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Variation AnalysisNew capabilities and enhancements
Roland Dixon
Siemens PLM Centre of Excellence EMEA
25 October 2017
October 2017Page 2 R Dixon / EMEA CoE
Variation Analysis Update
Introduction
Model-Based Quality (MBQ) and the Digital Twin
Variation Analysis Value and Use-Cases
Product Direction
Model Based Definition: Leveraging PMI for Variation Analysis
PLM: Variation Analysis in a managed environment
CAE: Combining Finite Element Analysis with tolerance simulation
Conclusion
• Customer perspectives
• Q and A
October 2017Page 3 R Dixon / EMEA CoE
Variation Analysis Update
Introduction
Model-Based Quality (MBQ) and the Digital Twin
Variation Analysis Value and Use-Cases
Product Direction
Model Based Definition: Leveraging PMI for Variation Analysis
PLM: Variation Analysis in a managed environment
CAE: Combining Finite Element Analysis with tolerance simulation
Conclusion
• Customer perspectives
• Q and A
October 2017Page 4 R Dixon / EMEA CoE
Bill of ProcessPlant Model
Bill of Materials Quality/CAQ
Common Manufacturing Model
To bring Digital Twin and Digitalization to our customers
Enabling industry 4.0 / smart manufacturing
Digital Twin
Digital twin
of the
equipment
Digital twin of
production
process
Digital twin of
the product
Physical production system
Smart Product
Smart Supply chain
Smart Factory
October 2017Page 5 R Dixon / EMEA CoE
Integrated Solutions
Quality Lifecycle Management (QLM)
Siemens “Digital Enterprise” Software Suite
Top-down Product-driven
PLM Software Portfolio
• Product Planning, Design, Test
and Simulation
• Production Planning,
Engineering and Simulation
Bottom-up Process-driven
Integrated Automation Portfolio
• Integrated engineering and
runtime for controllers,
distributed I/O, HMI, drives,
motion control and motors
• Industrial Safety and Security
• Planning & Scheduling
• Quality Management
• Manufacturing Execution
• Manufacturing Intelligence
• SCADA / Linemonitoring
MES/MOM Software Portfolio+ +
October 2017Page 6 R Dixon / EMEA CoE
Quality Lifecycle
Model Based Quality
Inspection Planning
BCT Inspector
Design Model
NX- PMI/CheckMateResults Analysis
NX CMM
Post Processing
NX CMM
CMM inspection
Execution – I++
CMM Programming
NX - CMM
Inspection Instruction
EWI
Shop floor data
access - SFCResource libraries
NX CAM/Tc MRL
ProductionPlanning
Data & process management - Teamcenter
Statistical Reports
DPV R&A
Single Part Reports
DPV WebTolerance Stack
Variation Analysis
October 2017Page 9 R Dixon / EMEA CoE
Variation
Analysis
Finished
Product
Critical
Process
Base
Assembly
Other Sources of Variation
Assembly Process & Sequence
PMI - Datum Features & Tolerances
CAD Geometry
Run
Simulations
& Analysis
Variation and Distribution
Measurement Definitions
Deflections, Thermal, Dynamic, Material, …
Create Model
Sources of Variation
Variation Analysis
Input and output
Deviated Mesh
Inspection Planning
October 2017Page 10 R Dixon / EMEA CoE
Variation Analysis – Why?
Opportunites vs Cost of Quality
ProductionRamp-UpTooling & Systems
Integration
Process Design
Product Design
Cost
Exponential Cost
Growth
Example: locator design issue for transmission mount
Would have cost a couple
of hours of design time to
correct at this stage.
Actually cost ~$250k
to correct at this stage.
Would probably have cost
$M in warranty and lost
production if it had got to
this stage.
Cost of Poor Quality
Cost of Good Quality
October 2017Page 11 R Dixon / EMEA CoE
Validation
Achieve a robust design
Maximize returns
High potential value
Requires investment
Analysts/Consultants
Variation Analysis – Why?
3 main use-cases
Verification
Identify key characteristics
Predict capability
Part of existing process
Potential for savings
Design/Manufacturing
Diagnosis
Find and fix issues
Typical entry point
Manufacturing/Quality
October 2017Page 12 R Dixon / EMEA CoE
Variation Analysis – Why?
1. Validation – Achieving a robust design
Typical Tasks:
• Sensitivity Analysis – datum and locator strategies
• Optimise assembly process and tooling
• Validate functional requirements
• Simulate aesthetics, styling, craftsmanship
Key Capabilities:
Capture concept geometries (multi-CAD)
Create and modify real-world assembly constraints
Handle small and very large assemblies
Simulate physical behaviors (flexibility, gravity, ….)
Kinematics for assembly and product function
Visualize variations (animations, realistic rendering)
Re-use previous studies and results (closed loop)
October 2017Page 13 R Dixon / EMEA CoE
Variation Analysis – Why?
2. Verification – Identifying key characteristics
Typical Tasks:
• Capability studies, machining processes, ..
• Drawing/tolerance checking
• Key characteristic documentation
• Set functional or aesthetic limits and targets
• Design gateways, production buy-offKey Capabilities:
Capture design configurations (integrated PLM)
Capture design tolerances (integrated PMI)
Support for change control
Simulate real assembly and measurement processes
Automate modeling to handle volume of work
Generate inputs to measurement planning (integrated DPV)
Publish and share results
October 2017Page 14 R Dixon / EMEA CoE
Variation Analysis – Why?
3. Diagnosis – Find and fix problems
Typical Tasks:
• As-built analysis
• Quality process support (Six Sigma, etc)
• Supplier quality issues / requests
• Validate fixes – virtual process change
• Investigate change proposals Key Capabilities:
Root cause analysis
Measurement data capture
Mean shift analysis
Export deformed geometries (for FEA or visualization)
Share data with other tools (DPV)
October 2017Page 15 R Dixon / EMEA CoE
Variation Analysis Update
Introduction
Model-Based Quality (MBQ) and the Digital Twin
Variation Analysis Value and Use-Cases
Product Direction
Model Based Definition: Leveraging PMI for Variation Analysis
PLM: Variation Analysis in a managed environment
CAE: Combining Finite Element Analysis with tolerance simulation
Conclusion
• Customer perspectives
• Q and A
October 2017Page 16 R Dixon / EMEA CoE
Variation Analysis Linear Plus Minus PMI Flowdown
• Enables the flowdown of linear plus
minus tolerances from NX to VSA
• Origin definition added in NX10
Enhanced PMI Flowdon (10.1.5)
October 2017Page 17 R Dixon / EMEA CoE
Variation Analysis PMI Reconciliation
Enable JT PMI Updates (11.x)
• Enable PMI extracted from JT to be
updated
• Extension of existing feature
reconciliation functionality
• Notification of feature geometry and/or
PMI changes will be provided to user
• User will be required to take action on
whether to apply the PMI change
October 2017Page 18 R Dixon / EMEA CoE
Variation Analysis Improved PMI Flowdown
Additional PMI enhancements (11.x)
• Associated Objects Name Flowdown
(NX12)
• Angular Plus Minus Tolerance Flowdown
(NX12)
• Support for circle U modifier
• Assy Level PMI as Single Part PMI in VSA
October 2017Page 19 R Dixon / EMEA CoE
Variation Analysis - DemoWorking with Model Based Data (PMI)
• Start a new VA model
• Import a JT assembly
• Link PMI to get datums and tolerances
• Update the NX assembly
• Reconcile the changes in the VA model
October 2017Page 20 R Dixon / EMEA CoE
Variation Analysis Revision Control of Managed Data
Easy Product Data Updates with Managed Data (10.1.5)
• Allows process documents with
managed product data to
selectively update part geometry
• Enables users to dynamically
react to design changes during the
analysis process
October 2017Page 21 R Dixon / EMEA CoE
Variation Analysis Feature Reconcile Auto Update
Improved efficiency in analysis product data updates (11.x)
• Feature reconciliation enhancements
• Add the option to automatically re-
snap features to new location,
size, etc.
• Requires that the underlying CAD
reference does not change
• Move associated mating features in
assembly operations when features
are reconciled
October 2017Page 22 R Dixon / EMEA CoE
Variation Analysis DPV Engineering Spreadsheet Creation
• Enables a DPV engineering spreadsheet to
be generated from analysis features in
Variation Analysis
• Facilitates initial creation of inspection
routines based on key features identified in
Variation Analysis
Analysis Forms the foundation for DPV (10.1.5)
October 2017Page 23 R Dixon / EMEA CoE
Variation Analysis - DemoWorking with Teamcenter managed data
• Create a new VA model
• Import an assembly item from Teamcenter
• Update the NX assembly
• Update the Teamcenter item revision
• Import the changes to the VA model
October 2017Page 24 R Dixon / EMEA CoE
Variation Analysis Next Generation Flex Analysis
• Next generation solution: increase functionality &
usability
• Goal: 75% workflow reduction time
• Embed meshing & FE solving capability in
Variation Analysis
• Leverage Siemens FEMAP & Nastran technology
• Represent flexed parts using a mesh
• Flexed mesh comprehends
• Variation due to tolerancing
• Bending due to clamping, welding, riveting, etc.
• Visual deformation during simulation provides
realistic feedback
Incorporation of Meshing / FE Solving in VSA (11.2.3)
October 2017Page 25 R Dixon / EMEA CoE
Variation Analysis Flex Analysis Enhancements
Expanding Flex Analysis Capabilities (11.2.3)
• Adding support for
• Assemblies
• Component sagging due to gravity
October 2017Page 26 R Dixon / EMEA CoE
Variation Analysis
Deviated Mesh Export
• Enables a deviated mesh to be exported for use in
downstream analyses
• Nominal mesh associated with part(s)
• New custom assy extension for export
• Part mesh(es) to be exported
• Export file path
• Monte Carlo simulation runs specified for export
• This also serves as a visual aid for viewing applied
variation
Deviated mesh from part / assembly variation (11.2.3)
October 2017Page 27 R Dixon / EMEA CoE
Variation Analysis Minimum Feature Clearance
Feature to Feature Minimum Clearance (11.2.3)
• Determine minimum clearance between any two
features
• New measurement operation type
• No measurement points required
• Supported features include
• Planes
• General surfaces
• Pins
• Holes
• Utilizes part-level surface mesh for minimum
clearance calculation
October 2017Page 28 R Dixon / EMEA CoE
Variation Analysis - DemoFEA integration – flexible analysis
• Take an existing VA model
• Create an FEA mesh
• Create a flexible assembly operation
• Simulate and visualize deformation
October 2017Page 29 R Dixon / EMEA CoE
Variation Analysis Update
Introduction
Model-Based Quality (MBQ) and the Digital Twin
Variation Analysis Value and Use-Cases
Product Direction
Model Based Definition: Leveraging PMI for Variation Analysis
PLM: Variation Analysis in a managed environment
CAE: Combining Finite Element Analysis with tolerance simulation
Conclusion
• Customer perspectives
• Q and A
October 2017Page 30 R Dixon / EMEA CoE
Customer Success – Spirit Aerosystems
October 2017Page 31 R Dixon / EMEA CoE
Customer Success – Chery
"This lets us assess and optimize
the product design, configure part
tolerance, improve the positioning
and assembly processes, and
manage and take control of
downstream manufacturing
errors."
Wu Shiqiang
Director, Process
Technology
Department,
Engineering Planning &
Design Institute I
Challenge:
• Improve product quality
• Reduce production & maintenance costs
• Expand brand image; strengthen
competitiveness in the global market
Solution:
• Dimensional tolerance analysis software that
simulates manufacturing and assembly
processes
• Tecnomatix data in lightweight JT format
• Siemens’ extensive knowledge of
dimensional management
Results:
• Company meets product quality targets
• Production problems identified in the product
development cycle
• Avoided errors, eliminating rework time and
costs ($150,000 saved on one mold)
October 2017Page 32 R Dixon / EMEA CoE
Customer Success – Hewlett Packard
Challenge:
• Pen to paper spacing – critical to quality
output
• Many parts contributing to tolerance variation
• Adjustment steps causing bottleneck in
manufacturing
Solution:
• Allowed focus most important parts &
dimensions
• Optimized selection of datum features and
dimensioning schemes
• Validation provides confidence of design
updates
Results:
• Reduced tooling and metrology costs
• Robust designs / lower parts cost
• Huge cost savings
• Eliminated bottleneck in manufacturing
October 2017Page 33 R Dixon / EMEA CoE
As such, presentations help
define the company’s reputation
and provide both internal
and external orientation.
Questions
Q&A
Answers
May 3 – May 5 2017
www.plm-europe.orgwww.siemens.com/plm
October 2017
Roland Dixon
(DF PL S&SE EU PDE COE LCS )
Life Cycle Solutions Team
EMEA CoE
Solihull UK
Phone: +44 121 745 0525
Mobile: +44 7921 247 161
E-mail: