Post on 03-Aug-2018
VOLVO Construction Equipment Korea LTD
Engineering Process InnovationWith New IT Solution
Volvo Construction Equipment Korea
Engineering Process InnovationWith New IT Solution
Volvo Construction Equipment Korea
• EPI History• Target• Integration Strategy• VPM Function Analysis and Data Migration• Applications• Implement to Development Process• Keys to a Successful Implementation
VOLVO Construction Equipment Korea LTD
�� History of Engineering Process InnovationHistory of Engineering Process Innovation
● EPI (phase 0) Consulting Project : Jul. ’96 ~ Feb. ’97– Analysis AS-IS and Exhibit TO-BE Vision– Present Implementation Plan
11. . The 1st StepThe 1st Step (Consult with ITI)
22. . The 2nd StepThe 2nd Step
33. . The 3rd StepThe 3rd Step
● Set up EPI Master Plan : Apr. ’97– Consider the resource of SHI
● E-CIM & Technical Support Team Organization : Jul. ’97● Modify EPI Master Plan : Jan. ’98● E-CIM Center of Daeduck R&D move to Changwon : Jun. ’98● Merge to VOLVO : Jul. ’98
● Set up IT Master Plan : Sep. ’98● Set up VPM Implementation Plan : Oct. ’98
VOLVO Construction Equipment Korea LTD
● Organized VPM Project Team : Sep. ’98● Prepared Project : Dec. ’98● VPM Function Analysis : Feb. ’99● VPM User’s Scenario : Mar. ’99● Data Base Design : Apr. ’99● Investment for Infrastructure(2 Billion won) : Apr.’99● Data Conversion & Migration Method : May. ’99● Applications : Jul.’99
✧ Part Master Management✧ Approval & Drawing Support✧ VPM Web✧ Engineering Change Reporting✧ SAP & COLS Interface(~on going)✧ Multi Model Effectivity Validation(~ on going)✧ Cost & Weight Summation (~ on going)
● Education & Training : Jul.’99✧ Super User :20 persons✧ Engineer : 100 persons✧ Manager : 30 persons✧ Casual User :100 persons✧ General User(WWW) :All Volvo User (on going)
● Current Data Conversion & Migration :~Dec.’99
�� VPM Project HistoryVPM Project History
VOLVO Construction Equipment Korea LTD
�Target••ProcessProcess••OrganizationOrganization••Information TechnologyInformation Technology
VOLVO Construction Equipment Korea LTD
AdvancedEngineering
(CAB)
AdvancedEngineering
(CAB)ProductPlanningProductPlanning
ConceptDesign
ConceptDesign
Prototyping/Test
Prototyping/Test
DetailDesignDetail
Design
ProcessPlanningProcessPlanning
Prepare forMass/salesPrepare forMass/sales
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•Strategic Suppliers•CAD/M/ID
•QFD•S.E•Design for Quality
•CAPP•Predict Performance•Reliability Growth
•CAD/E/M•CAPP•Cost Modeling
•Generative Technical Publishing •Reliability Monitoring
● Advanced develop in Core technology & Family design● Product planning & Concept design C.E ● Detail design & Process planning C.E● Prototyping with Mass Process● Commence reliability before pilot parts are available
Self Managing Team / Data Share/System Interface
SAVING23
● Encourage empowerment● Integrate information
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ProductPlanningProductPlanning
ConceptDesign
ConceptDesign
ProtoDesignProto
DesignPrototyping
/TestPrototyping
/TestProcessPlanningProcessPlanning
Prepare forMass/salesPrepare forMass/sales
36
•• ProcessProcess
VOLVO Construction Equipment Korea LTD
•• OrganizationOrganization
Functional MatrixFunctional Matrix
• Difficult cross functional communication• Absence of Continuous Improvement culture• Task Oriented not Result Oriented• Results are not owned• Responsibility can be avoided
Current
Balanced MatrixBalanced Matrix
Transition
Self Managing TeamSelf Managing Team
● Project based organization ● Basically full-time and co-located● Follows throughout its life cycle● Result Oriented Project Management ● Responsibility for product development● Empowerment
Vision
VOLVO Construction Equipment Korea LTD
•• Information TechnologyInformation Technology
External AccessWWW
DataInterface
M-BOM
BOM
ECM
DocumentManagement
PDM
PARTMASTER
Internet orTCP/IP
SAP/R3
Mfg.Asm
QualityData
Simul.Data
TestData
QMS/FMECA
CAPP
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ForecastCost
Cost Modeling
SEDB
Test
ArchiveData
DesignHistory
Step 1Step 2
STEPIGES
M-BOM,Part,ECN,Price
ForecastPrice
ProductPart info.
DesignAlternative
CompareData
Report
Report
VOLVO Construction Equipment Korea LTD
�Integration Strategy••System IntegrationSystem Integration••BOM IntegrationBOM Integration••Product Data Flow Over ViewProduct Data Flow Over View
VOLVO Construction Equipment Korea LTD
Single System for:Single System for:••Data Consistency &AccuracyData Consistency &Accuracy••Remove non valued double ActivityRemove non valued double Activity••earlier Communicationearlier Communication
Part Part master
EBOM Engineering Bill of Materials
MBOM Manufacturing Bill of Materials
SBOM Part Planning
ECN Engineering Change Notices
PP Process Planning
VPMVPM
R/3Client / Server
ABAP/4
COAM
PS
WFIS
MM
HR
SD
PP
QM
FI
PMInterface
Production Bill of Materials
Production Change Notices
Routing
InterfacePart Catalogue
Generation
Process Plan Sheet
••System IntegrationSystem Integration
VOLVO Construction Equipment Korea LTD
••BOM IntegrationBOM IntegrationSingle-BOMSingle-BOM
ValueValue
E-GroupE-Group
RCVRCV KnobKnob
C/FrameC/FrameS/FrameS/Frame
BushingBushing
Framewa
FramewaCABCAB
BoomBoom
EngineAssy.
EngineAssy.
LeverAssy.LeverAssy.
BoltBolt
BracketBracketPlatePlate
FrameFrame
PlatePlateGlassGlass
S/DoorS/Door
Boomassy
Boomassy
Process PlanProcess Plan
ProcessProcess
PP_ValuePP_Value
LowMaterial
LowMaterial
SectionSection
Part PlanPart Plan
CS_ValueCS_Value
Cyl. HeadCyl. Head CamshaftCamshaft
Boomassy
Boomassy
GearGear KeyKey
EngineeringServiceManufacturing
Effectivity(Machine Serial No)QuantityEffectivity(Machine Serial No)QuantityIllustration Fig noEffectivity(Component Serial No)QuantityIllustration Fig noEffectivity(Date)QuantityProcess OrderTact no
VPMVPMR/3
Client / ServerABAP/4
COAM
PS
WFIS
MM
HR
SD
PP
QM
FI
PM
M-BOMM-BOM
ValueValue
Boomassy
Boomassy
Framewa
Framewa CABCABEngine
Assy.EngineAssy.
LeverAssy.LeverAssy.
C/FrameC/FrameS/FrameS/Frame
BracketBracketPlatePlate
Interface
VOLVO Construction Equipment Korea LTD
Model & DrawingsModel & DrawingsPrototype, E, M, A/S BOMPrototype, E, M, A/S BOM
Std. Configuration by Country Std. Configuration by Country Configuration & parts by Machine Configuration & parts by Machine EngEng., ., MfgMfg. & Service Part Master. & Service Part Master
Engineering Change NoticeEngineering Change NoticePart & Process PlanningPart & Process Planning
IllustrationIllustrationSupplier, Cost, Weight...Supplier, Cost, Weight...
Sales ConfigurationConfigured DMU
Part MasterE-BOM, DrawingEffectivity & ECN
Data interfaceWEB Viewing
Next stepExportExportImport
Production-BOMPart Master
Sales ConfigurationECN
Configuration byCountry & machine
EC Result
Part MasterModel & Drawings
ECNSupplier & Cost
Single-BOMPart Master & ECNProcess Plan SheetModel & Drawings
3D Product Models3D Die Models
Service Part MasterA/S BOM
Part Catalogue
Service Part MasterA/S BOM, DrawingEffectivity & ECN
Service Part MasterDrawing
Effectivity
••Product Data Flow Over ViewProduct Data Flow Over View
VOLVO Construction Equipment Korea LTD
�VPM Function Analysis and Data Migration••Part Master ManagementPart Master Management••BOM ManagementBOM Management••Drawing, Model & ECN ManagementDrawing, Model & ECN Management••Configuration ManagementConfiguration Management••Design History Control & ManagementDesign History Control & Management
VOLVO Construction Equipment Korea LTDPart CategoriesPart Categories
PNS WebPNS Web
•• Part Master ManagementPart Master Management
Part nameStandardization
(about 10,000 Part name---> 803 Part name)
Old pname New pname C-code FGI C/S Eng0501209270 DW2 SHIFT LEVER LEVER-SHIFT DW2 2302 Y Y050370000 U/JOINT ASSY PROPELLER SHAFT-ASSY 2204 4510 Y100B-91301 BALL V/V 10K VALVE-DRAIN 8220 Y Y1010-11350 B DATA PLATE DECAL-DATA PLATE 8460 8970 Y1015-02670 RAD.TOTAL ASS'Y RADIATOR-ASSY TOTAL 0530 2611 Y Y1020-03460 H/LIGHT&T/S-RH HEADLIGHTS-RH TURN SIGNAL 1400 3500 Y Y1022-00640 H/LIGHT&T/S-RH HEADLIGHTS-RH TURN SIGNAL 1400 3500 Y Y1023-00770 CONTROL-W/AMP INSTR PANEL-WITH AMP 1100 8810 Y Y1023-00780 B CTRLR-W/AMP CONTROL UNIT-WITH AMP 1190 Y Y1023-03890 A CTRLR-W/AMP CONTROL UNIT-WITH AMP 1190 Y Y1072-03980 L BOOM BEARING ARM-WA 4580 Y Y1090-90781 NAME PLATE DECAL-CAB 8460 8970 Y Y1091-01530 STRIPE-FUEL DECAL-STRIP 8460 8970 Y Y1123-00460 END PIECE PLATE-END PIECE 4274 Y Y1123-02990 SW A'Y-ST.&FUEL SWITCH-ASSY FUEL AND START 1137 Y Y1123-03180 R/S-ROOM LAMP SWITCH-ROOM LAMP 8460 3870 Y Y
pno
Conversion
Migration
••Recommendation GradeRecommendation Grade••Old-New Part RelationOld-New Part Relation••Function Group IndexFunction Group Index••……......
••176,353 176,353 Part noPart no
VPMVPMDATABASEDATABASE
Unique PartUnique PartInformationInformation
••MaturityMaturity••VersioningVersioning••……......
VOLVO Construction Equipment Korea LTD
VPMVPM
•• Drawing, Model & ECN Information ManagementDrawing, Model & ECN Information Management
Engineering Change Notice
2D Drawings 3D Models
VOLVO Construction Equipment Korea LTD
••BOM ManagementBOM Management
VPMVPMDATABASEDATABASE
Strong System ConstraintStrong System ConstraintUnique BOM StructureUnique BOM Structure
Easy to useEasy to use
•Weak System Constraint•No Configured BOM support•Text Based BOM
••About 1,100,000 recordsAbout 1,100,000 records
P NO Version P NO Version QTY start end Model1115-03760 1115-00021 1 1 9999 EC2101115-03760 1115-00110 1 1 9999 EC2101115-03760 1115-00160 2 1 9999 EC2101115-03760 1115-00373 1 1 9999 EC2101115-03760 1115-00410 1 1 9999 EC2101115-03760 1115-00420 1 1 9999 EC2101115-03760 1115-00430 1 1 9999 EC2101115-03760 1115-00440 1 1 9999 EC2101115-03760 1115-00620 1 1 9999 EC2101115-03760 1115-01010 --A 1 1 9999 EC2101115-03760 1115-03780 1 1 9999 EC2101115-03760 1115-03870 1 1 9999 EC2101115-03760 2022-02350 3 1 9999 EC2101115-03760 9011-10803 11 1 9999 EC2101115-03760 9011-10804 16 1 9999 EC2101115-03760 9011-11006 8 1 9999 EC2101115-03760 9011-11007 4 1 9999 EC2101115-03760 9011-11207 8 1 9999 EC2101115-03760 9035-10602 2 1 9999 EC2101115-03760 9211-08000 27 1 9999 EC2101115-03760 9211-10000 12 1 9999 EC210
Parent Child EffectivityC
onve
rsio
n
Migration
Error Check Error RateBOM Structure Error 1.7%Quantity Error 3.2%Assembly Part Structure Error 0.1%Part Name Error 8.0%Non Standard Part Usage Error 0.6%Part Revision Error 1.1%Drawing Information Error 4.3%Sub Engieer Group Code Error 9.0%Engineer Group Code 3.1%Duplicate Part Information Error 25.5%Error Record Count 48.3%
VOLVO Construction Equipment Korea LTD
DDEC210
DD00A001BASIC
DD04A002 ALTER 70DD04B002ENG W A.H
DD04J004F.F FUMP 50
DD08A001CAB FIXED
DD08B001SEAT FABDD08B003
SEAT W A.H
DD08A015CAB SLIDE
DD04J001NO F.F FUMP
DD04A001 ALTER 50
SAME
EU Variant
DD04B002ENG W A.H
NA Variant
VPMVPM
••Configuration ManagementConfiguration Management••Effectivity ManagementEffectivity Management -Range(Product Serial No.) -Option(Model Name or Value code)
DDEC210
DD00A001BASIC
DD04A002 ALTER 70
DD04B002ENG W A.H
DD04J004F.F FUMP 50
DD08A001CAB FIXED
DD08B001SEAT FAB
Configuration Handler ManagementConfiguration Handler Management•Pre-defined Configuration -Engineering Standard Configuration -Standard Configuration by Country -Actual Configuration by Model
EC210 Serial No.78
Compare EUwith NA
DDEC210
DD00A001BASIC
DD04A001 ALTER 50
DD04B002ENG W A.H
DD04J001NO F.F FUMP
DD08A015CAB SLIDE
DD08B003SEAT W A.H
DDEC210
DD00A001BASIC
DD04A002 ALTER 70
DD04B002ENG W A.H
DD04J004F.F FUMP 50
DD08A001CAB FIXED
DD08B001SEAT FAB
DD-51-1201-001-AA
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1112-00010BRACKET F1112-00020BRACKET F1112-00030BRACKET R1112-00070COUPLING
1112-00770INSERT
1112-00200HUB SPLINE
1112-00760ELEMENT
1112-00780INSERT
EU Standard NA Standard
VOLVO Construction Equipment Korea LTD
•• Design History Control & ManagementDesign History Control & Management••Design Action ControlDesign Action Control••Part Structure Status ControlPart Structure Status Control••Engineering Change Status ControlEngineering Change Status Control•Engineering Change Notice Generation•Effectivity Management
VOLVO Construction Equipment Korea LTD
�Applications•Part Master Accuracy•Approval & Drawing Support•Engineering Change Notice Generation•Engineering Data Web Searching•Part Catalogue Technical Publication•SAP Interface(part & BOM)
VOLVO Construction Equipment Korea LTD
••Part Master AccuracyPart Master Accuracy
Part MasterPart Master
Part Name Reference TablePart Name Reference Table
FGI Reference TableFGI Reference TableAccuracy CheckAccuracy Check
Part No
Generation
Service Usage GenerationService Usage GenerationCategory Reference TableCategory Reference Table
Fixed FGI GenerationFixed FGI Generation
Fixed Category GenerationFixed Category Generation
Accuracy CheckAccuracy Check
Accuracy CheckAccuracy Check
Product & Dangerous Code GenerationProduct & Dangerous Code Generation
VOLVO Construction Equipment Korea LTD
Draw the StandardDrawing Formatfrom CADAMSymbol Library
••Approval & Drawing SupportApproval & Drawing Support
Make up theProductStructure(BOM)in VPM DB
Register/ Save theDrawing in VPM DB
ApproveUsing ActionFlow in VPM
VOLVO Construction Equipment Korea LTD
••Engineering Change Notice GenerationEngineering Change Notice Generation
VOLVO Construction Equipment Korea LTD
••Engineering Data Web SearchingEngineering Data Web SearchingR&D WebR&D Web
VPM WebVPM Web
••Part InformationPart Information - Part Master- Part Master - Drawing Information - Drawing Information - Suppler Information - Suppler Information - Where Used - Where Used••Product StructureProduct Structure - Configured Part Structure - Configured Part Structure - Parent-Child Link Information - Parent-Child Link Information (Effectivity, Quantity) (Effectivity, Quantity) - Part Information - Part Information••Engineering Change NoticeEngineering Change Notice
PNSPNS
••ABC SearchABC Search••Conditional SearchConditional Search
VPM StandardVPM Standard
••Bulletin BoardBulletin Board••IntroductionIntroduction••VPM DataVPM Data - Sales Configuration Code - Model Master - Value Master - Engineering Group Master - Part master - VPM Management - Code Table - Trigger & Constraint•Engineering Change•Interface•Data Migration•User’s Scenario
Web DocWeb Doc
••Document SearchingDocument Searching - Engineering Report - Engineering Report - Technical standard - Technical standard - Engineering Change Request - Engineering Change Request - Patents - Patents - Purchasing Information - Purchasing Information - General Standard - General Standard - Manufacturing Information - Manufacturing Information••UserUser’’s Manuals Manual••Bulletin BoardBulletin Board••Document Check InDocument Check In••Administrator FunctionAdministrator Function
VOLVO Construction Equipment Korea LTD
Part & DrawingPart & DrawingVPM WebVPM Web
Part StructurePart StructureEngineering Change NoticeEngineering Change Notice
VOLVO Construction Equipment Korea LTD
KOREA
SWEDEN
•Part Planning•Build Service BOM•Illustration
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VPM
••Part Catalogue Technical PublicationPart Catalogue Technical Publication
•Image Generation
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FrameMaker
•Add Data•Translation(Sweden,German,French,Spanish)
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COLS
FTP
FTP
NFS
Parts Catalogue
Publishing
CD
PROSIS
CD
Publishing
VOLVO Construction Equipment Korea LTD
�Next Applications•Process Plan Sheet Technical Publication•SAP Interface(Engineering Change & Routing)•Multi Model Effectivity Validation•Cost & Weight Summation
VOLVO Construction Equipment Korea LTD
�Application to Development Process•Engineering Process•Engineering Change Process•Cab Development Process•Frame Design Process
VOLVO Construction Equipment Korea LTD
••Engineering ProcessEngineering ProcessProduct Planning Prototyping Pilot Mass Product
••Generate VariantGenerate Variant ••Build Build ProtoProto BOM BOM
••Define RestrictionDefine Restriction ••Create Part MasterCreate Part Master
••Interface Material MasterInterface Material Master
••Fix Total BOMFix Total BOM••Fix Part MasterFix Part Master
••Add Service DataAdd Service Data
••Interface Manufacturing BOMInterface Manufacturing BOM••UpdateUpdate Material Master Material Master
••Fix Configuration by CountryFix Configuration by Country••Part Structure by ModelPart Structure by Model
R/3Client / Server
ABAP/4
COAM
PS
WFIS
MM
HR
SD
PP
QM
FI
PM
••BuildBuild Configurable Configurable BOM BOM
VOLVO Construction Equipment Korea LTD
Participation of BOM user function in structuring BOM
EngineeringConfigurationEngineering
Configuration
AdvancedEngineeringAdvanced
EngineeringProductPlanningProductPlanning
ConceptDesign
ConceptDesign
DetailDesignDetail
DesignProto/Test
Proto/Test
ProcessPlanningProcessPlanning
Prepare forLaunching
Prepare forLaunching
PS I ED PD A
R&D S&
M
P/P
P/C
R&D
Proto BOMDrawing
Proto BOMDrawing Single BOM
Drawing&Illustration
Single BOMDrawing&Illustration
R&D
MFG
Purc
hasi
ng
P/C
R&D S&
M
P/P
P/C
S/P
LaunchingPackage
LaunchingPackage
ManufacturingConfiguration
ManufacturingConfiguration
R&D S&
M
P/P
P/C
ProcessPlanningProcessPlanning
Part PlanningPart Planning
Process PlanningSheet
Process PlanningSheet
Part CataloguePart CatalogueM
FG
MFG
S/P
Pub
SalesConfiguration
SalesConfiguration
R&D : Research & DevelopmentS&M : Sales & MarketingP/P : Product PlanningP/C : Production ControlMFG : ManufacturingS/P : Service PlanningPup : Publication
BOM Generation ProcessBOM Generation Process
VOLVO Construction Equipment Korea LTD
••Engineering Change ProcessEngineering Change ProcessProposed In-Work Ch/Re/App/Agree Release Complete
••UpdateUpdate Material Master Material Master
••Engineering Change Order ControlEngineering Change Order Control
••Execution Engineering ChangeExecution Engineering Change
••ValidateValidateEffectivityEffectivity -Serial No-Serial No
••UpdateUpdateTarget dateTarget date
R/3Client / Server
ABAP/4
COAM
PS
WFIS
MM
HR
SD
PP
QM
FI
PM
VOLVO Construction Equipment Korea LTD
••Cab development ProcessCab development Process
ConceptConceptDesignDesign
CAIDCAID
Manufacturing MuleManufacturing Mule
Advanced EngineeringAdvanced Engineering
CAICAI
RPRP
VPMVPM
CADCAD
CAPPCAPP
CAMCAM
VOLVO Construction Equipment Korea LTD
••Frame Engineering ProcessFrame Engineering Process
VPMVPM
Weight 15% ReductionWeight 15% ReductionNo. of Items 15% ReductionNo. of Items 15% Reduction
VOLVO Construction Equipment Korea LTD
�Key to a Successful Implementation•Project Team•Preparation at Just in Time•Education & Training
VOLVO Construction Equipment Korea LTD
••Team Work Team Work ••Project Manager PowerProject Manager Power
••Product Development Experience Product Development Experience ••Process Design CapabilityProcess Design Capability••Current Data Gathering/Analysis/Conversion CapabilityCurrent Data Gathering/Analysis/Conversion Capability
••Data Base Design CapabilityData Base Design Capability••Software TechnologySoftware Technology••CooperationCooperation
••Project TeamProject Team
VOLVO Construction Equipment Korea LTD
••Preparation at Just in TimePreparation at Just in Time
If NotIf Not……... ...
�� BPR Method BPR Method - 3 years ago! - 3 years ago!
�� New Process Design - New Process Design - 2 years ago! 2 years ago!
�� Volvo - 1 year ago! Volvo - 1 year ago!
�� Millennium - Millennium - this year! this year!
VOLVO Construction Equipment Korea LTD
••Education & TrainingEducation & Training
••Who is the most Conservative Manager?Who is the most Conservative Manager?
••Who gets the most benefit?Who gets the most benefit?
••Who are Super-Users?Who are Super-Users?