ProSTEP iViP Symposium 2009
VIRTUAL TEST-BED-INSTALLATION (“TEST-BED-DMU”)
K. Zamazal, K. Klöckl, W. Faustmann, H. Sorger AVL List GmbH
B. Gruhn
FOCUSON Business Consulting Gmbh
AVL COVERS ALL CUSTOMER SEGMENTS
Engineering
Simulation
Testing
Passenger Cars 2-Wheelers Racing
Construction Agriculture Commercial Vehicle
Locomotive Marine Power Plants
India Ann Arbor,MI
Plymouth, MI
Headquarters Graz UK
China
France
Lake Forest, CA
Korea
Germany
AVL – TECHNICAL CENTERS POWERTRAIN
Turkey Sweden
Haninge Södertalje
Remscheid München Regensburg Stuttgart
Neuenstadt Ingolstadt
Nagoya Tokio Moscow
Sao Paulo
AVL’s Development Challenges Virtual Test-Bed-Installation
Development Process Improvement Project Benefits and Project Results
Summary and Conclusion
Content
1 1 10 10 100 100 0.1 0.1
1 1 1000 1000
Displacement / Cylinder [L]
10 10 100 100
Power / Cylinder [kW]
AVL’s Development Challenges
Broad variety of projects – virtual and physical
1 1 10 10 100 100 0.1 0.1
1 1 1000 1000
10 10 100 100
Number of projects
2006 2006 2007 2007 2007 2008 2008 2006 2008
0 20 40 60 80 100 120 140 160
Passenger Cars Commercial Vehicles Large Vehicles
AVL’s Development Challenges
Increasing number of projects in short time
Engine Development Process (EDP)
(standardized and continuously improved since 1998)
Concept study
Prototype development
Preproduction development
Production validation
0 6
12 18
24 30
36 42
Detail design Concept design update
Concept definition and choice of major suppliers
Thermodynamic layout EMS specification
Mechanical calculation
Procurement engine generation 1 Engine build / first engine run Gen. 1 Baseline performance & emission development Baseline engine mapping & ECU calibration
Tolerance investigations Emission development (dyn. test bed) Driveability & emission development in vehicles Basic concept selection
Component development
Functional development (test bed & vehicle) Durability development (test bed)
Vehicle endurance testing: mileage accumulation Baseline acoustic development (test cell)
Pass-by noise & vehicle interior noise development CAD data transfer
Acoustic calculation
Specification engine Gen. 2 Release of concept for preproduction development Release of concept design
Project kickoff meeting
Concept design
Thermodynamic calculation Mechanical calculation Concept FMEA
Design update for engine generation 2 Mechanical calculation engine generation 2
Procurement engine generation 2 First engine run generation 2 Performance & emission verification Tolerance investigations
EMS optimization (steady state and dynamic test beds) Driveability & emission optimization in vehicles
EMC tests & OBD calibration Component development & fatigue tests
Functional development
Durability development (test bed)
Functional development in vehicles; hot & cold climate tests
Vehicle endurance testing Mileage accumulation Release procedures for supplier developed systems
Design freeze MLI Design freeze SLI Engine & vehicle acoustic verification
Analysis of acoustic vehicle conformity
Engines & vehicles from production tooling
Vehicle validation (fleet tests): emissions & OBD-system Hot & cold climate tests
EMC validation Durability validation (test bed)
Vehicle endurance validation Acoustic validation
Quality assurance tests Start of production Start of pilot production
Release of casting pattern and forging die procurement
Homologation
EMS data release EMS preparation
FIE rig tests Target costing
OBD software development (if required) Cold start development Hot & cold climate tests
ECU data release for validation tests Development support
Update of engine documentation
Months before SOP
Thermodynamics Design
Mechanics
EMS-Calibration
Acoustics
AVL’s Development Challenges
Virtual Test-Bed-Installation
Optimization Approach
“Technical” Results of the Test-Bed-DMU
Development Process Improvement Project Benefits and Project Results
Summary and Conclusion
Content
9 14 Test Tasks
9 Description of
Results for each tasks
? Optimisation for all engine development projects
Engine Test Process
Start of production Product validation Concept study
Preproduction development
Improve AVL’s Frontloading by Virtual Test Bed Installation
First engine enabling fully relevant performance emission and also durability targets
Product maturity
Frontloading
Prototype development
Virtual Powertrain
Effort
Development time
Virtual Test-Bed-Installation
Optimization Approach
Æ Define concept
Æ Design all sensors, weldingrings, adapter, … Æ Adapt / convert existing test rigs
Æ Create a library for component administration Æ Consider different CAD-Systems
Æ Allow automatic adjusting of fixtures Æ Define collision free mounting
Æ Define Standard ETS
Æ Adapt files to make available with PARTSolution Virtual Test-Bed-Installation
Activities to make an optimization come true
Virtual Test-Bed-Installation
„Technical“ Results
AVL’s Development Challenges Virtual Test-Bed-Installation
Development Process Improvement Project
Challenges and Gains
The General Model
Analysis of Processes Affected
Process Improvement Tools Applied
Project Results
Benefits and Project Results Summary and Conclusion
Content
Challenges
Surgery on the „Living Body“
Workflow and Interface Changes
Data Structures in Complex Environments have to be Changed Carefully
Impact on the Organisation and the People within
Quantification of the Improvement (Costs, Time)
Gains
Process Costs: Reduction around 20% for the Processes Improved
Development Time: Benchmark with Competition shows 30% shorter Time
Secondary additional Effects: Quality
Design Process Improvement Project
Process Challenges and Gains with Development Process Redesign
Design Process Improvement Project The General Model
Advanced development
Personnel Layer
Organization Layer
Process Layer
Design Process Improvement Project Analysis of Processes affected
Concept study
Prototype development
Preproduction development
Production validation
0 6
12 18
24 30
36 42
Detail design Concept design update
Concept definition and choice of major suppliers
Thermodynamic layout EMS specification
Mechanical calculation
Procurement engine generation 1 Engine build / first engine run Gen. 1 Baseline performance & emission development Baseline engine mapping & ECU calibration
Tolerance investigations Emission development (dyn. test bed) Driveability & emission development in vehicles Basic concept selection
Component development
Functional development (test bed & vehicle) Durability development (test bed)
Vehicle endurance testing: mileage accumulation Baseline acoustic development (test cell)
Pass-by noise & vehicle interior noise development CAD data transfer
Acoustic calculation
Specification engine Gen. 2 Release of concept for preproduction development Release of concept design
Project kickoff meeting
Concept design
Thermodynamic calculation Mechanical calculation Concept FMEA
Design update for engine generation 2 Mechanical calculation engine generation 2
Procurement engine generation 2 First engine run generation 2 Performance & emission verification Tolerance investigations
EMS optimization (steady state and dynamic test beds) Driveability & emission optimization in vehicles
EMC tests & OBD calibration Component development & fatigue tests
Functional development
Durability development (test bed)
Functional development in vehicles; hot & cold climate tests
Vehicle endurance testing Mileage accumulation Release procedures for supplier developed systems
Design freeze MLI Design freeze SLI Engine & vehicle acoustic verification
Analysis of acoustic vehicle conformity
Engines & vehicles from production tooling
Vehicle validation (fleet tests): emissions & OBD-system Hot & cold climate tests
EMC validation Durability validation (test bed)
Vehicle endurance validation Acoustic validation
Quality assurance tests Start of production Start of pilot production
Release of casting pattern and forging die procurement
Homologation
EMS data release EMS preparation
FIE rig tests Target costing
OBD software development (if required) Cold start development Hot & cold climate tests
ECU data release for validation tests Development support
Update of engine documentation
Months before SOP
Thermodynamics Design
Mechanics EMS-Calibration Acoustics
Advanced development Advanced
Advanced development
Advanced development
Design Process Improvement Project Analysis of Processes affected
Concept study
Prototype development
Preproduction development
Production validation
0 6
12 18
24 30
36 42
Detail design Concept design update
Concept definition and choice of major suppliers
Thermodynamic layout EMS specification
Mechanical calculation
Procurement engine generation 1 Engine build / first engine run Gen. 1 Baseline performance & emission development Baseline engine mapping & ECU calibration
Tolerance investigations Emission development (dyn. test bed) Driveability & emission development in vehicles Basic concept selection
Component development
Functional development (test bed & vehicle) Durability development (test bed)
Vehicle endurance testing: mileage accumulation Baseline acoustic development (test cell)
Pass-by noise & vehicle interior noise development CAD data transfer
Acoustic calculation
Specification engine Gen. 2 Release of concept for preproduction development Release of concept design
Project kickoff meeting
Concept design
Thermodynamic calculation Mechanical calculation Concept FMEA
Design update for engine generation 2 Mechanical calculation engine generation 2
Procurement engine generation 2 First engine run generation 2 Performance & emission verification Tolerance investigations
EMS optimization (steady state and dynamic test beds) Driveability & emission optimization in vehicles
EMC tests & OBD calibration Component development & fatigue tests
Functional development
Durability development (test bed)
Functional development in vehicles; hot & cold climate tests
Vehicle endurance testing Mileage accumulation Release procedures for supplier developed systems
Design freeze MLI Design freeze SLI Engine & vehicle acoustic verification
Analysis of acoustic vehicle conformity
Engines & vehicles from production tooling
Vehicle validation (fleet tests): emissions & OBD-system Hot & cold climate tests
EMC validation Durability validation (test bed)
Vehicle endurance validation Acoustic validation
Quality assurance tests Start of production Start of pilot production
Release of casting pattern and forging die procurement
Homologation
EMS data release EMS preparation
FIE rig tests Target costing
OBD software development (if required) Cold start development Hot & cold climate tests
ECU data release for validation tests Development support
Update of engine documentation
Months before SOP
Thermodynamics Design
Mechanics EMS-Calibration Acoustics
Advanced development Advanced
Advanced development
Advanced development
Design Process Improvement Project Process Improvement Tools Applied
Method Target of Method Applied
Maturity Models
Customers readiness is an indicator for volume and scope of the resulting project
Process Map
Overview of relevant business processes, their relations and implementation in the complete R&D resp. test field process
SIPOC
Process model with respect to:
Supplier Input Prozess Output Customer.
This is a first rough picture of the value-chain process, helping to identify all parties involved
PCAT for Development
Process Cost Analysis Tool is a prerequisite to give a quantitative picture of possible process improvments in the development process
IAM
The interface-analysis-matrix shows to which extend the organization is living the processes resp. has a process understanding. Furthermore starting points for
improvements will be detected.
Techn.
Vorbereitung Prüf-Planung und –Administration
Inkl. Rechnungsstellung Technischer
Prüflauf Techn.
Nachbereitung&
Ergebnis-Lieferung
Instandhaltung Prüffeld
Personal-Planung und Administration Technische Langfristplanung Prüffeld Übergreifender Entwicklungsprozess Prüflings-Beschaffung (Prototypen-Erstellung inkl. Logistik
Prüflings-Entsorgung
Prüf-
Auftrag Ergebnis-
Lieferung
Organisatorische Langfristplanung Prüfablauf
Legende:
Primärer Geschäftsprozess Sekundärer Geschäftsprozess
• Versuchsingenieur (A&G)
• Entwicklungsingenieur (A&G)
Supplier
• Anforderung an Messprozess (Dauer, Start, Art und weitere Spezifikationen)
• Prüfling?
• Prüfprogramm (Ist, Soll zu klären)
Input Process
• Prüfling
• Prüfergebnisse (Messdaten, Zwischen- auswertungen, elektronisch online oder auf Datenträger)
• Betriebsdaten (Laufzeit, Stillstands- zeiten und -ursachen Finanzdaten,…)
• Kontrolldaten, wie z.B.
nötiger Ölwechsel Output
• Versuchsingenieur (A&G)
• Entwicklungsingenieur (A&G)
• Entwicklungsingenieur Fahrzeug (Kunden des Kunden)
• Teamleiter
• Abteilungsleiter
• Bereichsleiter
• Virtueller Leitstand (zukünftig)
• Techn. Controlling (z.B. Rechnungsdaten)
Customer Auftragsankündigung
trifft ein
Auslieferung ist erfolgt Auftrag + Erstellung Prüfprogramm
Anlieferung & Aufbau Prüfling
Prüflauf (inkl. Kontrolle, Teilaus- wertung, ggf. Neulauf) Abbau
Lieferung von Prüfling und Ergebnissen
an Kunden
Standard-Prozesse
• Versuchsingenieur (A&G)
• Entwicklungsingenieur (A&G)
Supplier
• Anforderung an Messprozess (Dauer, Start, Art und weitere Spezifikationen)
• Prüfling?
• Prüfprogramm (Ist, Soll zu klären)
Input Process
• Prüfling
• Prüfergebnisse (Messdaten, Zwischen- auswertungen, elektronisch online oder auf Datenträger)
• Betriebsdaten (Laufzeit, Stillstands- zeiten und -ursachen Finanzdaten,…)
• Kontrolldaten, wie z.B.
nötiger Ölwechsel Output
• Versuchsingenieur (A&G)
• Entwicklungsingenieur (A&G)
• Entwicklungsingenieur Fahrzeug (Kunden des Kunden)
• Teamleiter
• Abteilungsleiter
• Bereichsleiter
• Virtueller Leitstand (zukünftig)
• Techn. Controlling (z.B. Rechnungsdaten)
Customer Auftragsankündigung
trifft ein
Auslieferung ist erfolgt Auftrag + Erstellung Prüfprogramm
Anlieferung & Aufbau Prüfling
Prüflauf (inkl. Kontrolle, Teilaus- wertung, ggf. Neulauf) Abbau
Lieferung von Prüfling und Ergebnissen
an Kunden
Standard-Prozesse
Beauftrag- ung
Vorprüfung Prüflauf und
Daten- erfassung
Admin- istrativer Abschluss SP 7 0,0,2 1,2,0
2,2,0 1,1,2
3,1,0 0,5,0
4,0,0 2,1,0
2,0,0
3,0,0 1,3,0 1,0,0
0,0,1 0,0,3
Kunde
SP 5 SP 4 SP 2 SP 1
1,1,0 Vorbereitung
u. Aufbau Vorprüfung 4,1,0
1,2,1 0,0,2
SP 3 1,0,0
Kunde SP 8 1;1;0
0;0;0 0;0;0
2;0;0
Technischer Abschluss SP 6 2;0;0
0;0;0
Lieferanten -sicht
Kunden- sicht Lieferanten -sicht
Kunden- sicht
A
A(Eigen-) Leistung „Prüfauftrag prüfen“
