturing the complete lifespan of a product.”He emphasized that in today’s global market,an innovative company is one that is open bybuilding on what already exists and that hasunderstood that they cannot do it alone but in a collaborative fashion by taking advantageof the talents and resources of the world wherever they may be.

WALTER H. DONALDSON JR.[General Manager, WW Product Lifecycle Management, IBM.]

New Comers in the DS Group

• 45 exhibitors• 1400 visitors “ ”

Customer Corner

ProductivityInno

vatio

n

GrowthCycle

Collaboration

Live from ECF 2005By Dora Lainé]

Imag

es c

ourt

esy

of P

SA

Peu

geot

Citr

oën

Nick Donofrio Bernard Charlès

4 Contact mag | Dassault Systèmes 5Contact mag | n°1

3882-UK/Dassault 7/11/05 9:34 Page 4

7Contact mag | n°1

A new customer : Vaton DesignRight after the Monaco Yacht Show,Vaton Design selected Dassault Systèmes’V5 PLM solution and immediately startedthe general design of a large high speedvessel with new CATIA V5 yacht packagesincluding structures and systems design,with the support of IBM/DS French business partner DSF.

For the first time Dassault Systèmes waspresent among the exhibitors on theSeptember Monaco Yacht Show with

the CAA V5 Partner OPTIS and four IBM/DSBusiness Partners – Cenit, DSF, Spaziosystemand Transcat PLM.The Monaco Yacht Show is the only show in theworld devoted exclusively to luxury yachting.With 530 exhibitors over 14000 m2 and 93handpicked 70-to-200-foot yachts in the water,this is the yacht show for professional yachts-men, owners and the industry as a whole.

As usual, in addition to the marine exhibitors,there was a considerable presence of luxurygoods companies such as Baccarat crystal,Jaguar cars, Blancpain watches etc, that are ofinterest to the typical well-heeled show attendee.Among the celebrities, HSH Prince Rainier III,who died earlier this year, was an enthusiasticyachtsman and patron of the show, a passionshared by his son, HSH Prince Albert II who offi-cially joined the show this year •)

INTERIOR DESIGN WITH OPTISOPTIS is the first company to pro-vide light simulation solution fully based on aphysical model inside CAD/CAM software to answer industrial needs for interior design. Its unique colorimetry, ergonomy and lightingsolutions answer the needs of the yacht industry,architecture and design. SPEOS integrates photometry, colorimetry, lighting and photo-realism capabilities to build highly realistic virtualprototypes. LIGHT computes the illuminationlevel inside any 3D architecture scene andbrings it exact light levels, aspects and colors.Both modules are CAA V5-based and smoothlyintegrated within CATIA V5.

A great reference : Yonca OnukYonca Onuk design and manufacture theirhigh speed and patrol boats in Turkey.They have been using CATIA V5 since

2001 and have just introducedtheir latest model in the

YONtech S line of luxury highspeed motor boats. Intended to be

the symbol of excellence and perfection,the “YONtech S36” (for 36m long) is a radical machine capable of speeds in excess of 65 knots, accommodating 8 guests in extreme luxury and styling. It features advanced composite DNV classified structures.

Packaged for Delivery:SMARTEAM’s capabilities for

reconciling 3D CATIA dataacross design environments.

GET READY TO RECONCILE ! The supply chain faces daily obstacles in getting its work done, burdened by complexdata exchange methodologies, threats to design integrity, manual entry of OEM data and other interaction pains. SMARTEAM’spowerful new engineering package exchangetool (SMARTEAM – CATIA Supply ChainEngineering Exchange - SEE) provides a swift,cost-effective collaborative solution to thesechallenges and more.

SEE enables suppliers to interactively compareand reconcile a set of CATIA assemblies andparts coming from an OEM or other supplierwith those stored in a targeted SMARTEAM installation, while preserving all relational linksand data integrity.

Any CATIA-SMARTEAM site can use SEE to col-laborate with any other CATIA site, including OEMsusing ENOVIA or SMARTEAM, suppliers usingSMARTEAM, and another with alternative PDM.

Seamlessly accessed through the SMARTEAMmenu, SEE lets CATIA users import packagesof 3D engineering data – assemblies, drawings,parts and/or analysis documents. After loadingthe source in CATIA V5, users identify and com-pare documents common to both source andtarget. Advanced queries, application of busi-ness rules, such as to file naming, and otherknowledge management features optimizereconciliation and related decision-making. SEE helps suppliers improve productivity andquality, while adding muscle to their competitiveedge: a supplier of windows for car doors can

ensure that the glazing is a tight and accurate fit with the OEM’s latest model for the door. A Frankfurt-based supplier can collaborate witha small team of engineers at its Seoul-basedsales office, capturing product configurationinput closest to the customer. A backloggedengineering unit can rapidly parcel out work off-site to meet delivery targets. End users canenjoy productivity gains through offline work onextracted files, relying on SEE to import themsmoothly back into SMARTEAM.

SEE joins multi-site, Web, and community por-tals in providing robust SMARTEAM enterpriseand supply chain collaboration. “SEE powerfullyexpresses SMARTEAM’s overall value proposi-tion: giving the mid-market competitive edgethrough fast, flexible, low cost of ownership collaboration,” comments Stéphane Deleville,SMARTEAM European competency centermanager at DS.

More information on SEE will be available uponV5R16 release •)

Collaborative design facilitator: Visualized comparison and selective reconciliation of CATIA V5 3D models.

A collaborative design facilitator, SEE enablesvisualized comparison and selective

reconciliation of CATIA V5 3D models.

Engineering data package before reconciliation

Solutions for the Luxury Yacht Market

solution spotlight

Powerful CATIA Data ExchangeBased on SMARTEAM

DASSAULT SYSTÈMES LEADERIN THE YACHT INDUSTRYThe luxury yacht business is riding on the crestof a wave at the moment. Yachts are bigger,clients more confident and service providersmore professional than ever. The naval archi-tects and the yards compete fiercely andtoday have a strong demand for efficient integrated shipbuilding system to replace the suite of non-integrated niche tools thathave been used until now for design andmanufacture. Capabilities, cycle time, costs andquality are no longer good enough to supportthe requirements on the Megayachts market.

After a great success in the small and mediumyachts segments with references such asBeneteau, Jeanneau, Hallberg-Rassy, PoncinYachts, Seaway, Cranchi, Berret-Racoupeau,H2O Yachts, Dassault Systèmes now addres-ses the Megayachts industry with a completeV5 PLM solution based on CATIA V5, DELMIA and SMARTEAM which supportsdesign in context with modern shipbuildingmodeling and manufacturing features. Highend functionalities coming from aircraft andcruising ships industries have been madeavailable for the yachting industry, such as fullsupport of composite materials, now widelyused for yachts.

The YONtech S36 made by Yonca Onuk.

By Céline Pérès]By Diane Benjuya]

3882-UK/Dassault 7/11/05 9:34 Page 6

9Contact mag | n°1

Dassault Systèmes’ Solutions to accelerate Transformation

in the Automotive Supply ChainBy Olivier Sappin, Manager, Automotive Solutions, Dassault Systèmes]

The industrial automotiveenvironment is transforming

into a comprehensive networkof specialized suppliers and

integrators to manage nearly allaspects of a vehicle’s

development plan. The growthopportunities for these

equipment manufacturers andsuppliers will thus tend to

increase and companies whoknow how to innovate will be

taking the lead.

Suppliers in automotive product deve-lopment and manufacturing are subject to strong market demands in

terms of technological innovation. Companiesin this industry must deal with fierce internatio-nal competition and they must offer manufac-turers a rapid and accurate response to theirrequirements.

The initiatives allowing suppliers to deal withthese major challenges are various in nature:

• The implementation of design and manu-facturing processes which allow a rapid response to RFQ (Request For Quotation)

nCapitalization and reutilization of know-how.

• The use of standardized business processes to ensure compliance with the quality standardsof OEMs

n Management of projects and workflows.

• The complete control of solutions for theexchange of engineering data in order to savetime and money and protect intellectual property

n Communication between OEM and sup-plier in order to extract, compare and recon-cile engineering data.

• The optimization of the collaboration environ-ments around product data, in order to maximize knowledge re-use and reduce timeto market

n Multi-site collaboration across extendedenterprise.

• The capability to introduce innovation, evenvery late in the process, in order to generateincremental business, reduce costs and minimize the risks of reduced profit margin

n Generative design.

Today, the percentage of value creation out-sourced by OEM to suppliers is around 65% and shows a trend to increase to a level of 80%in the near future. Companies able to offer themost innovative solutions will necessarily bebest positioned to win contracts.

DASSAULT SYSTÈMES’ SOLUTIONSFor a supplier, working with several OEMswhile managing concurrently various

projects generates large quantities ofinformation, of which the sharing and the reuse become a critical success factor for future projects.

In order to allow companies to meet these challenges, Dassault Systèmes and IBM haveimplemented the “Automotive SynchronousSupplier Solution Set (S4)” offer on a world-wide scale and in collaboration with the auto-

motive industry. This offer - “S4” – is specificallyadapted to automotive suppliers in order to pro-vide them with the means to better collaborate,in an efficient and consistent way. “S4” hasalready been adopted by several manufacturersfor their supply chains.

An offer specificallyadapted to manufac-turers and their suppliers in order to provide them withthe means to bettercollaborate, in an efficient and consistent manner.

«

Customers

OEMs

> > > > >

Supply Chain

>> >

Customers

> > > > >

Supply Chain

>> >

Customers

>> > >

SpecializedSupply Chain

>>> >

>

>

>>>>>

Today

Car resellers

Assemblers

OEMs

Multiple-BrandDistribution

Integrators

ProductionR&D65%

80%

APQPTIER n

TIER 1

OEMs

Body inWhite

ConcurrentDesign

Interior andExterior

Equipment

GenerativeTooling

Chassis

RFQ Response

Powertrain

EngineeringPackageExchange

ElectricalWiring

❯❯

feature

OEMs

8 Contact mag | Dassault Systèmes

3882-UK/Dassault 7/11/05 9:34 Page 8

11Contact mag | n°110 Contact mag | Dassault Systèmes

feature

The “S4” offer from Dassault Systèmes includes:

ƒ Design solutions based on CATIA V5:‘Generative Car’, adapted to the vehicle processes, allowing innovation even very late inthe design stages, for the following domains:• Body-in-white,• Powertrain,• Chassis,• Interior and exterior equipment,• Electrical wiring.

‘Generative Tooling’, adapted to the toolingbusiness, with the aims of standardization andknow-how re-use:• Injection molding,• Forging,• Tooling.

The CATIA V5 products and the “S4” solutionswith their associated methodologies are

available for each of the automotive domainsand allow optimal re-use of product developmentprocesses. They provide a working environ-ment that facilitates innovation and 3D communication for products, processes andknowledge.

ƒ Collaborative solutions based on SMARTEAM:• RFQ Response,• Advanced Product Quality Planning (APQP),• Concurrent Design,• Engineering Package Exchange (EPE).

The functionalities of SMARTEAM that are apart of the “S4” offer, allow the sharing and the data management within the companyextended entreprise – between the engineeringunits, manufacturing, the suppliers and theOEMs. The supplier thus becomes the “hub” of the project and controls all data and resources that will allow delivering the right product as quickly as possible and with the best profit margins.

Whatever domain the suppliers are dealing with, these dedicated “S4” solutions are available through packages built with CATIA and SMARTEAM products and with metho-dologies adapted to the company’s size, processes and IT architecture.

ILLUSTRATION OF SOME OF THE CHALLENGES ADDRESSED BY DASSAULT SYSTEMES’ “S4” SOLUTIONS:

Need: Reduce the time between projectkick-off and start of production (SOP)•Real-time concurrent engineering with the OEM• Real-time access to updated information for

suppliers participating in the project thanks toa single bill of materials

• Reduction of costly iterations between thevarious partners in the project

n Solution: Concurrent Design.

Need: Collaborate with various OEMsworking with multiple CAD and PDMtools, while protecting intellectual property• Engineering change facilitated by a relational

design approach• Management of product data from heteroge-

neous solutions• Protection of intellectual property

nSolution: Engineering Package Exchange.

Need: Answer to RFQ (Request forQuotation) quicker and more accurately• Rapid response to RFQ with predefined

generic models and re-use of existing productinformation

• More precise analysis of product configurationprerequisites thanks to standard processes

n Solution: Management of RFQ.

Need: Ensure the satisfaction of OEMswhile remaining compliant with their quality standards (ISO/TS16949)•Quality control through process optimization•Development costs lowered by providing

quality information on time and to all projectpartners

n Solution: Advanced Product QualityPlanning - APQP.

Need: Reduce the significant costs of non-standardized tooling and avoid starting design from scratch for each new project•Reuse of generic tooling models from one

project to the next one

• Capability of tooling simulation in the contextof an assembly line

•Standardization of tools thanks to catalogs of generic models from car makers

n Solution: Generative Tooling Design.

CONCLUSIONDassault Systèmes’ V5 PLM solutions meetsuppliers needs to provide automotive manu-facturers with parts, modules and systems.These suppliers support an important part ofthe R&D activity, while working closely withOEMs from the early stages of product designto maintenance and recycling.

CATIA V5 and SMARTEAM represent an integrated solution for the management ofproducts data and business processes. Ithelps suppliers to answer manufacturersexpectations: the best possible combinationof innovation, reactivity, quality and cost •)

The CATIA V5 products, the

“S4” solutions andtheir associated

methodologies areavailable for each of

the automotivedomains.

«

Accelerating Transformation in the Automotive Supply Chain

Shared strategiesfor product life-cycle management.

«

❯❯

To learn more about the “S4”configurations that fit your projects: info-solutions@ds-fr.com

3882-UK/Dassault 7/11/05 9:34 Page 10

13Contact mag | n°1

success story

Panasonic Toyota Racing is the officialname for Toyota’s Formula 1 Team.Established in 2001, the team is run on

behalf of Japan’s Toyota Motor Corporation byToyota Motorsport GmbH. 2005 is Toyota’sfourth season in Formula 1, making it one of theyoungest teams on the grid.

With more than 600 staff from 32 differentnations, Toyota Motorsport has developed itscomplete Formula 1 car —chassis and engine—from scratch under one roof at its factory inCologne, Germany. Toyota’s long-term goal is tobeat the more established teams in Formula 1and become a world championship constructor.

A TIGHT TWO-WEEK RACE SCHEDULETo win races, Toyota Motorsport (TMG) mustprovide its two drivers with the fastest car possible, respecting the tight, two-week race schedule. This means that, for every single race, TMG must quickly adapt car design toupcoming racing conditions, such as circuitconfigurations, driver racing style, and weatherconditions. “Ultimately, when you win races, you win themin the design area,” says Mike Gascoyne,Technical Director Chassis, Toyota Motorsport.“Getting new ideas into the car is key when

you’re working on a two-week timeframe.That’s where Dassault Systèmes V5 PLMsolutions are absolutely crucial to our corefunctions.”

V5 PLM TO COVER THE ENTIREDEVELOPMENT PROCESSTo accelerate F1 car development, TMG choseDassault Systèmes’ V5 PLM solutions basedon CATIA V5, ENOVIA, DELMIA and DSGenerative Car Solution. Specialized applica-tions from Dassault Systèmes’ software partners CAA V5 are also used. They includeABAQUS for CATIA V5 for nonlinear simulation,LMS Virtual.lab Motion for dynamic motionsimulation, CENIT’s CAA V5-based FasTRIMproduct for automatically programming laser-cutting robots and Transcat PLM’s Q-checkerfor data exchange quality insurance.

“We needed a long term PLM solution that covers our entire development process,as well as a partner capable of under-standing our job,” says Thomas Schiller,General Manager, IT department, ToyotaMotorsport. TMG has achieved clear andtangible benefits from its V5 PLM imple-mentation throughout its entire developmentprocess.

Chassis process: time gainsThe V5 PLM Digital Mock-Up (DMU) tools arecrucial to achieving the harmony between thechassis and the engine. “By using V5 PLMDMU solutions, we can check the car’s assem-bly while we’re still in the design stage, becausethe designers are not designing in isolation,”says Mike Gascoyne. “We quite simply no lon-ger see the problems we used to have in termsof car’s first physical assembly. Before, it couldtake two or three weeks. Now we do it in two orthree days. The time gain gives us a tremen-dous advantage.”

Aerodynamics process: productivity gains“Moving from CATIA V4 to CATIA V5 hasenabled us to almost double the number of prototypes we can make in a given time,” MikeGascoyne adds. “This in turn enables us todouble the number of tests in the wind tunneland double the car aerodynamic performance.That’s absolutely essential to high performanceon the track!”

Toyota Motorsport, Toyota’s Formula 1 racing team, has obtainedsignificant benefits from its V5 PLM implementation – and thatacross the whole development process.

Doubling Design Productivity with V5 PLM

Key V5 PLM benefitsfor Toyota Motorsport

Another benefit measured by TMG’s aerody-namics team comes from implementing theGenerative Car solution. “Using the GenerativeCar solution in the aerodynamics department hasincreased design productivity by 30%, and by upto 80% if we look at parts such as the front wing,”notes Stéphane Chosse, Wind tunnel ModelDesign Manager, Aerodynamic department,Toyota Motorsport.

Engine process: design quality improvementThe powertrain challenge lies in producing themost powerful engine while keeping it as light-weight and reliable as possible. “Design qualityis the key issue to a successful Formula 1 carengine,” says Luca Marmorini, Technical DirectorEngine, Toyota Motorsport. “In particular, CATIAV5 analysis tools enable us to simulate theconstraints endured by extremely complex mo-dels, such as blocks or crankshafts. This definitelyhelps us increase the engine’s design quality.”

Car transmission process: time savingsTMG has obtained very significant time gains inthe development of its car transmission sinceupgrading from CATIA V4 to CATIA V5. “CATIAV5 implementation in the transmission area wasvery impressive,” Thomas Schiller points out. “It took us the same amount of time to imple-ment, train people, and design the car transmis-sion in CATIA V5 as it took us just to design it in CATIA V4. Plus, we were able to double design and analysis iterations!”

Cockpit ergonomics: innovation for the F1 driverV5 PLM enables engineers to design the car in away that optimizes its interactions with the driver.“With V5 PLM Human Modelling ergonomicstools, we insert the driver virtually into the digi-tal mock-up of the car,” says Mike Gascoyne.“We can then optimize the ergonomic design of the monocoque to ensure that the driver will fit perfectly and be able to operate the car whiledriving it at the limit.”

EXTENDED COLLABORATIONAROUND THE DIGITAL MOCK-UPWith CATIA V5 and ENOVIA, TMG has a virtualFormula 1 development hub, where any teammember can access the car’s digital mock-up.

For instance, the car’s digital mock-up can beaccessed by the purchasing or marketingdepartments to perform specific tasks in CATIAV5. “In our marketing department, we useCATIA V5 Real Time Rendering to get an ideaof what the car will look like before we build it,”says Markus Schwarze, Manager, TechnicalApplications, Toyota Motorsport. “It is absolu-tely essential for our sponsors to see what mil-lions of people will see on TV screens before thecar is on the track.”

Furthermore, V5 PLM solutions are actually present on the track, too. “By using CATIA V5and ENOVIA, the track mechanics are able to see, in 3D, how they have to fit all the car components,” adds Mike Gascoyne •)

Time reduction• up to 80% in the aerodynamics design

process (Generative Car solution)• 90% for first physical assembly – down

from 3 weeks to 2 days (DMU V5)

Improved car performance• +100% wind tunnel prototype production

and test (knowledge-based designs)• One of the most reliable F1 engines

(the department has moved to CATIA V5)

Cost reduction*• 60% cost and time savings searching for

information during the design processes• 40% cost savings fixing BOM errors• 48% cost savings for administering

Engineering Change Requests (adminis-tration, tracking, distribution, etc.) and57% savings in labor costs to completeECRs

*findings based on an independent study performedby CIMdata, PLM consultant.

“”

We view all partnerships as a win-win opportunity. Dassault Systèmesoffers us car development solutions that give us the cutting-edgeperformance that is required in Formula 1. At the same time, we like to think we’re pushing their technology to new limits because of the ultimate challenge of material and performance that Formula 1 demands.

JOHN HOWETT

President, Toyota Motorsport GmbH12 Contact mag | Dassault Systèmes

3882-UK/Dassault 7/11/05 9:35 Page 12

15Contact mag | n°114 Contact mag | Dassault Systèmes

product overview

Contact: What are the main benefits of ENOVIA V5?Nordine Marouf: ENOVIA V5 is designed forthe high-end of manufacturing industries, thosewhich have complex products to develop and a high degree of diversity to manage. These are large enterprises such as aerospace andautomotive OEMs but are also medium-sizedcompanies such as in the machinery industries.The unique strength of ENOVIA V5 is the abilityto manage innovation processes in an increasingly complex environment for design collaboration, manufacturing and after-sales. With a complete implementation of ENOVIA V5together with CATIA V5 and DELMIA V5, ourhigh-end customers get the full power of V5PLM and maximum ROI. They can replace theircostly legacy PDMs and multi-CADs by a single PLM system where every aspect is optimized from end-to-end until linkage to theproduction systems. And this can occur inmany different ways and steps to cope witheach customer’s priorities.

Contact: How does ENOVIA V5 affect thekey milestones in the development process?NM: ENOVIA V5 contributes to reducing theproduct development cycle time with improvedCATIA V5 feature management, rapid access tostructured data, upfront manufacturing andimproved collaboration across the extended

enterprise. It also allows customers to readjusttheir relative design and manufacturingtimes to optimize cycle time and cost.

Contact: Who is using ENOVIA V5today and how?NM: From the growing number of customersin production, it is easy to notice that ENOVIAV5 customers have all made a clear decisionto deeply transform their end-to-end proces-ses. Such a decision may result from mergingenvironment as Volvo AB is having in theirtruck division with Volvo, Renault and Mackbrands: here the primary goal is to enable acommon way to develop trucks across multipleengineering and manufacturing sites and atthe lowest cost. It can also be driven by a hugetransformation as the one that Boeing decidedto implement for their 787 program which isco-developed with 40+ risk-sharing partners. For medium-sized companies, the most frequent decision factor is the globalizationwhich requires to re-think the value chaininside the enterprise. Strategic aspectsaround management of product structure,in-house components, sourcing and intellectualproperty are coupled with enhancement ofconfigured DMU processes or know-howcapture and re-use. This is the case at Bobst,

a Switzerland-based group which produceslarge machines for the packaging industry orat Homag, a German group which is verysimilar but for the wood industry.

Contact : What about your existing customers with VPM?NM: We also have customers who implementpart of ENOVIA V5 in order to first enhance their design environment thanks to the tight integration with DMU processes based on CATIA V5. This is typical of Tier 1 supplierssuch as Bertrandt Engineering in Automotiveor Latécoère in Aerospace. Our VPM V4 customers often start with this step as itappears quite logic when they want to getmaximum benefit from CATIA V5.

Contact: Then tell us what does ENOVIA V5consist of?NM: The ENOVIA V5 portfolio is basically madeup of three lines of applications:VPM V5 enables relational product develop-ment so that manufacturers can rapidly opti-mize product definition early in the life cycle.Inside CATIA V5, this is called VPM Navigator.LCA V5 is a set of Web-based applications thatmanage lifecycle. It provides access to both 3Dand non-3D data and manages the proces-ses between engineering and manufacturing.DMU V5 is a collaborative decision supportplatform for real-time virtual product visualization,navigation, analysis and simulation. It reducesthe number of physical prototypes required andincreases the visibility of design changes onproduct variants •)

ENOVIA V5 - Meeting the Challenges for the High-endThe ENOVIA V5 suite is available on the market, helping large and mid-sized enterprises alike. Contact Mag asked Nordine Marouf, ENOVIA Market Development Manager, to give a run-down on the ENOVIA V5 benefits and the challenges it helps solve.

Meissner AG is under pressurefrom global competition.

Its response has been toleverage the unique benefits

of CATIA V5, SMARTEAM, andCADBAS-PartExplorer for

modeling its tooling and molds.

CATIA V5CATIA V5 handles all modeling methods,the modeling of parts and assemblies aswell as the production of technical drawings.CATIA knowledgeware modules are exten-sively used.

SMARTEAMManagement of CAD documents comingfrom a multi-CAD environment is crucial forMeissner. This will be progressively extendedto management of other documents (Office,archives, etc.). SMARTEAM also manages alldata exchange processes and security.

CADBAS-PartExplorerThe PartExplorer solution ensures clas-sification of repetitive parts in order toimprove reuse and carry-over. The librariesof standardized parts and supplies as wellas the expanded intelligence of the TG1and MDT CATIA modules allow automaticgeneration of CAD geometry.

For over 80 years, Meissner ofBiedenkopf-Wallau in Germany hasbeen a hallmark of foundry tools, blow

molds, and tooling for vehicle bodies.Investing in CATIA V5, SMARTEAM, andCADBAS-PartExplorer will underpin its worldwide leadership and enhance its com-petitive edge.

The combination of these solutions helpsMeissner achieve several objectives. Itenhances development and modeling productivity, but also increases flexibility and creativity in general. It helps standardize their CAD/CAM environment, better shareknowledge, tighten data exchange securityand reduce IT spendings.

Short term focus areas have been selected by Meissner in order to quicklycollect benefits:• Document management (of CAD and non-

CAD objects);

• Bills of materials and performance data;• Certifications of parts utilization;• Classification of repetitive parts (assemblies,

proprietary drawings, standardized parts and supplies);

• Use of libraries of standardized parts andsupplies;

• Elimination of isolated solutions and redun-dant data entry;

• Optimization of the modeling methodologythrough knowledge management.

WORKING TOGETHERCUTit! Systeme is the IBM/DS PLM BusinessPartner selected by Meissner to implementCATIA V5 and SMARTEAM with the right design methods. CADBAS advises Meissneron classification methods and processessupported by CADBAS-PartExplorer.Dassault Systèmes AG provides additionalguidance to make sure the latest technicalenhancements are made available to theusers •)

World-class Tool Modeling

3882-UK/Dassault 7/11/05 9:35 Page 14

Iam delighted to introduce thefirst UK section of the all newEuropean Contact Mag. This year

is an exciting one for DassaultSystèmes in the UK, not leastbecause our new subsidiary DassaultSystèmes Ltd has been up and

running since July 1st. We have established a strong team of40 specialists, half of whom are dedicated to our channeldevelopment activity. Our office, located in the Midlands, inthe City of Coventry, means we are centrally situated for ourbusiness partners, and we are also close to Birmingham airport. I have extended an open invitation to all BPs and theircustomers to use our new facilities as if these were their own,since I really want to create an atmosphere of an extendedDassault Systèmes family amongst us all.

Our Channel Development team comprises Sales,Technical, Marketing and Business Administration peoplewith many years of PLM experience between them. Theycome from diverse backgrounds and have a variety ofskills, but today they have one common goal, which is tohelp our Business Partners to be even more successfulwith their customers.

Having worked for a BP myself, and through speaking tonumerous BPs and customers at length, I know howimportant it is to have good local technical support, both accessible and well qualified. Consequently, our organization includes a Technical PLMCompetency Centre to address this need. Our techni-cal team is closely linked with the European PLMCompetency Centre in Paris and ultimately, of course,to the Dassault Systèmes software developmentorganisation.

In this issue you will find the latest information onnew solutions that are now available, togetherwith some interesting articles about how custo-mers are reaping the benefits of our PLM solu-tions, not only in the UK but also overseas.

PHILIPPE BOULAYDirector Channel Development

United KingdomDassault Systèmes Ltd

in practice

GENERATIVE MECHANICAL DESIGNDiscover the benefits of GMD and seehow it can be used as a differentiator

LAWTONUnderstand how thisleader can stay aheadin the MedicalInstruments market

SECURISTYLESee how the combination ofCATIA V5 and SMARTEAMgive a window manufacturera clear competitive edge

MECH-TOOLLearn how Mech-Tool are on track to achieve a 25-foldreduction in time within their design process

18

Viewpoint

]

UK and Ireland

Dassault Systèmes and Intel join forces in PLM

A Product Lifecycle Management solution for small and medium manufacturing businesses.

The challenge: increase innovation and profitability for SMEs by reducing developmentcycle time and cutting costs without having to invest in expensive mainframe computertechnology.

The solution: CATIA V5 and SMARTEAM.CATIA V5 is the product design component, allowing manufacturers to simulate all theindustrial design processes. SMARTEAM provides knowledge and process manage-ment, enabling users to optimize business processes through product knowledge mana-gement and collaboration.

The technology:The following technologies are used to deliverreal-time visual collaboration for distributedproject teams in the manufacturing industry:Intel® processor-based server platformsPowered by the Intel Xeon™ processor familyClient devices based on powerful mobile tech-nologies developed by Intel. (LDAP) server 7

• High performance client desktop systemsbased on the Intel Pentium 4 processor cancontribute significantly to the overall proces-sing power available to the end user.

• Mobile laptops based on Intel Centrinomobile technology were designed, testedand tuned specifically for mobility and enablesecure wireless connectivity that protects thenetwork from misuse.

Today’s typical manufacturer is faced with an overwhelming array of issues – devisingcustomized products, getting to market fast,eliminating inefficiencies, communicatingeffectively with partners and suppliers, meeting performance and quality objectives,designing for manufacturability and servi-ceability.

CATIA V5 and SMARTEAM, in combinationwith Intel technology enable SMEs to acquirean entry-level PLM solution and then grow itas the business thrives.

THE CASE OF MASCHIOItaly's Maschio Group is a world leader in themanufacture of agricultural machinery. Its challenge is to bring to market innovative andmarket-specific machines, but also to dramati-cally shorten the product development cycle to meet seasonal deadlines.

Maschio implemented Dassault Systèmes’ PLMsolution in 1999, integrating the 3D productdevelopment capabilities of CATIA V5 with the data and lifecycle management features of SMARTEAM.

The benefits: since then, Maschio designershave been able to explore 50% more designoptions for each project, which improves qualityand fosters innovation. In some areas, thedevelopment cycle of new machines has beenreduced by 55%.

“By slashing the cycle time, we are nowmuch more able to adapt to market demand.The benefits to us are priceless”

Massimo Crozzoli, Maschio IT Director.

Advertorial

20

22

26

24

BLACKFLAG COMPOSITERead how this young company

exploited tailored functionality for a successful yacht project

If you would like to receive future issues of this magazine please contact David Treacher via dtp@ds-fr.com 17Contact mag | n°1

3882-UK/Dassault 7/11/05 9:35 Page 16

19Contact mag | n°118 Contact mag | Dassault Systèmes

in practice

Generative Mechanical Design a ‘Must Have’ for SMEs

There are various ways to improve theuse of in-house knowledge, the forma-lization and standardization of business

rules, plus the automation of repetitive tasksand the management of a design’s evolution.These are all factors which enable a companyto get a head start, at the concept design stageof a product, so freeing up more resources toinvest in innovation.

A rapid return on investment is only possible if the right tools and the right methodologies are applied. In particular, significant gains canbe made through:

Design process optimization. Customizationshould be minimized, to avoid having to re-invent entire designs. The re-use of standard parts reduces risk.

Enhanced flexibility. Companies areobliged to design increasingly complexproducts that meet standards whichare constantly evolving, while delive-ring innovation and quality.

Collaborative work. Coordination iscrucial. The various partners must

speak the same language, exchange consistentdata, and be able to access the right informa-tion at the right time.

Lifecycle management. The design of a productmust take into account its total lifecycle. Theassociated documents must evolve with the va-rious versions of the product. The more its con-tent and processes are standardized, the easierand cheaper the product will be to maintain.

If companies are to achieve these improve-ments, they must set up an environment thatpromotes innovation. But that means that lowvalue-added tasks need to be automated.

Leveraging know-how • Use previous projects to develop quotations

for new ones. • Analyze which part in a new project is

unique and which part is repetition. • Use the best methodology to design and

manufacture the product.• Guide the sales people toward standardized

solutions with automated technology toreduce costs and risks and increase margins.The ultimate objective is to sell productsmade of standard modules.

Standardizing functions and componentsThis can represent sets of data describing sub-sets (3D geometry, 2D drawings, cablingdiagrams, functional architecture, componentcatalogues, etc.), standard component bills ofmaterial, or any other recurrent information.Standardization imposed by business rulesincorporated in the system ensures that two dif-ferent designers work towards the same solution.

Deploying company rulesThis will ensure product traceability and standards compliance. Spreading the businessrules to all the partners of a project and integra-ting them into the working tool is a key benefit.These factors, integrated into the traditionalCAD working tool, ensure that the companydesigners are really focused on innovation andadded value. In turn, this enables a company to get a competitive edge, rapidly launch newproducts, and secure its margins.

INTRODUCING GMDBased on CATIA V5, Dassault Systèmes’Generative Mechanical Design (GMD) integratesa logical layer above the parametric setting of thedesign data. This is a true differentiator compa-red to tools currently on the market. It allows youto define the design rules, standardize the com-ponents, and capitalize on the business rules.

Some of the benefits of CATIA V5 GenerativeMechanical Design:

Rule management controlling dimensionalparameter setting• If a designer has to define the length of a given

component, he does not do so manually; hespecifies the required length and the systemupdates the component.

• In the example of the conveyor belts illus-trated above, the user’s only role is to specifythe height of the conveyor belt. CATIA V5 auto-matically selects the required type of support.

Maintenance constraints taken into account• A maximum number of components of a

certain type can be imposed in a sub-set to make maintenance easier.

• The rules for choosing components can take into account maintenance department requirements to select the best components.

IMPLEMENTING GMDDassault Systèmes and its partners offer usertraining and the methodology for implementingand optimizing use of Generative MechanicalDesign for companies of all sizes.

Implementation stages:• Identify the repetitive modules. Each module

must always be adapted to client needs, and this can be entirely using the generativeapproach.

• Define the design rules for these modules.• Build the generic module and integrate the

design rules into CATIA V5.• Implement on site.

Two modes of implementation:• The company defines its design rules in the

specifications and does not need to modifythem in the short term. In this case, the company only acquires the ‘Run’ modules.

• The company defines its own rules and wantsthem to evolve. In this case the ‘Build’ modulesare required to integrate the rules in its proces-ses and modify them later, plus the ‘Run’ modu-les to use them.

The initial investment will be rapidly amortized.Gains of over 50% have been measured in thedesign stages.To promote collaborative work and optimizethe business processes in SMEs, DassaultSystèmes recommends SMARTEAM. This is a

collaborative data management tool providingworkflow management, a Web interface, mana-gement of bills of material, and the automaticproduction of quotations. SMARTEAM alsoallows for rule sharing and process complianceby the different teams.

CONCLUSIONSMEs implementing Generative MechanicalDesign can promote innovation, reduce errors,increase margins, and gain market share.Whatever the business processes or the com-pany standards, Generative Mechanical Designis a differentiator for those wishing to explore the limits of PLM and offer their clients the best products at a competitive price •)

The design of a productmust take into accountits total lifecycle.

«

Reducing time and cost while improving quality are key prioritiesfor most industries.

The Benefits ofthe GenerativeMethod • Integrate ‘design rules’ into design

activities; this avoids task repetitionand the duplication of errors.

• Re-apply know-how within newcontexts (client projects).

• Focus on innovation.• Improve communications among

project partners.• Give reliable and accurate

quotations.

Implementation ofa technological element takingconstraints into account.

Publication of trade design rules. Definition of the parameters for a flange.

ModificationDesignPreparation

3D DesignSoftware

BasicCATIA-V5

Usage

CATIA-V5Generative

DesignApproach

By Fabrice Dreneau and Olivier Boces]

3882-UK/Dassault 7/11/05 9:35 Page 18

21Contact mag | n°120 Contact mag | Dassault Systèmes

3DXML

in practice

New Challenges for Leaderin Medical Instruments

Lawton is a medium-sizedcompany located on the river Danube in Fridingen,Southern Germany.Established in 1947, Lawtondesigns and manufacturessurgical devices and medicalequipment. The product rangeincludes most types ofmedical instruments, andcomprises around 14,000individual products, available in 80 countries around the world.

For a company of our size the experienceof our workforce is our most valuableasset. While our standard products can

be produced overseas, our premium productscan only be produced in-house. Therefore a primary objective is the long-term security of Lawton’s facility in Germany together with our profitability.

In recent years, we have faced growing com-petition for our standard products, particularlyfrom the Far-East. Consequently, new strate-gies were developed and implemented to overcome this trend:

• New materials, new technology and new processes were introduced. Quite clearly, that calls for new procedures with more engineering. CATIA V5 provides the basis to describe complicated products and their

variants, while taking into account the effectsof manufacturing. For example, the CATIARealistic Surface Optimiser automaticallycompensates for any shape deformationsthat result from our production processes.

• To react quickly to market demands, efficientcommunication is essential. For example,when the sales and development peoplework together, new ideas and opportunitiesare generated. Representatives from ourdealerships are in the loop also, whichmeans we need fast communication toolsand media such as the internet, images, film,presentations and even rapid prototypemodels. In addition to the traditional data for-mats, we are now exploiting the new 3DXMLviewer. This enables us to communicateabout new ideas and concepts instantly withany customer.

• By reusing our successful designs and embra-cing the latest technology, we are able tomanage the innovation which is becoming thenorm. Without innovation, even our premiumproducts will quickly become obsolete. Weare able to not only accelerate our designtime, but also to improve and optimise at thesame time. For example, we can now investi-gate the mechanism of an instrument muchearlier and more extensively than before.

• Our future products will be even more attrac-tive, better styled and more user-friendly. Thisfurther differentiates us from competitors whooffer cheaper products. Achieving this is moreexpensive, but the result is a superior qualitythat is really obvious and tangible. The surfacesof our new products all blend smoothly toge-ther and match the quality commonly seen inthe Automotive and Consumer Productsindustries. At the same time, the amount ofbasic CAD modelling effort is being reduced.One outcome - our ergonomic handles - will revolutionize medical instruments, and prevent operator’s hands from slipping.

• Even though we have introduced changes,any new way of working together necessitatesthe need for clearly defined processes.Therefore, our future PLM vision includes a rolefor Product Data Management in addition toa long-discussed ERP system. The exchangeof data with our customers and our suppliers,all operating within a network, will bring costsavings and a competitive advantage.

• Market leading products are ‘lean products’and our offerings must be available at the

price the customer is willing to pay, but alsoinclude some product differentiation. However,they must also be cost effective for us to produceand we have found that premium products donot necessarily have to include every latestgimmick. With the help of CATIA V5 we areable to develop a sophisticated product for aparticular price and this does not alwaysmean the lowest price on the market.

• Time to Market can always be improved. Sincecustomers like to shop around for the bestcontract, it inevitably means that a very shorttime is available to develop a product from theinitial idea though to market readiness. We havea strong reputation for our fast turn-around timefrom concept to production. Many Doctors,with whom we have developed instruments,are delighted by our responsiveness.

We installed CATIA V5 in January 2005. Initiallywe thought about using a mid-range system,but soon realized that with such a system ourrequirements were not achievable. After the initial basic training course in CATIA SolidModelling and GSD Surfacing, we completedour first project. During this learning phase wecontinued to work as before while using thenew tool. But we soon had an ideal opportunityto change when one of our sales people sug-gested a new type of instrument handle. We

modelled his idea and sent him back a 3DXMLfile to visualise the result. In this way we wereable to discuss the first design within a week.After 2 more iterations and an STL represen-tation, the optimum design was found.

Meanwhile, as a parallel exercise, we investiga-ted new production methods. Our supplierswere able to provide accurate cost estimates atan early stage and hence we were well placed todecide upon the best manufacturing procedure.

The parts and assemblies we have previouslydeveloped have been split into basic buildingblocks and further developed into so called‘Powercopies’. This has been a real boost forour development team because these elementsare now used as templates which enable us todevelop new offerings from these individualcomponents. For example, to design a new pairof scissors we bring together tips, blades andhandles based on previous projects. We do notwaste much time in modelling, but immediatelystart to optimize the product.Our sales people take advantage of the innovativepower of our development tool and present ourproducts in a totally new way ( 3DXML ). We canalready attribute our first commercial successesto this approach, and we have shortened ourdevelopment time by two weeks •)

Reiner Haag-General ManagerHarald Müller-EVP Product

Development and Production.

The new 3DXML viewer enables us to communicate about new ideas andconcepts instantlywith any customer.

«

By Reiner Haag, General Manager, Lawton, Fridingen]

3882-UK/Dassault 7/11/05 9:35 Page 20

23Contact mag | n°122 Contact mag | Dassault Systèmes

in practice

Mech-Tool Engineering Proves the Value of CATIA V5

The North Sea is one of the world’s harshest environments for offshore oilproduction. But Ron Davison, Technical

Director of Mech-Tool Engineering, knows thecompetitive environment can be just as puni-shing for the industry’s suppliers. “Not long agothere were companies all across the UK servi-

cing the offshore industry andmaking a reasonable living,”Davison recalls. “Today, 80%of our products are sold intothe world market and only a third of our business is offshore.” Margins, meanwhile,continued to shrink.

Mech-Tool responded by diversifying from itscore business of explosion and fire-proof enclo-sures for offshore oil rigs. It added industrialnoise-control enclosures and packaged equip-ment modules for pumps and engines. But everywhere it turned, it ran into foreign compe-titors with labor costs as much as 65% lowerthan in the UK.

“We knew that making a small tweak here andthere wasn’t going to work any more,” Davisonsaid. “Our biggest cost centers are engineeringand manufacturing. We had to make a radicalchange if we were to recapture our margins.”

CATIA V5 AND TRANSCAT PLM:THE RIGHT SOLUTIONJust moving Mech-Tool’s design process from2D to 3D could fundamentally improve Mech-Tool’s economics. But finding a system thatcould deliver was difficult. “Our manufacturingprocess relies totally on drawings of a certainquality,” Davison said. “The first system we triedwas fine for modeling, but on the drawing sideit was totally inadequate.”

Mech-Tool next turned to IBM/DS BusinessPartner Transcat PLM. Sales engineer AndySimkins introduced a novel approach to creating new designs. Transcat PLM helpedMech-Tool create reusable knowledgewaretemplates in CATIA V5, to capture its processesand standards, leverage its existing know-how,and avoid having to create new designs fromscratch.

These reusable knowledge templates wereintegrated with the Generative MechanicalDesign (GMD) solution in CATIA V5. So GMDhas enabled Mech-Tool to slash new designdevelopment time, reduce engineering andmanufacturing costs, and boost accuracy.

“We knew instinctively that Transcat PLM wasright,” Davison said. “But when the name CATIAV5 was first mentioned, I thought I’d neverconvince my board. We thought CATIA wassomething that Ford and Boeing use – a solutionthat costs lots of money and is way above whatMech-Tool needed. Now we know better.

We no longer look at the cost of the softwareonly. We look at the value of the return. TranscatPLM’s know-how was invaluable in getting thereturn on our investment. Although all of thiswas new to us, it wasn’t new to them.”

ON TRACK FOR A 25-FOLD IMPROVEMENT Mech-Tool is implementing CATIA V5 in stages,beginning with the intake modules for its acous-tic enclosures. Although that is just 25% of oneproduct line, the company is on track to achievewhat it believes can be up to a 25-fold reductionin the time taken to produce manufacturing drawings for components modeled in CATIA V5.

Creating Bills Of Material (BOM) from conven-tional drawings once consumed 30% of thecompany’s design hours. Now BOMs are gene-rated instantly and error-free. “A serious mistakein a BOM can result in dire commercial conse-quences,” Davison said. “We can substantiallymitigate that risk.”

Seeing the finished product in 3D helps the company’s metalworkers better interpret their2D drawings, saving time and eliminating guess-work. “In the past we generally had to go to thefactory floor and sort problems,” said MartinHarris, Mech-Tool’s CAD Team Leader, whorecently used CATIA V5 to engineer a complex3D box. “With this one, it was a first-time fit.”

3D visualization is also valuable in client-facingsituations. Harris recently showed a client

design variations for a 45-ton pump enclosurein real-time using CATIA V5. “Because theycould see it and watch as we played withvarious options, the client was able to do thingsin a more efficient way,” Davison said. “Theywere very appreciative and impressed. We thinkthat kind of extra value will help differentiateMech-Tool in the marketplace”•)

A serious mistake in a BOMcan result in dire commercialconsequences. Now BOMs are generated instantly and error-free.

«UK enclosure manufacturer, Mech-Tool Engineering, opted for CATIA V5 and GMD Solution to radically

transform its design process and recapture margins in a highly competitive market.

It’s early days,but progress is very promising andwe expect to makesubstantial savingsin the time it takes to produce manu-facturing drawingsfor componentsmodeled in CATIA V5.

RON DAVISON

[Technical Director, Mech-Tool Engineering]

”

“

3882-UK/Dassault 7/11/05 9:35 Page 22

25Contact mag | n°124 Contact mag | Dassault Systèmes

in practice

Securistyle of the UK is a global leader inthe manufacture of window hardware.Until recently, it had worked mainly

with a 2D system. As a result, it faced majordesign challenges when tackling 3D productssuch as handles, gears and the increasinglycomplex components used in hinges. At thesame time, specialized architects’ require-ments combined with rapid legislative changes within the industry instigated theneed to change towards an alternative system.Moreover, Securistyle had built a vision anddefined objectives to expand its worldwidemarket position.

To meet all these challenges, Securistyle’smanagement decided to modify the company’sdesign processes to produce new productsmore rapidly. Their aim was to manage datacommunication between Securistyle and itscustomers to provide prompt, professionalresponses to customer requests. Extensivebenchmarking was carried out to determinethe best system for Securistyle to adopt.

“We were looking for a unified PLM (ProductLifecycle Management) solution that combineduser-friendly and powerful capabilities such as

clash detection, finite element analysis, and3D visualization, seamlessly integrated with a Product Data Management system,” saysStephen Hall, Senior Project Engineer atSecuristyle.

CATIA V5 AND SMARTEAM: THE RIGHT CHOICE In the end, Securistyle opted for a V5 PLM solution supplied through the IBM/DSBusiness Partner Applied PLM Solutions. Thesolution combines the 3D product develop-ment capabilities of CATIA V5 with the data andlifecycle collaboration features of SMARTEAM.“We chose CATIA V5 and SMARTEAM notonly because of their unique capabilities butalso because we have an excellent relationshipwith Applied PLM, our local IBM/DS businesspartner, which implemented the project andalways provides us with good support,” saysRichard Gurmin, Senior Engineer, Securistyle.

CATIA V5 and SMARTEAM providedSecuristyle with the competitive edge it requiredto meet and surpass its business challenges.With a sharp reduction in its design phase anda better response to the market by designing rightthe first time, Securistyle increased innovationfor greater reactivity and competitiveness.Today, Securistyle has achieved clear andtangible benefits from V5 PLM solutions:• increased innovation, allowing the company

to penetrate new markets, while respectinginternational safety standards

• reduced product development time and costsin response to customer demands and worldwide competitive pressures

• a streamlined bidding process to develop high-quality proposals for customers more rapidly.

MULTIPLE BENEFITSSecuristyle has achieved a whole range oftangible benefits from its CATIA V5 and SMARTEAM implementation.

Increased innovation“With CATIA V5’s advanced styling and visuali-zation features, we can now design, validateand easily demonstrate to architects and specifiers all of the ideas and innovations wehave in mind,” says Stephen Hall. CATIA V5enables Securistyle to develop more innovativewindow hardware to meet perpetually-changinglegislation and very specific requirements fromarchitects. “Our capability to offer more inno-vative products helps us to position ourselvesas a window-hardware solution provider andeven to influence the legislation. This distingui-shes us from Far-East competitors, who gene-rally design low-cost commodity products,”adds Grant Stratford, Technical Manager.

Reduced development costs and time*“For new products, we have reduced designtime by up to 44% and overall development

costs by up to 60%, which gives our companythe flexibility it needs to meet customer requi-rements right first time,” Stratford continues.

Thanks to the assembly and tolerance analysiscapabilities of CATIA V5, and SMARTEAM’sability to control and revise document mana-gement, Securistyle has cut the number ofdesign errors by 50%. This generates timesavings of 65% for design change manage-ment and 80% cost reduction at the manu-facturing stage to correct errors. It alsoreduces the number of prototypes. In thepast, Securistyle needed three successiveprototypes per project to validate their design.Now they generally only need one. This cansave up to three months per project.

In addition, the flexibility of CATIA V5 paramete-rization enables designers to more thoroughlyintegrate new design options and to adaptexisting, validated designs for a new project.The costs of designing a new part from anexisting one have been halved.

Increased business revenuesWith CATIA V5, Securistyle has streamlinedthe bidding process as it provides more accurate cost calculation using weight estimates of parts. “With SMARTEAM, wehave deployed a collaborative participation of Sales, Production, Testing, and Quality. All departments can visualize the latest, upda-ted information. As a result, we provide ourcustomers with more accurate answers totheir enquiries,” says John Mayes, TechnicalCustomer Services. “In the coming years, weplan a 50% increase in the number of projectswe can launch using the same number ofdesigners,” says Paul Cook, ManagingDirector •)

Fire Escape Hinge.

Dual Action Lock Mechanism with Sprung Hook.

Latest 'Vision' Handles. High Security AncillarySecurity Device.A Window of

Competitive Opportunity

CATIA V5 and SMARTEAM join up to give UK windowhardware manufacturer Securistyle a competitive edge.

Market Leading 'Defender' Friction Hinge.

High Security Lock Housing.

Securistyle has cutthe number of design

errors by 50%.

«

About SecuristyleSecuristyle is based in Cheltenham,Gloucestershire, in the United Kingdom. It is one of the world’s most advancedmanufacturers of window hardware withmore than 45 million pairs of friction hingesused worldwide. Securistyle designs and manufactures market-leading friction hinges, handles, and lock mechanisms for all types of window frames and exports tomore than 50 countries across the globe.Securistyle’s full product range is designedfor worldwide use in commercial, residen-tial, and public-sector applications.

3882-UK/Dassault 7/11/05 9:35 Page 24

26 Contact mag | Dassault Systèmes

BlackFlag Composite was recentlyinvolved in an extension for the sternof a sailing yacht. This project meant

that the lines of the hull had to be lengthenedand also raised at the back above the waterlineto create a platform. Only 5 weeks were avai-lable for manufacture and during that time theboat could not be immobilized. Consequentlythis customised part had to be designed andproduced remotely and then installed on theboat in just a few hours.The company invested in a CATIA V5 to gainaccess to all the necessary tools for innovationand to ensure the best quality and cost of its pro-ducts. The use of digital mockup was a majorfactor contributing to the success of the project.

“We needed to create a 3D model in order torapidly simulate the different design variations,”explains Charles Pourreau, Design Manager,BlackFlag Composite.

The project itself was made up of following stages:

Accurate representation - A digital represen-tation of the hull was captured using a laser scan-ning device which generated a cloud of points.Point data was taken every 100 mm along thehull and at 10 mm intervals for detailed sections.

Surface reconstruction - “From the cloud of points, the CATIA V5 reverse engineeringmodules enabled us to rapidly recreate the actualsurfaces of the boat hull,” says Charles Pourreau.

Digital mockup and validation - Thanks tothe digital mockup, BlackFlag Composite was

able to create a virtual model to validate theshape of the hull. “The digital model is an assetfor our clients as it allows them to see their product in 3D”.

Digital tooling - Digital mockup representa-tions of the tools were made, i.e. the templatesfor the mold, then those shapes were developedfor the mold surfaces.

Manufacture and final assembly - The newsection was laminated in the mold, then coatedin the workshop prior to assembly on the client’sboat. During final assembly, extra laminationswere made followed by a finishing coat toensure a perfect join.

“We were able to fix this section on the boat infour days thanks to CATIA V5. I learned the product functionalities during the project,without having taken any formal training, and byasking advice from Dassault Systèmes. I reallyappreciated how easy it is to learn CATIA. The benefit of this software is the direct exploi-tation of the design data for manufacturing,which thereby reduced our overall project timeconsiderably” •)

BlackFlag CompositeLaunches CATIA V5 Project

for Yacht Customisation

The company BlackFlagComposite was established

in 2004 and specialized in thedesign and manufacture of

customised composite parts for the yacht industry.

This industry is graduallyevolving from one using

traditional processes to thosefound in other industries suchas automotive and aerospace.

Meanwhile, the market has beengrowing significantly, and

shipyards are now offering a larger selection of models of a higher quality and with

more innovation.

Extension for the stern of a sailing yacht.

SCOTLAND

WALESWALES

ENGLANDENGLENG ANAN

nd on Seauthend onSouthendnd

gBrightonBrightonPortsmoPortsmouthrtsmou

Southampton

BRISTOL

GLOUCESTERGLOOUCE EREST

OXFORD

BEDFORDNORTHAMPTONORT A

WARWICK

Leicester

CoventryBIRMINGHAMBIRMBIRRMINMIN

STAFFORD

Sheffield

nKingstonKingstonpon Hullpon Hullupon Hull

gg

NNNORTHALLERTONNORTHALLERTON

URHAMDURHAM

EWCASTLE UPON TYPENEWNE

GLGLGLASGOWGLASGGOWEDINBURGHEDINBURGH

EEDUNDEEDUNDE

STIRLINGSTIRLINGSTIRL

ABERDEENABERD

York

LeedsLeedse

MANCHESTERCHESTER

LIVERPOOOOL

NOTTINGHAMStoke-on-Trentnt

WORCHESTERW HWOR IPSWICH

NORWICH

CAMBRIDGE

SWANSEANSEANSEA

LLANDANDBRIDOD WELLSBRIDOD WELLS

READINGRE

Plymouth

EXERTER

WINCHESTERINCCH

CARARDIFFCARDIFF

LONDON

Transcat PLMUnit 3, Interchange 25Bostocks LaneSandiacreNottinghamNG10 5QG0115 9210000

Design Rule24 Charter GateMoulton ParkNorthamptonNN3 6QB01604 491661

Dassault SystèmesSuite 9-10 Riley CourtMilburn Hill RoadCoventryCV4 7HP0247 685 7400

Applied William Lee BuildingsNotts. Sci & Tech. ParkNottinghamNG7 2RQ0115 9259990

Cadtek Cadtek HouseStation RoadFurness ValeHigh PeakSK23 7QA 01663 741 405

in2grateWaterslade HouseThame RoadHaddenhamBucksHP17 8NT01844 295 245

Solid ApplicationsThe Old MarketplaceMarket StreetOldburyWest MidlandsB69 4DH0121 544 1400

Dassault SystèmesSupporting Business Partners in the UK

INCATINCAT HouseProspect wayLuton AirportBedfordshireLU2 9QH01582 878750

CenitDesktopEvenlode CourtMain RoadLong HanboroughOxfordOX29 8SZ01993 883555

IntrinsysDenbigh RoadBletchleyMilton KeynesMK1 1DB01908 278606

INCAT6 Monarch CourtEmerald ParkEmersons GreenBristolBS16 7FH0117 970 9715

Dassault Systèmes’ strategy is to helpthe boat industry to modernize its tools andprocesses by offering solutions specificallytailored to this industry. This project, madeuse of software packages which enabled allthe participants to have immediate accessto the best technologies, while supportingvalidated boat-building methodologies.

By Anne-Catherine Delecroix]

3882-UK/Dassault 7/11/05 9:35 Page 26