Ilan Weitzer Ford Motor Company - Siemens PLM Software · • Visual inspection for overall quality...

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2010 International Conference

SEPTEMBER 12 -14 2010 International Conference

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JT and Validation

Ilan Weitzer

Ford Motor Company

2

JT and Validation

JTOpen 2010 International Meeting

Orlando Florida.

Ilan Weitzer

Ford Motor Company

Copyright © Ford Motor Company, 2010 - Ford Proprietary 3

Overview

• JT at Ford

• JT Validation

– Visualization and Digital Compatibility

– Interoperability

– Long-term CAD Data Retention


Evolution of JT at Ford

Key Milestones

1994 1995 1996 1997 1998 1999 2000 2001 2002

Manual Digital BuckPeriodic manual generation of the digital mockup to support major program milestones

Distributed VisualizationMore frequent generation of the digital mockup available on numerous visualization servers

Automatic TessellationContinuous, automatic generation of a general purpose digital mockup

Web-Based PC AccessBroad web-based access to Digital Mockup

Immersive BuckDigital Human with motion capture

Clearance ManagementSystematic analysis of clearance / clash

PDM based VisualizationVisualization imbedded in the PDM

2003 2004 2005 2007 20082006

JT for CAD InteroperabilityDesign-in-context

2009

LTDR

2010

Suppliers Integration

Real-time

Digital/ Proto


Vision Along the JT Pipeline

Released

Content(2000)

Full Vehicle

Buck(1996)

Dealers

Catalogs(2003)

Warranty Part

Support Desk(2001)

Plant

Visualization(1998)

1st Buck

“On Road”(1999)

Ergo-based

Serviceability(2000)

Mfg PMI(2000)

Service

Manuals(2001)

Marketing

For 20 Vehicles(2007)

1st Marketing

Process from JT (2006)

Ford GT

Marketing(2004)Swept Volume

for Serviceability(2005)

Digital

Pre-Assembly(2005)

Service Tools

“InClass”(2006)

Marketing

For 20 Vehicles(2007)

PD and Mfg

Illustrations(2007)

Photo-Realistic

Engineering

LIVE Reviews(2007) Immersive

Buck(2007)

Interactive

Service Pubs(2008)

“Shadowed”

Underhood

Drawings(2007)

Web-based Build

and Price(2008)

Teamcenter Buck

(2009)

http://www.mercuryvehicles.com/mariner/gallery_colors.asp





Role of JT

• Product Visualization - Light weight product data everywhere– Ability to move native geometry interactively to the visualization

tool, enabling real-time viewing and analysis

• Verification and Digital Prototyping – Digital Pre Assembly (DPA) Process enabler

• Visualization-based Interoperability– Data sharing and collaboration across multiple design and

engineering disciplines using efficient product data representation.

– Design-in-Context with reference data• Ability to work with geometry in one CAD tool with reference

geometry from another CAD tool

• Geometry pipeline to ancillary applications and products (CAD, KBE, CAE, Mfg, Illustration, etc.)

• Legacy Migration & Archival– Bridging between next generation and carryover systems and

Long-term data retention


Data consumption (extracted Digital

Buck and Teamcenter Buck)

Extracted Digital BuckTeamcenter Buck

Digital Buck Build

Data Distrubution

Access via UNIX / PDV Nightly Structure Build

Synch to other Sites

Access Rich / Thin Client

Save back Session

Collaborate xSite

Save back Snapshots

Web Server

Business

Logic Server

Database

ServerFile

Server

Web Server

Business

Logic Server

Database

ServerFile

Server

Web Server

Business

Logic Server

Database

ServerFile

Server


Digital Prototyping

DPA Validation Processes

• TCBuck Creation Process– Validating the creation of the

buck for timing and success

– A loose collection of reports

– some automated and other executed daily.

• Buck-to-BOM– Validating the completeness

and correctness of the Buck

9-Aug-10 10-Aug-10 11-Aug-10 12-Aug-10 13-Aug-10 15-Aug-10

Monday Tuesday Wednesday Thursday Friday Sunday

Vehicle Prog 1 6:13:19 5:49:21 5:18:02 6:08:54 5:03:28 4:45:29 6 0 0 6 5:33:06

Vehicle Prog 2 3:13:44 3:15:26 3:25:30 2:38:52 2:39:48 2:09:18 6 0 0 6 2:53:46

Vehicle Prog 3 14:53:41 14:18:10 15:24:43 MI (PSE) 12:38:53 11:32:34 2 3 1 6 13:45:36

Vehicle Prog 4 16:26:12 9:19:41 9:40:28 10:06:01 11:14:22 7:47:01 5 1 0 6 10:45:37

Vehicle Prog 5 15:32:30 12:04:03 12:40:47 12:08:21 12:46:00 8:56:50 5 1 0 6 12:21:25

Vehicle Prog 6 8:57:26 6:24:58 7:00:46 7:42:18 8:08:23 5:37:31 6 0 0 6 7:18:34

Vehicle Prog 7 10:55:27 11:26:03 8:33:17 9:34:00 10:06:55 6:17:31 6 0 0 6 9:28:52

Vehicle Prog 8 16:04:38 12:57:14 11:25:20 11:53:18 13:27:11 8:32:44 5 1 0 6 12:23:24

Vehicle Prog 9 2:38:56 2:30:44 2:33:27 2:50:44 2:35:41 2:02:10 6 0 0 6 2:31:57

Vehicle Prog 10 2:42:37 2:29:11 2:38:08 2:29:48 3:41:22 2:05:11 6 0 0 6 2:41:03

Vehicle Prog 11 3:11:40 1:45:03 1:43:31 2:34:37 1:34:01 1:23:11 6 0 0 6 2:02:00

Vehicle Prog 12 1:55:15 0:57:12 1:06:28 1:12:47 1:19:35 1:07:36 6 0 0 6 1:16:29

Vehicle Prog 13 2:58:05 2:24:25 2:39:47 2:20:59 2:20:22 1:55:17 6 0 0 6 2:26:29

Vehicle Prog 14 6:52:45 6:23:42 6:37:13 6:13:12 6:19:41 5:24:01 6 0 0 6 6:18:26

Vehicle Prog 15 18:40:13 MI (HW) 14:36:42 MI (PSE) 15:12:25 10:25:29 1 3 2 6 14:43:42

Vehicle Prog 26 10 13 13 13 14 15 78

Vehicle Prog 27 5 1 2 0 1 0 9

Vehicle Prog 28 0 1 0 2 0 0 3

TOTAL RUN 15 15 15 15 15 15 90

AVERAGE RUNTIME 8:45:06 6:34:39 7:01:37 5:59:32 7:16:32 5:20:08 7:06:02

Less than 10 hours 9 10 11 10 9 13 62 69%

10-11 hours 1 0 0 1 1 1 4 4%

11-12 hours 0 1 1 1 1 1 5 6%

12-13 hours 0 2 1 1 2 0 6 7%

13-14 hours 0 0 0 0 1 0 1 1%

More than 14 hours 5 1 2 0 1 0 9 10%

AV

ERA

GE

RU

NTI

MEBuild started ON

TOTA

L O

N T

IME

TOTA

L LA

TE

TOTA

L

INTE

RV

ENTI

ON

TOTA

L R

UN

Manual (local host)

ETS Server

Submit nightly automated TcBuck

runs to ETS

Create plmxml file(bomwriter)

Load plmxml file to Tce

Create jt file(plmxmltojt)

Load jt file to Tce

Success

Success

COMPLETED (ETS)

Y

N

Y

N

ETS Server


Load plmxml file to Tce


Load jt file to Tce

Success

Success

RESUBMITTED

Y

N

Y

N

Manual (local host)


Upload plmxmlfile to Tce


Upload jt file to Tce

Success

Success

UPLOADED

Y

N

Y

N

Re-submit to ETS

Re-submit to ETS

Download plmxml file

from Tce

jtavailable

PLMXML FAIL

P2J FAIL

FAILED

ON TIME

Before 6am

LATE

N

NY

Y


JT/TCBuck Quality Reporting

• Minimum requirement for a TCBuck data quality

– Report missing parts (JT) in TCBuck.

• The report should contain all items that have missing jt-files and are

therefore not shown in TCBuck ("red cross").

• Item ID, Revision, Parent Item ID, Owning site

– Report quality related issues with parts

– Report position related issues with parts

– A "wanted" requirement is the ability to run a missing items report in a

remote site against a multi-sited TCBuck file, in order to identify items

that have not yet been multi-sited to the remote site.

• Visual inspection for overall quality

– Only for Vehicle programs at critical milestones

Wagon

5-dr3-dr


JT-Based Interoperability

Multi-CAD Design in Context

Teamcenter Engineering

CATIA V5IDEAS

JT Read/Write

• JT generated in ETS and Managed in TCe

• JT Read Capabilities in CATIA V5 and

IDEAS

• Seamless Integration. No manual

translation/exchange is necessary

• What the Users Want:– Geometric Integrity maintained (accuracy)– Volume, Areas, Centre of Gravity, etc.– Part position maintained– Topology preserved– Any entities lost/added during translation?

• Surfaces, Wireframe etc.

– Some fail in a way that the user would not care about

– Some fail in a way which the user can not accept.

• Guide the user directly to the problem• Show old geometry alongside new

– Product structure translated correctly?• Assembly instance position, rotation

– Gather and publish metrics.


…And there is more

• Metadata – Non Geometric Attributes in the CAD– Revision & Title blocks

• PDM attributes

• Product Manufacturing Information (PMI)– 3D geometric dimensions and tolerances (GD&T)

– Annotations (notes)

– Compliance with Standard, Size, Font

• Comparing Source/Destination approach is the way to go

Missing Hole Missing Surface PMI


JT Pipeline

Re-purposing & Conformance

12

Marketing& Sale

MarketingMarketing& Sale& Sale

Corp DesignCorp DesignCorp DesignPTOPTOPTOMfgMfgMfg

PD/KBEPD/KBEPD/KBEServicesServicesServices

PDVPDVPDVJackJackJack

TCeTCeTCeD BuckD BuckD Buck

VVTVVTVVT

TCMTCMTCMeMSeMSeMS

JackJackJackFIDESFIDESFIDESPartViewerPartViewerPartViewer

PDVPDVPDVJackJackJack

TCeTCeTCeD BuckD BuckD Buck

VVTVVTVVT

CAE MashingCAE MashingCAE Mashing

TessOnDemandTessOnDemandTessOnDemand

ePEdsePEdsePEdsPTO BuckPTO BuckPTO Buck

IooDrawIooDrawIooDrawIooDrawIooDrawIooDrawIooDrawIooDraw

Adobe Illustr.Adobe Illustr.Adobe Illustr.Adobe Illustr.PDVPDVPDVPDV3DsMax3DsMax3DsMax3DsMax

AutoTrolAutoTrolAutoTrolAutoTrol

TCVisTCVisTCVisTCVisVisJackVisJackVisJackVisJack

TCViTransCabelsTCViTransCabelsTCViTransCabelsTCViTransCabels

VSPVSPVSPVSP

ICIDOICIDOICIDOICIDOOpticoreOpticoreOpticoreOpticore

BunkspeedBunkspeedBunkspeedBunkspeed

EMS PlannerEMS PlannerEMS Planner

Indirect Indirect Indirect JackJackJack

TCeTCeTCePDVPDVPDV

JackJackJack

JT Pipeline (Teamcenter, Satellite Servers, PDV)JT Pipeline JT Pipeline (Teamcenter, Satellite Servers, PDV)

• “One JT fits all” strategy

• Investigating Multiple

configurations in JT

• VEV Example: scan data

• JT Fits for purpose

• JT content for specific workflows

• Conformance as far as content,

parameters and validity.


Long Term CAD Data Retention

• Ford Global Information Standard Retention mandate that:

– Product data in Metaphase retained for 35 years.

– All Mfg data in Metaphase be retained for 15 years.

• JT was selected as the format for 3D data.

• Geometric accuracy, PMI, Metadata, etc. are important factors and need to be preserved.

• Ultimately, before deleting the native, we need to make sure that the

alternative representation is complete and accurate.

MetaphaseMetaphase

Team Data Team Data

Manager (TDM)Manager (TDM)

II-- DEASDEAS

MetaphaseMetaphaseMetaphaseMetaphase

Team Data Team Data

Manager (TDM)Manager (TDM)Team Data Team Data

Manager (TDM)Manager (TDM)

Team Data Manager Team Data Manager

(TDM)(TDM)

C3P ClassicC3P Classic

II-- DEAS / DEAS /

CATIACATIA

C3P Next GenerationC3P Next Generation

Teamcenter Teamcenter

Engineering Engineering

TCeTCe



TCeTCe


Engineering TCeEngineering TCe



TCeTCe



TCeTCe


Engineering TCeEngineering TCe


Validation for LTDR

The Pre and Post Approaches

• Requirements are the same as JT for interoperability

• Pre Approach: Handle all errors as part of migration process, and

annotate translated JT files with the error information or repair it.

• Post Approach: Do not do special error handling or annotation of

translated data; append/insert error logs and other information to the

archived data sets. Repair on as needed basis

Ext

ract

ion

Tra

nsl

atio

nV

alid

atio

nS

tora

ge

Export Package

File from

Metaphase

Import Package

File into I-DEAS /

Standalone TDM

Convert I-DEAS

data to JT data

using I-DEAS

built-in translator

Run Validation

Tools

Prepare Archive

Data Set, adding

Metadata, and

store JT files into

Archive solution

Basic Flow of Migration of an I-DEAS Item from Metaphase to Archive

Can’t delete Master/Native before making sure representation is available, complete and accurate


Summary

• Validation and Conformance are important

• Validation is an extra effort and cost - “its not my job” syndrome.

• But we need to make sure quality and completeness is guaranteed.

Mother of all “It’s not my job”

• So what we really like to have is:

– A transparent validation and conformance capabilities

– A streamlined process to support it

– Implemented and integrated with existing tools and environment


Thank you!

Ilan Weitzer Ford Motor Company - Siemens PLM Software · • Visual inspection for overall quality...

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