Contact
5
mag
02 2008
The Americas PLM Magazine
feature
C&D
C&D Zodiac Leverages
Knowledge Corporate-
Wide with DS PLM
Page 10
success story
SAIL
Lockheed Martin puts
F-35s onboard ships
virtually, avoids up to
$100 million in costs
Page 18
Lean Product
Development
Featuring Hyundai
PENTAIR WATER
Pentair Processes Flow
Faster with ENOVIA
Page 20

Editorial Americas
L
“ ean” is a concept all product-driven
success story
companies understand – in terms of their
4 Sauder Woodworking Finds Perfect Fit with
manufacturing. But lean has another
application with the same potential to ENOVIA and Windows
revolutionize cost structures and time to market:
we call it Lean Product Development (LPD).
18 Lockheed Martin Puts F-35s Onboard Ships
Virtually, Avoids up to $100 Million in Costs
If you have difficulty imagining how lean principals
can be applied to product development, this edition
20 Pentair Processes Flow Faster with ENOVIA
of Contact is for you. Filled with examples of
companies that are leveraging LDP to change the competitive realities of their
business daily, it is a roadmap for your own LPD journey.
feature:
lean product development
How does LPD manifest itself? One indicator is “first-pass success,” (see Page
8) a metric developed by Archstone Consulting to help companies measure
8 First-Pass Success: Applying Lean Principles
waste in product development. First-pass success is a key indicator of efficiency:
to Product Development with PLM
the more engineering change orders required to get a design right, the more
waste is inherent in the process.
10 C&D Zodiac Leverages Knowledge
Corporate-Wide with DS PLM
If your product development process isn’t lean , how do you put it on a diet?
The challenge is to fully leverage the DS PLM solutions you already have to
bring product knowledge as far forward as you can. Knowledge-forward design 12 Hyundai-Kia Saves 51,000 Engineering Hours
is efficient design. Capturing your knowledge so that you know what you with DS Business Value Assessment
know up front, when everything is possible and change involves inexpensive
bits and bytes, pays exponential dividends.
solution spotlight
Consider the case of the Hyundai-Kia America Technical Center (Page 12).
6 The Power of CATIA for Mid-Size Companies
Tasked with doubling its engineering output with the same staff, HATCI
trained its engineers to fully leverage CATIA’s built-in, labor-saving tools. It
14 3DVIA Composer Delivers Product Information
made a firm corporate commitment to capture knowledge as templates and
Everyware™
rules, bring knowledge forward and make it accessible earlier in product
development. The result? HATCI identified $3 million in annual savings,
equivalent to 51,000 engineering hours or 25 full-time engineers – 15 ATI FireGL Graphics Accelerators Boost
effectively doubling its previous capacity. CATIA and ENOVIA DMU
You will find profiles of similarly inspired programs throughout this issue
16 It’s Time to Manage Simulation as a Valued
of Contact, including aerospace interiors leader C&D Zodiac (Page 10);
Corporate Asset
Sauder Woodworking, North America’s largest ready-to-assembly
furniture maker (Page 4); Lockheed Martin, which is using DELMIA-
22 Type3 Simplifies Graphics and Text Tasks in
driven virtual reality to put its planes onboard aircraft carriers digitally
CATIA
(Page 18); and Pentair, which is leveraging the knowledge from one
water-related business to another to help all of its processes flow faster
(Page 20). 22 IGE+XAO Masters the Art of Electrical
Harness Design
With so much valuable intelligence in every issue of Contact, you
shouldn’t have to wait six months for your next issue. So, in 2008,
schedule of events
Contact will publish three times. It’s just our way of bringing
knowledge forward sooner, to help you benefit from it faster. So
23 PLM Americas Events
“lean” on us, and make your product development engine as
powerful as the one that drives your manufacturing.
]
LORI WEBBER Contact mag
Vice President, The Americas PLM Magazine published by Dassault Systèmes Americas
Marketing and Communications Corp. - University Research Park - 10330 David Taylor Drive - Charlotte,
NC 28262 - USA • Publication Executive: Lori Webber • Chief Editor:
Dassault Systèmes Americas Bernadette Hearne • Photo credits: Dassault Systèmes’ customers and
partners • Printed in USA
To suggest a story or to receive future issues,
Contact mag | Dassault Systèmes Americas 3
please go to http://www.plmv5.com/contactmag/

Sauder Woodworking
Finds Perfect Fit with
ENOVIA and Windows
auder is now North America’s Development. “Over time, we had added a
S
Sauder Woodworking Co.
leading manufacturer of RTA team of people doing manual data entry,
began in 1934 in Archbold,
furniture and the sixth largest U.S. trying to keep those spreadsheets up to
Ohio, in the backyard garage
furniture company. Its 3,000 employees date with a lot of duplicate information.”
of Erie Sauder. In 1951 Sauder design and manufacture more than 800
developed the world’s first items in 30 furniture collections sold by But Sauder wanted to achieve a higher level
ready-to-assemble (RTA) table, some of the world’s largest retailers. The of confidence in the accuracy of the
company is privately owned by the second information. “Drawings on the manufacturing
and the rest is history.
and third generations of the Sauder family. floor sometimes didn’t match the ones in
Product Engineering,” Short says.
“Sometimes we would receive parts for the
SUCCESS CREATES NEW
wrong revision of the product design.”
CHALLENGES
As Sauder has grown, so has the challenge
of tracking the simultaneous development of DOUBTFUL DATA BECOME
as many as 60 new products and 200 new TRUSTED DATA WITH ENOVIA
SKUs (customer-specific product versions) To overcome these challenges, Short
per year. Each new design has its own envisioned a single, digital 3D database
unique collection of wood parts, screws and shared by the company’s engineering, ERP
fasteners, so parts number in the thousands. and MRP (Manufacturing Resource Planning)
systems. Early in the company’s search,
To manage the complexity, employees Short thought a document management
developed numerous spreadsheets. “We system could suffice. But then he discovered
had more than five spreadsheets and the ENOVIA collaborative Product Lifecycle
databases,” remembers Wendell Short, Management (PLM) solution for the SMB
Sauder’s Director of New Product market from Dassault Systèmes.
4 Contact mag | Dassault Systèmes Americas

success story
« We had been averaging more than
12 weeks per design and now we’re averaging
less than eight. Plus, we were doing about 130 SKUs
per year before ENOVIA, and now we have exceeded
200 with no staff increase.
Wendell Short, Director of New Product Development, Sauder
exceeded 200 with no staff increase. That’s FROM MARKETING TO SALES,
an increase of more than 50 percent.” EVERYONE USES ENOVIA
ENOVIA provides input to Sauder’s ERP
system, transferring the information needed
FOCUS ON RAZORLEAF
to issue purchase orders and shipping
Short credits Razorleaf, the company’s
documents and automatically filling in the
Dassault Systèmes Business partner, with
necessary fields. The ENOVIA user interface
helping Sauder make the right decision in
proved so popular with users, in fact, that
“Since the ENOVIA solution for SMBs was a choosing ENOVIA. “Had we known then
Sauder now allows many of its employees to
DS PLM solution, it provided functionality what we know now, we could have written a
use ENOVIA screens rather than ERP
that went way beyond what we could get better specification for what we needed.
screens to do their work.
from a document management system, out Fortunately, Razorleaf helped educate us
of the box,” Short says. “We challenged the about what ENOVIA could do relative to the
ENOVIA also provides the product data
other suppliers to quote the same other packages under consideration.”
required by the MRP system, which
functionality, but it would have required so
embellishes that information with detail
much custom development that it just Razorleaf stayed involved long after the sale,
needed to manufacture the parts, and
wasn’t a contest.” Short says, helping Sauder with
provides the data needed to create packing
implementation and facilitating the integration
diagrams that show precisely how all of the
The ENOVIA solution for SMBs also runs on of ENOVIA with the company’s CAD, ERP
parts can be fit into the smallest possible
the Windows platform, the standard at Sauder, and MRP systems. Razorleaf experts also
box. Workstations on the floor allow the
and uses Microsoft® SQL Server.™ “Any other advised the company on how to reengineer
packing department to print these
platform would have been viewed as a the company’s product development
instructions or view them onscreen.
negative,” Short says. “Because it’s Windows- processes to maximize the ROI achieved with
based, it increases our ROI by holding down ENOVIA, and provided training.
Writers use the product data in ENOVIA to
our cost to implement and maintain, since
create assembly instructions. Sales uses
everyone who works here
ENOVIA online reports to track the
is already familiar with the
development of new products, and
Windows environment.”
manufacturing to see what new units to
produce and when.
Trust in the accuracy of the
company’s data has been
“With ENOVIA, we’re now out of the
restored, and improved
spreadsheet maintenance business for
efficiency trimmed Sauder’s
status tracking,” Short says. “I can’t
design cycle by one third.
overemphasize the importance of having
“We had been averaging
one centralized source of data that everyone
more than 12 weeks per
)
knows they can trust”•
design and now we’re
averaging less than eight.
For more information:
Plus, we were doing about
www.sauder.com
130 SKUs per year before
www.razorleaf.com
ENOVIA, and now we have
Contact mag | Dassault Systèmes Americas 5

The Power of CATIA for
Mid-Size Companies
assault Systèmes has developed processes, including composites, machining
D four dedicated offerings built on and tooling. It embeds high-performance
CATIA PLM Express to provide mid- technologies that provide manufacturers
size companies in specific industry with a leading edge in productivity and
segments with the implementation that best domain leadership.
suits their needs and profiles.
CATIA provides the aerospace industry with
a standard working environment that allows
CATIA FOR AEROSPACE
users to easily and securely share and
SUPPLY CHAIN
« Based on more than 20 years of experience transfer data throughout the supply chain for
)
in the aerospace industry, Dassault Systèmes an accurate and innovative product•
The aerospace developed CATIA for Aerospace Supply
industry is practically Chain to help aerospace suppliers build and For more information:
www.plmv5.com/aerosuppliers/
maintain close relationships with OEMs and
all on CATIA, so if you
risk-sharing partners. The cutting-edge
don’t have it you may technologies and process-centric CATIA FOR AUTOMOTIVE SUPPLIERS
CATIA extends its automotive industry
architecture of this new offering enable
not even be considered
expertise to suppliers and tool makers of all
companies to leverage their know-how to
for the job. sizes with CATIA for Automotive Suppliers.
rapidly respond to customer needs and
This offering h e l p s
specifications, and to maximize productivity
Nagi Homsy, Vice President of
Engineering, Héroux Devtek s u p p l i e r s s t re n -
while seamlessly managing the supply chain
gthen competitive-
relationship to better serve aircraft programs.
ness by leveraging
their know-how to
In an environment where OEMs are
deliver high-quality
increasingly selective regarding their
products on time to
suppliers, it is crucial to be equipped with
their Tier 1 and OEM
the best-in-class, proven system in the
customers, while at
aerospace industry. CATIA is the leading
the same time reducing
PLM platform used to develop most aircraft
costs.
programs and is a leader in most aerospace
6 Contact mag | Dassault Systèmes Americas

solution spotlight
Aerospace Industrial Machinery Automotive
« On the whole, after 18 months of production, we had gained 30% to
40% in design time. Laurent Simon, CAD/CAM Manager, N. Schlumberger
CATIA for Automotive Suppliers enables CATIA for Style includes the ground-breaking Thanks to CATIA for Industrial Machinery,
engineering design rules, company CATIA Imagine & Shape for Industrial Design bidding and design phases are considerably
standards, and pre-defined norms to be and CATIA Functional Molded Parts for optimized since designers can re-use 50
captured and embedded in the design Mechanical Design. In addition, CATIA for percent to 70 percent of previous product
definition so that knowledge can be easily Style offers industrial and mechanical designs. The knowledge from prior projects
shared and re-used for new projects. This designers unique integration between is readily available, while ongoing and future
ensures that quality standards are advanced, robust surface design applications development are managed in a single,
maintained through every phase for and detailed design applications. secured collaborative environment.
improved product quality, faster delivery,
and increased standardization. Thanks to powerful 3D conceptual tools Company and international standards are
and associativity capabilities, CATIA easily embedded into templates, while built-
With 3D, a master can easily be created and facilitates bringing new technology online in simulation capabilities enable virtual
re-used in other areas such as simulation and rapidly and quickly exploring many different product review, further reducing errors
numerical control. Digital manufacturing design alternatives. CATIA for Style also and enabling product certification and
simulation and validation facilitate the creation helps improve product quality through the compliance with requirements the very first
of customer proposals with better accuracy. In re-use of proven design specifications and time. CATIA for Industrial Machinery also
addition, standardizing parts helps automotive advanced surface analysis tools. Intelligent simplifies customization by capitalizing on
suppliers reduce buying, manufacturing, features and corporate catalogs of standard pre-approved standard components and
storage and maintenance costs, enabling components help ensure product intelligent design templates, and
them to price parts more competitively. CATIA consistency and product architecture automatically incorporates manufacturing,
for Automotive Suppliers also automatically optimization. As industrial and mechanical purchasing and maintenance constraints.
updates associated tool designs when a part designers work on the same data, changes Late modification can be made quickly by
)
is modified• and late modifications reflecting the latest simply changing the parameters, and
trends in customers’ tastes are maintenance data and production
automatically propagated from concept to documentation are intuitively accessible via
For more information:
)
www.plmv5.com/autosuppliers/ manufacturing, minimizing the impact on an easy-to-use database•
)
final product delivery•
For more information:
CATIA FOR STYLE
CATIA for Style enables www.plmv5.com/im2/
For more information:
small- and medium-size www.plmv5.com/catiaforstyle/
design and engineering
companies to access CATIA FOR INDUSTRIAL MACHINERY
the power of styling tools CATIA for Industrial Machinery helps
in an intuitive and fun industrial machinery manufacturers be the
environment to easily first to bid on projects or introduce new
design new shapes and products, while ensuring feasibility and
products with speed and profitability.
creativity.
Contact mag | Dassault Systèmes Americas 7

First-Pass Success: Applying
Lean Principles to Product
Development with PLM
By Mark Strobel, Director Solutions Portfolio Management, Dassault Systèmes
In today’s globalized o succeed, companies need product every part, it is important to drop the ratio as
T development processes that are as low as possible. “Perhaps 20-30 percent of
economy, competition has
lean as their manufacturing excess releases are unavoidable,” Fitzpatrick
reached unprecedented levels.
processes have become. But what does says. “But the other 70-80 percent can be
For companies in many
“lean” look like in a product development eliminated.” Effective digital tools that improve
industries, bringing innovative
context, and how can executives drive it? the flow of information – Product Lifecycle
products to market more
Management solutions, in other words – are
quickly with high quality at David Fitzpatrick is a principal with critical to capturing and leveraging available
low prices isn’t just a Archstone Consulting, which specializes in information as early as possible to narrow the
strategy for domination – helping companies slim down their product ratio, Fitzpatrick believes.
development processes. Fitzpatrick
increasingly, it’s a
considers “first-pass success” a key THE RIGHT TOOLS PLUS THE RIGHT
requirement for survival.
indicator of efficiency. The more engineering PROCESSES
change orders that are required to get a While having effective digital tools is
design right, the more waste inherent in the a requirement for lean product development
process. For example, if a company issues success, it isn’t sufficient. Users also must
2,500 releases to get 1,000 final designs, build the right processes around the tools to
the process includes 150 percent waste – take full advantage of their capabilities.
waste that should be targeted for removal.
American Specialty Cars (ASC) is a classic
“Excessive administrative burden and example of how benefits multiply when the
excessive rework resulting from slippage in right tools are combined with the right
design processes is insidious and tough to get processes. ASC was an established CATIA
at,” Fitzpatrick says. “But if you’re designing a user when it developed the InfiniVu, a new
part, on average, 2 or 2.5 times to get it right open-air roof system for trucks and SUVs
once, you are paying for a great deal of waste.” that ASC knew would be a big hit with
automotive OEMs. To respond to anticipated
While it isn’t realistic to target one release for demand for the system, ASC needed the
8 Contact mag | Dassault Systèmes Americas

feature
« The changes ASC made in its processes not only saved time that
allowed the company to meet demand. It also empowered ASC to deliver a
design that is right first time, every time, and that becomes even better with
each new system it delivers due to the ongoing accumulation of knowledge.
Michel Tellier, President of DS Inc., the Services arm of Dassault Systèmes
ability to quickly morph the design to fit required to adapt the InfiniVu to each new
dozens of different vehicles. vehicle design from 20 days to just one.
“The good news was that we had the right The 19 days saved represented waste in the
tool,” says ASC Vice Chairman Chris P. ASC product development process; by
Theodore. “The bad news was that we leveraging the full potential of the Dassault
weren’t using the tool right.” ASC worked with Systèmes PLM solution ASC already used,
DS Services to evaluate its processes and that waste was eliminated. As a result, ASC
identify the best lean methodologies to apply. was able to respond to OEM demand for the
BRING KNOWLEDGE FORWARD
DS Services helped ASC recognize that the InfiniVu, which proved to be as high as the
TO GO LEAN
key to “using the tool right” was to capture company had anticipated.
ASC succeeded in going lean with help from
ASC’s designs as re-usable templates and
DS Services by bringing its knowledge
turbo-charge the power of those templates “If you multiply the savings that ASC achieved
forward in its product development process
by using CATIA Knowledgeware to capture with one automotive system by the total
and making it available to all. Knowledge-
ASC’s engineering knowledge as rules. By number of systems in an automobile, an
forward design also pays dividends in other
investing that time up front, before it airplane, or another complex product, you get
ways, from ensuring that products are
introduced the product, ASC cut the time some idea of the full potential of applying lean
designed for manufacturability and
principles to the product
maintainability to informing purchasing
development process,” says
decisions. PLM helps to not only apply lean
Michel Tellier, President of DS
to product development, but also to a
Inc., the Services arm of Dassault
corporation’s entire spectrum of activities.
Systèmes. “The changes ASC
made in its processes not only
To learn more about lean product
saved time that allowed the
development with PLM, visit
company to meet demand.
http://lean.plmv5.com to hear a replay of an
It also empowered ASC to deliver
e-seminar featuring Fitzpatrick, Theodore and
a design that is right first time,
)
Tellier or to download a free white paper•
every time, and that becomes
even better with each new
For more information:
system it delivers due to
http://lean.plmv5.com
the ongoing accumulation of
knowledge.”
Contact mag | Dassault Systèmes Americas 9
Source: Archstone Consulting

C&D Zodiac
Leverages Knowledge
Corporate-Wide with DS PLM
C&D Zodiac is a leading ike most aerospace suppliers, C&D challenges with a centralized 3D database
L traditionally invested large sums in shared by all.
global designer and
product development and recouped
manufacturer of aircraft
the costs over the life of an aircraft model. CATIA now also features Knowledgeware,
interiors, and has
But today, airlines and their OEM partners which allows C&D to capture each designer’s
developed numerous
are instituting extremely competitive pricing best practices and standardize them across
specialized materials
structures, creating intense pressure to the company. Relational design capabilities
optimized for the minimize upfront investments. allow C&D to build standardized design
industry’s high-stress, templates of “smart parts” that can be
low-weight demands. C&D has therefore focused on lean product quickly modified in hours instead of weeks.
development, eliminating the bottlenecks
and errors that drive up costs. C&D also ENOVIA structures all of the company’s
has worked to empower all of its design data, making information easy to
employees with access to information, locate and ensuring that everyone works
allowing them to positively influence the with the latest revisions. ENOVIA also
cost of designs early in the process. C&D is maintains the relationships among various
therefore optimizing its investment in PLM parts, automatically
from Dassault Systèmes, including CATIA applying the
and ENOVIA.
IMPROVED DATA ACCESS FOR
IMPROVED PRODUCTIVITY
C&D realized major improvements in
productivity as it applied CATIA V5 to its new
aircraft programs. In V4, every engineer
maintained personal directories of design
files, leading to duplication and increasing
the risk of error. V5 eliminated these
10 Contact mag | Dassault Systèmes Americas

feature
« DS PLM is helping us take our
product data and turn it into parts in
the most efficient manner.
Mike McCarthy, Vice President of Technical Operations
rules and templates that make parts there is still time to change the design, C&D To add even more value to its design work,
“smart,” and facilitates data sharing among optimizes cost and quality. ENOVIA also C&D’s goal is to maximize the flexibility of
C&D’s global offices. helps C&D ensure that data released to each design to give airline customers more
manufacturing is mature and reliable. options for changes throughout the life of an
aircraft. “CATIA gives us the power to
EFFICIENT PROCESSES
imagine what the maximums are that each
ENHANCE PROFITABILITY ACCOMMODATING LATE-CYCLE
C&D Zodiac’s innovative application of airline might want 10 years down the road
DESIGN CHANGES AFFORDABLY
CATIA and ENOVIA to the challenges of lean Outfitting corporate jets is a challenge and create a design today that will allow for
product development has generated a wide because customers often change their minds those options more economically in the
variety of benefits, including improved about the features they want, but won’t future,” Fontaine says.
profitability. “More than ninety-five percent of accept delivery delays. “Knowledgeware is
our revenue is from manufactured parts,” helping us accommodate those situations EXTENDING THE BENEFITS WITH
says Mike McCarthy, Vice President of because we can change a few attributes and WORKFLOW AND INTEGRATION
Technical Operations. “DS PLM is helping us the design adjusts automatically,” says C&D C&D’s next priority is to implement ENOVIA
take our product data and turn it into parts in IT Director Jon Ripley. “We can produce workflow capabilities, defining and digitizing
the most efficient manner.” drawings in hours instead of weeks. It’s the company’s processes so they can be
working so well with private jets, we’re carried out electronically rather than on
By allowing all of the company’s experts to beginning to apply it to every project.” paper. “Workflow will let us see where the
simultaneously see designs as they develop, bottlenecks are and eliminate them,
ENOVIA helps C&D take advantage of its DS PLM also contributes to job satisfaction reducing scrap, machine changes and all
knowledge. Purchasing, for example, can at C&D. “Engineers’ favorite activity is not the other waste that drives up costs,”
recommend the most cost-effective part reconfiguring, it’s designing,” Ripley says. Fontaine says.
selections, while Manufacturing can advise So C&D created a catalog of “smart parts”
on manufacturability or suggest tooling in ENOVIA that engineers can build into their C&D also plans to focus on integrating
improvements. By designs. When parameters change, the ENOVIA data with the enterprise application
identifying issues smart parts reconfigure the design that stores the company’s business data.
early, when automatically to accommodate them. “To succeed in business today you need
“When we showed this catalog to the team, smarter data, data that can be easily viewed
it was an easy sell to get them to give up and leveraged broadly,” McCarthy says. “We
their own directories,” he said. believe DS PLM is critical to helping us
)
accomplish that”•
“The response is always, ‘When can we have
more?’” says Brett Fontaine, Engineering For more information:
www.cdzodiac.com
Systems Manager. “Knowledgeware brings
automation to every designer’s hands so we
can capture how we do things.”
Contact mag | Dassault Systèmes Americas 11

Hyundai-Kia Saves 51,000
Engineering Hours with DS
Business Value Assessment
By Daniel D. Vivian, Director, Engineering Design, Hyundai-Kia America Technical Center
Hyundai-Kia Inc. has experienced 48 percent sales growth from 2000 to 2007 and produces
3.7 million vehicles annually, including 750,000 sold in the United States. With 2006 Initial Quality
Scores that ranked Hyundai as the Number One non-luxury brand, and an attractive ratio of quality
to price that spells value to millions of consumers, it’s a trend the company expects to continue.
hile exciting, such aggressive We called in the experts at Dassault
W growth brings challenges, and Systèmes to assist in identifying features and
management laid a major functions that could be leveraged in our
challenge at the doorstep of the Hyundai-Kia processes to achieve the required efficiency
America Technical Center (HATCI) in 2007: improvements.
Adding the Hyundai Santa Fe crossover
program to our existing focus on engineering The Business Value Assessment (BVA) that
the Hyundai Sonata sedan, doubling our Dassault Systèmes performed helped us
required engineering output. Clearly, meeting identify more than $3 million per year in
the challenge would require reengineering of potential savings. This is the equivalent of
our existing processes to improve efficiency more than 51,000 engineering hours or
without compromising quality. 25 full-time engineers – enough to
accommodate the second program.
APPLYING “LEAN” TO PRODUCT
Guided by Dassault Systèmes, 18
DEVELOPMENT
HATCI believed that moving from CATIA V4 employees from 11 HATCI departments
to CATIA V5 would help us achieve this goal. spent three days identifying areas for
12 Contact mag | Dassault Systèmes Americas

feature
« A major aspect of our reengineering involved leveraging CATIA’s
ability to streamline routine work by capturing corporate knowledge as
re-usable templates and creating global standards for how designs should
be structured. Daniel D. Vivian, Director, Engineering Design, HATCI
improvement and quantifying the potential created and structured – time that adds no capability through proficiency testing. We
value of the savings. The BVA process value for the consumer and that significantly were surprised to learn that even our top
allowed us to apply lean principles to our detracts from overall efficiency. We also experts were skilled at using only portions of
product development process. Our goals improved the re-use of design data and CATIA’s functionality.
were straightforward: intellectual property, allowing us to focus on
new, value-add work rather than re- Testing allowed us to identify each engineer’s
• Eliminate non-value-add activities by inventing the wheel (or the seat, the bumper, individual strengths and weaknesses. A
leveraging technologies to eliminate or the dashboard …) continuous learning program, geared to
automate routine work. close the gap between desired and actual
• Initiate collaborative design processes Finally, we focused on conducting vehicle performance, identified opportunities for
that would allow engineers to work evaluations in the digital phase, using CATIA improvement. Subsequently, specific on-line
concurrently on the same design and for visualization, variation and version exercises were developed and each person
be instantly aware of changes. analysis to minimize problems found in the was given targets for moving up the
• Support design re-use to avoid design prototype stage. proficiency scale. Each engineer was
re-invention with 24/7 access to required to reach 80 percent proficiency in a
information within three clicks. specific time period, ensuring they would be
BROADER, DEEPER SKILLS
• Improve the skill and efficiency of our adequately prepared to move on to the next
FOR IMPROVED EFFICIENCY
workforce through increased training in To ensure that we could keep our phase of scheduled training.
software functionality and methodology. commitment to support a second program,
• Streamline fit and assembly with right- we had to fully understand our baseline We did not expect our employees to start
first-time design utilizing digital using their new skills on the job immediately.
prototypes. Engineering is both a creative and an
• Streamline regulatory compliance intellectual discipline. It is therefore important
procedures. to give engineers time to experiment and to
learn how to think through new tools,
features and functions. By honoring this
LEVERAGING THE FULL
need, we moved our engineers as a group
POWER OF CATIA
A major aspect of our reengineering from 50 percent proficiency before training to
involved leveraging CATIA’s ability to 90 percent proficiency today.
streamline routine work by capturing
corporate knowledge as re-usable The Hyundai-Kia goal is to be a global leader
templates and creating global standards for in quality and performance. Our new, highly
how designs should be structured. The efficient processes, fully leveraging CATIA
Hyundia-Kia team in Korea was already with superbly trained engineers, ensure that
working with DS on templates, so HATCI is positioned to contribute fully to
collaborating with them was critical. ensuring Hyundai-Kia meets this goal for
)
years to come•
By standardizing our formats globally as re-
usable templates, we eliminated the For more information:
www.hyundaiusa.com
significant amounts of time previously
required to understand how data was
Contact mag | Dassault Systèmes Americas 13

3DVIA Composer
Delivers Product
Information Everyware™
Engineers used to have all applies the new information to the initial
documentation, quickly and easily.
the fun. But not any more,
because now there’s 3DVIA
Once deliverables are created, 3DVIA
Composer from Dassault
Composer offers content creators a
related product documentation, eliminating
Systemès, putting 3D to work
wide range of additional capabilities,
the need for manual, error-prone and
for the rest of us.
including access controls, protection of
expensive overhauls.
DVIA Composer harnesses the documentation and the ability to distribute
3 advanced 3D technologies long deliverables as discrete outputs for use with
Best of all, 3DVIA Composer requires no
available to engineers, and puts that or without the free, high-performance 3DVIA
special training and integrates with all bill-of-
data to work for users in sales, marketing, Player. Intelligent views overcome language
material (BOM), enterprise resource planning
customer service, training, support and barriers and the need for translation by
(ERP) or product lifecycle management (PLM)
manufacturing. From creating owner’s permitting complex product procedures to
systems through a simple XML interchange.
manuals and assembly directions to be communicated effectively with a
No matter where your company’s 3D data
maintenance and sales materials, 3DVIA minimum of text. Views can be annotated
resides, 3DVIA Composer can put it to work
Composer turns once arduous, time- and labeled in any way and format the user
to create powerful, impactful product
consuming and expensive tasks into natural desires, and styles can be applied to any
documentation on the user’s desktop. Output
)
extensions of the product creation process. content to ensure visual consistency•
options cover many standard file formats,
including Microsoft Office®, PDF, HTML, SVG,
By re-using the 3D data created to design CGM and more. For more information:
and build a manufacturer’s products, 3DVIA Visit www.3dviacomposer.com. Read the
Composer significantly cuts the time and cost 3DVIA Composer blog at www.3dmojo.com
3DVIA Composer also saves time and money
involved in crafting product documentation. and interact with the 3DVIA Composer
by allowing content creators to work with
What’s more, the same technology that community at www.3dmojo.com/forums.
partial product information as final designs are
automatically updates a product model as being completed. When updated product
designs change can automatically update all data becomes available, 3DVIA Composer
14 Contact mag | Dassault Systèmes Americas

solution spotlight
ATI FireGL Graphics
Accelerators Boost
CATIA and ENOVIA DMU
Dassault Systèmes and AMD have worked together to provide
a better solution for CAD modelers and designers with the ATI
FireGL™ line of workstation graphics accelerators
ecent years have seen dramatic performance of workstation graphics
R increases in the size of models the accelerators, which led Dassault Systèmes
mechanical designer is tasked to implement Vertex Buffer Objects (VBO) in
to create. This push has come from the OpenGL engine and AMD to optimize
two sources. First, improvements in its ATI FireGL OpenGL driver to fit all CATIA
Together, AMD and Dassault Systèmes are
manufacturing technology have allowed requirements. This allows the application to
providing a better solution for the more
products to be made with much smaller transfer much of the overhead required to
realistic modeling of larger datasets
mechanical tolerances. Second, design generate a model’s geometry to the
)
needed by today’s mechanical designers•
aesthetics have advanced to a point where graphics processing unit (GPU) on the ATI
ergonomics and style have become a more FireGL graphics accelerator.
For more information:
important part of the overall product design.
http://ati.amd.com/FireGL
The model’s entire geometry is stored on
At the same time that models have grown the graphics card’s memory and can be
larger, there has also been a push for more rendered at its maximum speed. With its
realism when reviewing these more complex industry-leading memory configurations
Design aesthetics have advanced to a
datasets. With the increased focus on featuring up to 2 GB, the ATI FireGL line
point where ergonomics and style have
usability, lights and shadows, the texture of can therefore accommodate larger models
become a more important part of the
surfaces get more attention than ever before. than ever before. Even the 32-bit version of
overall product design. ATI FireGL
No longer is it sufficient to just model a simply the software will see advantages in the size
enables CATIA users to create and
shaded object. The product needs to be of model that can be visualized. The ATI
interact with more complex models and
examined in a variety of lighting conditions. FireGL technology has also improved the
assemblies than ever before.
memory transfers from the CPU to the
The combination of these trends has GPU to better modify any data at any time.
created an unprecedented demand on the
Contact mag | Dassault Systèmes Americas 15

Multiple engineering
domains influence product
performance and design
decisions. By managing
their simulation tools, data,
and processes, organizations
are able to secure their
simulation-generated
Realistic simulation allows hundreds of
intellectual property and
virtual tests to be performed efficiently
gain significant efficiencies.
and cost effectively. Such simulation
processes result in a huge amount of
data and knowledge that must be
managed and secured.
It’s Time
to Manage
Simulation as a
Valued Corporate Asset
By Paul Lalor, Product Manager, SIMULIA
Most product development hy? Simulation technology processes and, similar to Product Lifecycle
W traditionally lives outside most Management (PLM) solutions, ensures
organizations know that using
organizations’ product lifecycle knowledge capture, data integrity,
realistic simulation throughout
management systems and tightly managed traceability, and collaboration throughout the
the design process delivers
business processes. The tools and data are simulation lifecycle. SLM assists
more innovative and reliable
often controlled by small groups of experts. organizations in leveraging their simulation
products to market faster and
Generally, simulation results are stored on assets more effectively and reaches a new
more cost effectively than local hard drives, meaning they are level of efficiency that shortens development
conventional prototyping and inaccessible to others. This leads to cycles, reduces waste, and improves
physical testing alone. repeating analyses unnecessarily, or — even product quality while fostering a culture
worse — losing valuable simulation results. of collaboration and
However, even those who
For simulation to be an integral part of the innovation.
apply simulation effectively
product development cycle, the associated
often fail to capture the
simulation processes, authoring tools, data, SIMULIA SLM
processes, manage and re-use
and resulting intellectual property must be The initial release of
the data, and secure their
managed, shared, and secured as strategic SIMULIA SLM provides
simulation-generated business assets. the technology for managing
intellectual property. simulation data, processes,
To address these issues, SIMULIA, the and tools in a collaborative
Dassault Systèmes brand for realistic environment. SIMULIA SLM is
simulation, has developed a new solution for built on a mature PLM
Simulation Lifecycle Management (SLM). platform from Dassault
The SLM vision brings order to simulation Systèmes — the ENOVIA
16 Contact mag | Dassault Systèmes Americas

solution spotlight
Collaboration Platform – enabling best-in- simulation results, which can be reviewed in gives individuals and groups access to
class PLM operations that act upon the relation to the full system performance simulation-generated information and
simulation entities exposed within SLM. specifications. knowledge through an intelligent and intuitive
interface. This dashboard provides the quick,
To associate the simulation process and key cross-functional insight into data needed to
SIMULATION DATA MANAGEMENT
results with product intellectual property, The SIMULIA SLM solution collects, support design and business decisions
SIMULIA SLM enables four critical elements secures, manages, and associates throughout the development process.
of the simulation lifecycle: simulation data with related product data in
• Collaboration a central repository. It maintains the WHY SLM NOW?
• Simulation data management relationship between engineering targets Shorter product lifecycles, higher material
• Integration and process automation and key simulation results, and provides a costs and the expanding role of international
• Decision support searchable environment for related data. It regulations are just a few of the factors that
also facilitates tracing the history of ensure simulation will play a growing role in
individual simulation processes, including overall product design and manufacturing.
COLLABORATION
Product development involves a number of parameters, assumptions, and results that In a December 2006 white paper entitled
teams working together to make design influence key design decisions. “Enterprise Simulation Management,”
trade-off decisions based on a variety of CIMdata predicts that the role of simulation
performance parameters such as strength, will expand beyond specific validation
INTEGRATION AND
weight, vibration, and durability. SIMULIA phases to permeate every element of
PROCESS AUTOMATION
SLM supports cross-functional collaboration A broad spectrum of best-in-class and product development. Its capabilities will
by giving everyone in the development proprietary simulation applications facilitates span an enterprise, from purchasing to sales
process access to complete product performance analysis. and many others, to empower more
the most current SIMULIA SLM connects these various tools informed and confident business decisions.
in an open, yet controlled, manner. As the
management of an organization’s simulation Together with the increasing volume of
data and processes mature, SIMULIA SLM simulations being performed, it is clear that
provides the resources to capture, organizations leveraging realistic simulation
automate, and deploy approved simulation on a regular basis need an economical and
workflows to a wider group of expert and effective tool to manage, share, and secure
non-expert simulation users. their simulation assets. SIMULIA SLM will
help these organizations gain control of their
simulation-generated intellectual property,
DECISION SUPPORT
To ensure a product meets its functional and transforming it into a valuable corporate
)
manufacturing requirements within the asset•
constraints of time and cost, organizations
must leverage simulation results across multiple For more information:
www.simulia.com/products/slm.html
departments. The SIMULIA SLM environment
Contact mag | Dassault Systèmes Americas 17

Lockheed Martin Puts F-35s
Onboard Ships Virtually, Avoids
up to $100 Million in Costs
Take an aircraft carrier n most cases, lots of challenges. But in “Everything is commercial off-the-shelf
I the case of the new F-35 Lightning II technology, and all of it connects easily
designed and built in a
fighter jet designed by Lockheed Martin, through the ENVISION open-software
shipyard, and a fighter jet
those challenges should be a thing of the architecture,” says Mike Dobbins, SAIL
designed and built years later
past. Thanks to a 3D virtual reality Systems Engineer for virtual maintenance
in a totally different
environment called SAIL (Ship/Air Integration and digital human modeling. CAVE
environment by another
Lab) that Lockheed Martin developed, the surrounds users with life-sized displays of
contractor, put them together company is identifying and resolving detailed engineering data, the flight deck
and what do you get? integration issues between its F-35s and and even the ocean in a new approach to
aircraft carriers already in service – in some comprehending complex data called
cases for decades – while the new planes “immersive engineering.”
are still in the digital design phase.
SAIL ANTICIPATES, ELIMINATES
DELMIA’s ENVISION software for assessing CLASHES EARLY
mechanical interferences is at the heart of Lockheed Martin is building three versions of
the SAIL system. SAIL also leverages CATIA the F-35 – one for traditional land-based
3D digital designs as a main source of data operations, one for carrier operations
on the configuration of both planes and and one for short takeoff vertical landing
ships. Lockheed Martin combined these operations. Of the three, the carrier-based
solutions with technologies such as version offers the greatest challenges due to
stereographic head-mounted displays and a the rigors of shipboard flight operations. To
six-camera spherical digital-video system to date, Lockheed Martin estimates the
create SAIL and CAVE (Cave Automatic lessons learned through immersive
Virtual Environment), the room where the engineering with SAIL have generated
virtual reality simulations are performed. benefits that have allowed the company to
18 Contact mag | Dassault Systèmes Americas

success story
SAIL is an immersive engineering
environment leveraging DELMIA and
CATIA together with other technologies.
avoid up to $100 million in costs, a payback millions of dollars and potentially disrupt machine interfaces and human factors in
of approximately 15-to-1 on Lockheed shipboard operations. Using SAIL to find virtual maintenance. “Its value is that it
Martin’s investment and the approximate them in the digital stage, before the aircraft represents reality accurately in space, in
value of two F-35 Lightning IIs – like giving are built, allows Lockheed Martin to correct time, and in movement that is true to life.”
the taxpayers two free aircraft. them when changes are easy and
inexpensive to make. This also allows its Lockheed Martin often brings Navy
“SAIL is all about affordability,” says Michael R. engineers to find the best solution – not just personnel into the facility to experience the
Yokell, Senior Manager, F-35 Basing and Ship the one that can be most quickly retrofitted simulations first hand. “SAIL lets maintainers
Suitability. “The savings come from finding into an already built aircraft. and ordnance specialists see within a few
and fixing design problems now instead of seconds whether something designed into
later, when the cost would be far higher.” the aircraft will work on the flight deck,
SAFER OPERATIONS THROUGH
because it is so easy for them to relate what
VIRTUAL REALITY
The value of SAIL lies in identifying issues in SAIL also helps Lockheed Martin anticipate they see in SAIL to their own shipboard
the design of the planes that normally and mitigate potential dangers to shipboard experience,” Yokell says.
wouldn’t be noticed until after they were put personnel, such as determining safe
into service. For example, SAIL helped distances from intake valves or the heat “SAIL is a radical approach for a
engineers recognize that the initial design for dispersed around an engine. SAIL is ideal for conservative company, but one that is
tie-downs used to lash the planes to the simulating almost any operation on the flight proving its worth every day,” Yokel says. “We
carrier deck wouldn’t work due to clashing deck, the weapons bay inside the aircraft, or have been working for a decade to find a
parts. Certain parts were redesigned or attachment points beneath the wings. SAIL way to quickly identify maintainability and
relocated to eliminate the clashes. Early on, simulations also can show two, three, or affordability issues and verify proposed fixes.
engineers also realized that mounting the even four crew members working together Without the credibility generated by the
engines on rails inside the fuselage would in an operation such as re-arming an F-35. realism and accuracy of the electronic tools
allow them to be removed through the rear working through DELMIA with CATIA data,
)
of the plane for servicing, which works best “The big improvement over previous SAIL might not have gained acceptance”•
at sea, rather than through the bottom, as is approaches to rendering engineering
customary for land-based aircraft. information is that SAIL integrates CAD, For more information:
www.lockheedmartin.com/aeronautics
human motion, sections of the aircraft,
Finding such issues after construction is the elements of the ship and surrounding
most expensive time to find them, forcing spaces,” says Pascale Rondot, the F-35
repairs and workarounds that can cost SAIL lead who is responsible for human-
Contact mag | Dassault Systèmes Americas 19

Pentair Processes Flow
Faster with ENOVIA
Minnesota-based Pentair Inc. arlos Moreno, Pentair Water’s PLM yet, those that are find that having a single
C (Product Lifecycle Management) source of data and a consistent data model
has evolved through
Systems Manager, wanted to help with revision and version management
acquisitions into a global
Pentair make consistent, reliable, up-to-date streamlines collaboration.
powerhouse focused on water
data available to everyone, regardless of
technologies and technical
location. Pentair executives searched the “Previously, one person had to do the entire
products. In 2006, the
marketplace for new solutions to address design,” says Dave Averbeck, Director of
company’s two divisions had four top needs: a common 3D design Engineering for the Filtration Group, the first
a combined 15,000 employees system; a single, centralized data repository Pentair division to adopt ENOVIA. “Now we
and locations in 40 cities with a common data model; a collaborative can split that project among four or five
platform capable of supporting multiple different people, and everyone knows what
from Sheboygan, Wisconsin,
sites; and a common approach to workflow. everyone else is doing. It cuts the time in half
to Shanghai, China.
and multiplies the brain power applied to every
When the dust settled, the clear winner was project, which makes for a better design.”
a PLM solution from Dassault Systèmes
featuring ENOVIA for product data and Centralized, reliable data managed in
workflow management. One key factor was ENOVIA also lowers the potential for
DS PLM’s introduction of Multi-Site, a mistakes, significantly decreasing the
solution to synchronize data across number of changes made at the tooling
distributed installations. “In the end, Multi- stage, when they are most expensive.
Site is what got everyone on board,” Moreno “ENOVIA has enabled Pentair to reap the
says. “To be able to interact was so benefits of engineering globally, without
appealing.” ENOVIA also works seamlessly boundaries,” says T. Balagangadaran,
with multiple CAD systems. Senior PLM Engineer.
“One of the huge benefits is the ability to
SEARCHABLE, CENTRALIZED DATA
avoid redundancy in design,” says Randy
DRIVES EFFICIENCY
Although not every division is live on ENOVIA Baker, Engineering Services Manager for
20 Contact mag | Dassault Systèmes Americas

success story
« ENOVIA has enabled Pentair to reap the
benefits of engineering globally, without boundaries.
T. Balagangadaran, Senior PLM Engineering, Pentair
Pentair Water, Pool and Spa. “When you sourcing. We track the regulatory certific- importance of having a single vision and a
don’t have a strong database, you can ations for every part in every product in single approach worldwide,” Moreno says.
waste two days searching for something every jurisdiction. DS PLM is making life “Having one cook in the kitchen, rather than a
you never find, and then you waste time re- easier for our entire organization.” different one in every sales territory, was
designing something you already had. critical to our success.”
That’s a huge cost, and a powerful tool like A phased implementation allows each new
ENOVIA eliminates it.” group to benefit from the development work Pentair plans to leverage its DS PLM
done by its predecessors. “It’s great that any investment for even greater future returns,
idea, process, or workflow developed for one including rolling out Multi-Site access to its
ONE COMPANY WITH ONE
group can be recycled for the benefit of the locations across Europe. “In an increasingly
TRUSTED DATA SOURCE
Every location equipped with Multi-Site, entire organization,” says Chris Lange, competitive market, it is only logical that our
including Pentair’s design centers in India, Director of Engineering for the Pump Division. efforts in 2008 concentrate on continuously
now has access to precisely the same data fostering innovation, in addition to our
)
and product structure and receives regular process improvements,” Moreno says•
FOCUS ON INFLOW TECHNOLOGY
synchronized updates of only that data that Pentair gives much of the credit for its DS PLM
has changed since the previous update. success to InFlow Technology, a Dassault For more information:
www.pentair.com
Systèmes value-added reseller that specializes
www.inflow-tech.com
Pentair’s DS PLM implementation also in PLM strategy and implementation. “Their
supports the broader enterprise with support has been phenomenal, and the
product data. “Our Supply people use the knowledge they have developed over the
system on a day-to-day-basis, Customer years in working with Pentair has really paid
Service stores product manuals in it, Quality off,” Baker says.
uses it extensively to store their ISO control
documents and manage processes such “InFlow has worked as an extension of our
as ROHS,” says Dan Turkoski, own group, as part of our team,” Moreno
who led the implementation adds. InFlow also supports Pentair’s rollout
team. “Production keeps worldwide. “We really appreciate
work instructions in it, that Dassault Systèmes
Purchasing uses it for supported us on
make-versus-buy this point and
decisions and saw the
Contact mag | Dassault Systèmes Americas 21