VOLVO Construction Equipment Korea LTD Engineering Process Innovation With New IT Solution Volvo Construction Equipment Korea Engineering Process Innovation With 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
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Engineering Process Innovation - IBM · VOLVO Construction Equipment Korea LTD Engineering Process Innovation ... & Service Part Master
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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
● 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)
● 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
• 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
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
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••……......
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
•• 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
••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
••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?