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                                                           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
Contact Mag   Bva Reference   Hyundai America Technical Center, Inc.
Contact Mag   Bva Reference   Hyundai America Technical Center, Inc.
Contact Mag   Bva Reference   Hyundai America Technical Center, Inc.

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Contact Mag Bva Reference Hyundai America Technical Center, Inc.

  • 1. 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
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  • 3. 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/
  • 4. 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
  • 5. 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
  • 6. 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
  • 7. 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
  • 8. 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
  • 9. 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
  • 10. 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
  • 11. 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
  • 12. 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
  • 13. 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
  • 14. 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
  • 15. 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
  • 16. 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
  • 17. 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
  • 18. 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
  • 19. 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
  • 20. 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
  • 21. 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