Globalisation ofGlobalisation ofR&D in theR&D in theAutomotive IndustryAutomotive Industry

Dr. Klaus P. MayerDr. Klaus P. Mayer

Paris, 22 October, 2001Paris, 22 October, 2001

201032

2

IntegratedIntegrated Innovation Innovation

CitizensCitizens / /Customer processCustomer process

TechnicalTechnicalPhenomenaPhenomena

ProductProductFeaturesFeatures

PhysicsChemistry

Mechanics

Technicalfeasibility

TechnologyMathematics Success factors

ScientificScientificBasisBasis

Industrial ResearchIndustrial Researchandand Innovation Innovation

AcademicAcademicResearchResearch MarketMarket

Convenience factors

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Oriented BasicResearch Applied ResearchApplied Research

University Institute Industry

BasicResearch

Critical MassCritical Mass in in Research Research

Inadequate Inadequate Co-Co-operationoperation

Intensive Co-Intensive Co-operationoperation

… to… to Achieve Critical Mass Achieve Critical Mass

BasicResearch OrientedOriented Basic Basic Research Research

University Institute

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MarketMarket

Supplier

Supplier

Service

IndustrialIndustrialCore CompetenceCore Competence

CentreCentreSupplier

MarketingProductionSupplier

Supplier

NetworkNetwork of ofExcellenceExcellence

CenterCenter of ofIndustrialIndustrial

R&DR&D

ProductDevelop-

ment

R&DR&D

UniversitiesUniversities & & ResearchResearch Institutes Institutes

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Co-Co-operation Industryoperation Industry / / Universities Universities

Exp. teamExp. team Exp. teamExp. team Exp. teamExp. team ExExmm Exp. teamExp. team

IndustryIndustry

Project teamProject team

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Co-Co-operation Industryoperation Industry / / Universities Universities

InstituteInstitute InstituteInstitute InstituteInstitute InInee InstituteInstitute

UniversityUniversity �� Transparent structuresTransparent structures�� InterdisciplinaryInterdisciplinary

AcademicAcademicProjectsProjects

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Co-Co-operation Industryoperation Industry / / Universities Universities

Exp. teamExp. team Exp. teamExp. team Exp. teamExp. team ExExmm Exp. teamExp. team

InstituteInstitute InstituteInstitute InstituteInstitute InInee InstituteInstitute

IndustryIndustry

UniversityUniversity �� Transparent structuresTransparent structures�� InterdisciplinaryInterdisciplinary

JointJointProjectsProjects

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IntegratedIntegrated Project Project

ProjectsProjects

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PartnersPartners for for AVL AVL Combustion Combustion Simulation Simulation

ExperExper..VerificationVerification

NumericalNumericalMethodsMethods

UniversityUniversity

6 6 EUEU Projects Projects

4 4 NationalNational ProjectsProjects((GermanyGermany))

3 3 NationalNational ProjectsProjects((AustriaAustria))

55 ResearchResearchProjects withProjects withIndustryIndustry

SoftwareSoftwareSuppliersSuppliers

IndustryIndustry

ProjectProjectModelsModels

fromfrom

PhysicsPhysics

&&ChemistryChemistry

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Customers

Challenges for IndustryChallenges for Industry

Suppliers Development Production Sales Marketing ServiceProcurement

- Netmarkets - Network Supply Chains

- eCollaboration

Technological Potential via Internet:Multiple Networks and Interactivity!

- Shorter Time to Market- Increase of Quality

- Cost Reduction- Rapid Technology Development

- Globalisation

Restructuring & Concentrationon Core Competences

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Customer

DevelopmentCustomer

Customer

Customer

CustomerCustomer

Marketing

Marketing

Development

Service

Sales

ProductionProcurementSupply

Ou

tso

urc

ing

Ou

tso

urc

ing

Ou

tso

urc

ing

Ou

tso

urc

ing

Split Split of Traditional Value Chainsof Traditional Value Chains

Customer

201024b

ProcessesNetworks

Infra-Infra-structurestructure

ToolsTools

QualityQualityprocessesprocesses

CommonCommonEngineering Engineering

LogicLogic

OperativeOperativeGuidelinesGuidelines

Success Factors for eCollaborationSuccess Factors for eCollaboration

PeoplePeople

13

D etail design

Concept design up date

Concept definition and choice of major suppl iers

Thermodyn amic la yout

EM S specification

Mechanica l calculation

Procurement e ngine gen eration 1 Engine build / firs t engine run Gen. 1

Baseline per formance & emission development

Baseline engine mapping & ECU calibration

Tolerance investigations

Emission development (dyn. test bed)

Dr iveability & emission developm ent in vehicles

Ba sic concept selection

Com ponent developmen t

Function al development (test bed & vehicle)

D urab il ity developme nt (test bed)

Vehicle enduran ce testing: mileage accu mulation

Baselin e acoustic development (test cell)

Pa ss-by noise & vehicle inte rior noise development

CAD data tra nsfer

Acou stic calculation

Specification engine Gen. 2 R elease of concept for preproduction develo pment

R elease of conce pt design

Project k ickoff m eeting

Concept design

Thermodyna mic ca lculation

Mechanical calculation

Co ncept FMEA

Design up date for eng ine generation 2

Mechanical calculation engine generation 2

Procurement engine generation 2 First engine run g eneration 2

Perfo rmance & emiss ion ver ifica tion Tolerance investigations

EMS optimization (steady state a nd dynam ic test b eds)

D rive ability & emiss ion optimization in vehic les

EMC tests & OBD calibra tion

Component d evelopment & fatigue tests

Functional development

Durability development (t est bed)

Functional de velopment in veh ic les; hot & cold c limate t ests

Vehicle endurance testing

Mileage accumulation

Release p rocedures for supplier develop ed syst ems

Design freeze MLI D esign freeze SLI

Engine & vehic le a coustic verification

Ana lysis of acoustic vehicle con formity

Engines & vehicles from pro duction tooling

Vehicle validation (fleet tests) : emiss ions & OBD-system

Hot & cold climate test s

EMC val idation

D urab ility validatio n (test bed)

Vehicle endurance val idation

Acoustic valid ation

Quality assurance testsSta rt of pi lot production

Release of casting pattern and forg ing die pro curement

H omologation

EMS data release

EM S preparation

FIE rig tests

Target costing

OBD softw are development ( if required)

Cold start development Hot & cold c limate t ests

ECU data release for validation tests

D evelopment suppor t

U pdate of engine documentation

Interaction of ProcessInteraction of Process Elements Elementsin in Engine Development ProjectsEngine Development Projects

StandardisedStandardisedDevelopmentDevelopmentProcessProcess

OrganisationalOrganisationalGuidelines forGuidelines forProject Project ExecutionExecution

Quality RegulationsQuality RegulationsandandProceduresProcedures

QualityQualityprocessesprocesses

CommonCommonEngineering Engineering

LogicLogic

Operative Operative GuidelinesGuidelines

14

Kanalanpassung (b. Bedarf)Motoraufhängung

Anpassung

Anordnung Nebenaggregate, Riementrieb

Einbausituation (Frischluftführung, Abgasstrang)

Ventiltriebsberechnung

Auslegung Was

Anordnung Kühl

Steuerzeiten Auslegung Aufladesystem Thd. Zielwertbes

Interne Freig

Bes

Kom

Komple

Konzept FMEA

AVLAVLEngine DevelopmentEngine DevelopmentProcessProcess::

DefinitionDefinition of the of therequired developmentrequired developmenttaskstasks,, description of the description of thelogicallogical links links between betweenthe tasksthe tasks,, and andoptimisation of theoptimisation of thetechnical data flowtechnical data flow in incourse ofcourse of an an engine enginedevelopment projectdevelopment project

Process OrientedProcess Oriented Organisation Organisation

15

Ka nalanpa ssung (b. Bedar f)Motoraufhängung

Anpassung

Anordnung Nebenaggregate, Riementrieb

Einbausituation (Frischluftführung, Abgasstrang)

Ventiltriebsberechnung

Auslegung Was

Anordnung Kühl

Steuerzeiten Auslegung Aufladesystem Thd. Zielwer tbes

I nterne Freig

Bes

Kom

Komple

Konzept FMEA

Key success factors forKey success factors forengineering collaborationengineering collaborationareare a a common under common under--standing of the developstanding of the develop--ment process andment process and a adetailed definition of thedetailed definition of therequired input asrequired input as well well as asthe output of eachthe output of eachdevelopment taskdevelopment task

AVLAVL Engine Development Process Engine Development Process

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RequirementsRequirements: : eCollaborationeCollaboration in Engineering in Engineering

ToolsToolsecollaboration

� Engineering-DataManagement

VIDEOCONFERENCE

� Instant messaging,web conferencing

� Project ManagementTools

� Tool-Networking / Application-Sharing

17

OverviewOverview ofof Tools Tools UsedUsed in in thetheEngineEngine DevelopmentDevelopment ProcessProcess

Detail design

Concept design update

Concept definition and choice of major suppliers

Thermodynamic layout

EMS specification

Mechanical calculation

Procurement engine generation 1 Engine build / first engine run Gen. 1

Baseline performance & emission development

Baseline engine mapping & ECU calibration

Tolerance investigations

Emission development (dyn. test bed)

Driveability & emission development in vehicles

Basic concept selection

Component development

Functional development (test bed & vehicle)

Durability development (test bed)

Vehicle endurance testing: mileage accumulation

Baseline acoustic development (test cell)

Pass-by noise & vehicle interior noise development

CAD data transfer

Acoustic calculation

Specification engine Gen. 2 Release of concept for preproduction development

Release of concept design

Project kickoff meeting

Concept design

Thermodynamic calculation

Mechanical calculation

Concept FMEA

Design update for engine generation 2

Mechanical calculation engine generation 2

Procurement engine generation 2 First engine run generation 2

Performance & emission verification Tolerance investigations

EMS optimization (steady state and dynamic test beds)

Driveability & emission optimization in vehicles

EMC tests & OBD calibration

Component development & fatigue tests

Functional development

Durability development (test bed)

Functional development in vehicles; hot & cold climate tests

Vehicle endurance testing

Mileage accumulation

Release procedures for supplier developed systems

Design freeze MLI Design freeze SLI

Engine & vehicle acoustic verification

Analysis of acoustic vehicle conformity

Engines & vehicles from production tooling

Vehicle validation (fleet tests): emissions & OBD-system

Hot & cold climate tests

EMC validation

Durability validation (test bed)

Vehicle endurance validation

Acoustic validation

Quality assurance tests

Start of production

Start of pilot production

Release of casting pattern and forging die procurement

Homologation

EMS data release

EMS preparation

FIE rig tests

Target costing

OBD software development (if required)

Cold start development Hot & cold climate tests

ECU data release for validation tests

Development support

Update of engine documentation

BOOST,TYCON,BRICKS,CRUISE

BOOST,TYCON,BRICKS,CRUISE

TYCON,FAME,FIRE,SWIFT,EXCITE,GLIDE

TYCON,FAME,FIRE,SWIFT,EXCITE,GLIDE

BOOST,TYCONBOOST,TYCON

BOOST,FIRE,HYDSIM,CRUISE

BOOST,FIRE,HYDSIM,CRUISE

TYCON,FAME,FIRE,SWIFT,EXCITE,GLIDE

TYCON,FAME,FIRE,SWIFT,EXCITE,GLIDE

BOOST,TYCONBOOST,TYCON

Calibration ToolsCalibration ToolsHIL ToolsHIL Tools

Calibration ToolsCalibration Tools

CADCADCADCAD

FEMFEMCAMCAM

FEMFEM

PDMPDMPDMPDM

PDMPDM

CADCADCADCAD

Steady State Test Beds:PUMA, EMCON,Indicating Systems, CEB II, Smart Sampler,Opacimeter, Smoke Meter,CAMEO, Concerto

Steady State Test Beds:PUMA, EMCON,Indicating Systems, CEB II, Smart Sampler,Opacimeter, Smoke Meter,CAMEO, Concerto

Road Testing:DRIVE,Noise Quality Map

Road Testing:DRIVE,Noise Quality Map

Component Test Beds

Component Test Beds

Dynamic Engine Test Beds:PUMA, EMCON, ISAC, CESAR,Compact Climatic Chamber, Indicating Systems, CEB II,CAMEO, DRIVE, Concerto

Dynamic Engine Test Beds:PUMA, EMCON, ISAC, CESAR,Compact Climatic Chamber, Indicating Systems, CEB II,CAMEO, DRIVE, Concerto

Vehicle Test Beds:CESAR (GEM)CEB II, CEC, OpacimeterCAMEO, DRIVE, Concerto

Vehicle Test Beds:CESAR (GEM)CEB II, CEC, OpacimeterCAMEO, DRIVE, Concerto

Vehicle Test Beds:CESAR (GEM),CEC (CVS, Part. Sampler, Dilution Tunnel), CEB II, Opacimeter, CAMEO, DRIVE, Concerto

Vehicle Test Beds:CESAR (GEM),CEC (CVS, Part. Sampler, Dilution Tunnel), CEB II, Opacimeter, CAMEO, DRIVE, Concerto

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Requirements Requirements to to eCollaborationeCollaboration Tools Tools

eCollaboration eCollaboration ToolsToolsused by project teams atused by project teams atdifferent different locations mustlocations mustprovide provide anan answer answer toto the thefollowing questions atfollowing questions atany any time:time:

Where Where am I am I locatedlocated in in thetheprocessprocess? ? What is the nextWhat is the nextproject stepproject step??

HowHow dodo I I havehave to to proceedproceed??

Where do Where do I find I find the currentthe currentstatus of information andstatus of information anddatadata??

Who has Who has to to be informed aboutbe informed aboutthe current status and resultsthe current status and results??

Method of documentation ofMethod of documentation ofmy workmy work??

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ProductProduct DataData Management (PDM) – Management (PDM) –IT OrganisationIT Organisation

SALESPLANNING

MANUFACTURE

ASSEMBLY

PROD.PLANNING

PURCHASE PROD.STEERING

DELIVERY

DEVELOPMENTDESIGN

DOCUMENTATION

JOBPREPARATION

MAINTENANCESERVICE

PDMCAX

SAP/3

DISPOSITIVE PROCESS CHAIN

TE

CH

NIC

AL

PR

OC

ES

S C

HA

IN201032

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Partner 2Partner 1

eCollaborationeCollaboration Tools: Tools: Product Data Product Data ManagementManagement

CAD

FEM

Testbed

Indicating systems

CAD

FEM

Testbed

Indicating systems

PDMPDM PDMPDM

Partner 1 Partner 2

...

...

...

...

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ImportanceImportance ofof Product DataProduct DataManagement (PDM) Management (PDM) forfor AVL AVL

AVL United Kingdom

AVL Nordiska

AVL Italia

AVL Iberica

AVL Moscow

AVL France

Zöllner

AVL Deutschland

AVL Cechy

AVL North America

AVL Powertrain Eng. Inc.

AVL India

AVL Beijing

AVL South America

AVL KoreaAVL Japan

AVL Singapore

AVL Shanghai

AVL Jakarta

AVL Graz

AVL Poland

AVL Bulgaria

Data storageData storage of overlapping of overlapping

development processesdevelopment processesin in differentdifferent locations locations

Navigation Navigation throughthroughEDPEDP

duringduring thethe completecompletedevelopment processdevelopment process

Data storageData storageofof SimulationSimulation models models

andand CADCAD models modelsduring the completeduring the complete

development processdevelopment process

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PeoplePeople

�� Open towards future developmentsOpen towards future developments�� Learn about new systems and theirLearn about new systems and their

advantages and applyadvantages and apply these systemsthese systems�� Open towards new organisational structuresOpen towards new organisational structures

and culturesand cultures

change

learn

trust

provide more room for creativity