Industrial Equipment

Transcription

Contactmag
development. Dassault Systèmes PLM
solutions enable collaboration between diverse design groups and support
systems integration - even across the extended enterprise. Take the essential
step to meet customers’ requirements even more effectively and achieve
Industrial
Equipment
PLM powers the Industrial
Special
edition
Equipment Industry
top line benefits.
9771-SPECIAL INDUSTRIAL EQMENT 05-04-11.indd 60-61
05/04/11 12:24
Table of contents
OVERVIEW
4 | PLM in the Industrial Equipment Industry
6 | PLM solutions power industrial equipment manufacturers
Contact mag
The PLM Magazine
published by
Dassault Systèmes
10, rue Marcel Dassault
78140 Vélizy-Villacoublay
France
Chief Editors:
Sabrina Khouchane
Bernadette Hearne
Michael Marshall
Editorial Board:
Steffi Dondit
Vivian Kimiko Imai
Photo credits:
Dassault Systèmes’
customers and partners
On the cover:
Centering station with vision
system for part orientation.
Courtesy of Schuler AG
Design and Production:
Images et Formes
industrial MACHINERY
Editorial
In today’s challenging economic conditions,
Industrial Equipment companies must be
agile and flexible enough to deliver more
value faster than ever before while
maintaining a reasonable margin.
9 | Alstom Power utilizes Abaqus FEA
to improve steam turbine efficiency
12 | Meyn speeds complex machine design
with realistic 3D visualization
The Industrial Equipment (IE) industry is a complex and diverse collection of
segments, each with unique customer and supply chain challenges. From industrial
machinery and installed equipment to heavy mobile machinery and equipment,
industrial equipment products and metal products, IE companies act both as OEMs
and as key suppliers. With a two-fold value chain that extends across the IE space and
outward to a vast horizon of customers, IE companies must be able to communicate
and collaborate both upstream and downstream.
14 | Schuler AG achieves production optimization
of press lines with DELMIA
16 | TYAZHMASH increases production by 80%
with CATIA and 3DVIA
18 | Tetra Pak optimizes process solutions with Dymola
20 | Langen Packaging customizes products with ENOVIA
SmarTeam and Microsoft
In today’s challenging economic conditions, IE companies also must be agile and flexible
enough to deliver more value faster than ever before while maintaining a reasonable
margin. From bidding, design, engineering and manufacturing to assembly, implementation
and maintenance, successful IE companies adopt integrated approaches that allow them
to minimize costs while satisfying customer requirements.
tooling
22 | Tool & Design Solutions: Pressing ahead
24 | Concours Mold slices cycle times 30%
with CATIA for Mold solution
manufacturing PROCESS
26 | AMRC: A fine example to manufacturing industry
28 | FORCE Technology simulates inspection devices
with DELMIA Cycle Time Performance
30 | Taira Promote: Next-generation online i-manuals
32 | Miller Formless makes short work of service manuals
with 3DVIA Composer
Mobile equipment
33 | Enquip improves manufacturing performance
by 30% with CATIA and ENOVIA
Vivian Kimiko Imai
VP Industrial Equipment
R&D Industries
Dassault Systèmes
No matter whether your company’s strategy is engineer to order, build to order, assemble to
order or make to stock, Dassault Systèmes solutions help you deliver on time with the quality,
performance and cost your customers expect. With CATIA for integrated 3D product design,
SIMULIA for realistic simulation, DELMIA for digital manufacturing and production, ENOVIA for
global collaborative innovation of changes and parts, 3DVIA for 3D lifelike experiences such as
work and maintenance instructions, and Exalead for structured and unstructured data search,
Dassault Systèmes delivers an integrated, end-to-end PLM platform. This empowers IE
companies to deliver top performance around the globe and capitalize on new opportunities
and sources of revenue, including service and support, while meeting the unique needs
of a diverse range of customers as though they were a “market of one”.
In this special IE edition of Contact mag, we invite you to discover how companies just like
yours are realizing the benefits of these solutions and how Dassault Systèmes can help you
expand the boundaries of what is possible – for your company and its customers.
34 | Maschio Gaspardo:
CATIA and ENOVIA SmarTeam take to the field
36 | MacGregor Cranes thinks PLM with ENOVIA V6
2
Contact mag | Dassault Systèmes
2010
Equipment
Special Edition
Contact
mag | Autumn
Contact mag | Industrial
3
05/04/11 12:24
Table of contents
OVERVIEW
4 | PLM in the Industrial Equipment Industry
6 | PLM solutions power industrial equipment manufacturers
Contact mag
The PLM Magazine
published by
Dassault Systèmes
10, rue Marcel Dassault
78140 Vélizy-Villacoublay
France
Chief Editors:
Sabrina Khouchane
Bernadette Hearne
Michael Marshall
Editorial Board:
Steffi Dondit
Vivian Kimiko Imai
Photo credits:
Dassault Systèmes’
customers and partners
On the cover:
Centering station with vision
system for part orientation.
Courtesy of Schuler AG
Design and Production:
Images et Formes
industrial MACHINERY
Editorial
In today’s challenging economic conditions,
Industrial Equipment companies must be
agile and flexible enough to deliver more
value faster than ever before while
maintaining a reasonable margin.
9 | Alstom Power utilizes Abaqus FEA
12 | Meyn speeds complex machine design
The Industrial Equipment (IE) industry is a complex and diverse collection of
segments, each with unique customer and supply chain challenges. From industrial
machinery and installed equipment to heavy mobile machinery and equipment,
industrial equipment products and metal products, IE companies act both as OEMs
and as key suppliers. With a two-fold value chain that extends across the IE space and
outward to a vast horizon of customers, IE companies must be able to communicate
and collaborate both upstream and downstream.
14 | Schuler AG achieves production optimization
of press lines with DELMIA
16 | TYAZHMASH increases production by 80%
with CATIA and 3DVIA
18 | Tetra Pak optimizes process solutions with Dymola
20 | Langen Packaging customizes products with ENOVIA
SmarTeam and Microsoft
In today’s challenging economic conditions, IE companies also must be agile and flexible
enough to deliver more value faster than ever before while maintaining a reasonable
margin. From bidding, design, engineering and manufacturing to assembly, implementation
and maintenance, successful IE companies adopt integrated approaches that allow them
to minimize costs while satisfying customer requirements.
tooling
22 | Tool & Design Solutions: Pressing ahead
24 | Concours Mold slices cycle times 30%
manufacturing PROCESS
26 | AMRC: A fine example to manufacturing industry
28 | FORCE Technology simulates inspection devices
with DELMIA Cycle Time Performance
30 | Taira Promote: Next-generation online i-manuals
32 | Miller Formless makes short work of service manuals
with 3DVIA Composer
Mobile equipment
33 | Enquip improves manufacturing performance
Vivian Kimiko Imai
VP Industrial Equipment
R&D Industries
Dassault Systèmes
No matter whether your company’s strategy is engineer to order, build to order, assemble to
order or make to stock, Dassault Systèmes solutions help you deliver on time with the quality,
performance and cost your customers expect. With CATIA for integrated 3D product design,
SIMULIA for realistic simulation, DELMIA for digital manufacturing and production, ENOVIA for
global collaborative innovation of changes and parts, 3DVIA for 3D lifelike experiences such as
work and maintenance instructions, and Exalead for structured and unstructured data search,
Dassault Systèmes delivers an integrated, end-to-end PLM platform. This empowers IE
companies to deliver top performance around the globe and capitalize on new opportunities
and sources of revenue, including service and support, while meeting the unique needs
of a diverse range of customers as though they were a “market of one”.
In this special IE edition of Contact mag, we invite you to discover how companies just like
yours are realizing the benefits of these solutions and how Dassault Systèmes can help you
expand the boundaries of what is possible – for your company and its customers.
34 | Maschio Gaspardo:
CATIA and ENOVIA SmarTeam take to the field
36 | MacGregor Cranes thinks PLM with ENOVIA V6
2
2010
Equipment
Special Edition
Contact
mag | Autumn
Contact mag | Industrial
3
05/04/11 12:24
OVERVIEW
Dick Slansky
Senior Analyst
ARC Advisory Group
PLM in the Industrial
Equipment Industry
Dick Slansky is Senior Analyst at
ARC Advisory Group, a leading
research and advisory firm for
industry and infrastructure, and Sal
Spada is Research Director, Discrete
Automation. Contact mag spoke with
them about the challenges facing
the Industrial Equipment (IE) Industry
and the role PLM can play in
meeting these challenges.
Contact mag: What are the
major trends you see in the
IE Industry?
Dick Slansky: One of the main
challenges is maintaining a
reasonable margin as customers
ask for more functionality from
equipment, leaving a lot of machine
builders in a bind. They have very
little to squeeze out of the
machine in terms of cost and so
what they try to do is lower the cost
of design to get it to market faster.
The recent global recession
also dramatically reduced the
demand for standard machinery in favor of specialty
machinery that better meets customers’ new
requirements. This can be higher machine utilization,
the ability to handle a wider range of parts, and much
higher productivity rates. Machine builders had to
adapt to these changes and look for ways to satisfy
these new demands without driving up costs.
4
Sal Spada: As more and more machine builders ship
globally they are faced with another challenge adhering to safety and regulatory requirements. They
don’t want to over-design to meet the worst case
requirements because this would eliminate their cost
advantage. So what they do is have multiple designs
that enable them to minimize their costs while satisfying
the regulatory and safety requirements of each
customer.
Another challenge is that many Industrial Equipment
manufacturers have not yet made the cultural change
from having individual design teams work separately
to implementing cross-disciplinary collaboration
and information sharing. Usually, a design is initiated
by a mechanical designer and then passed over to
the electrical designer, followed by the automation
software developer, creating an iterative process
that can increase development time considerably.
The IE Industry needs to replace this sequential
way of working with one that approaches the design
process as a whole, as an integrated system.
Sal Spada
Research Director
Discrete Automation
ARC Advisory Group
Contact mag: Why is PLM relevant to the
Industrial Equipment Industry?
Dick Slansky: Virtually simulating the way the machine
will function before it is manufactured considerably
reduces development costs since design changes
based on multi-engineering discipline constraints can
be made in an early concept design phase. As a result,
the product can be brought to market faster. With
respect to safety issues, simulation can also help
identify possible hazard points well in advance before
the design is complete. It is a powerful way to show
customers before the machine is built how it meets
their safety requirements.
Maintaining a machine can also be simplified thanks to
many of the simulation tools available in PLM.
Simulation can be used up front to design a machine
to be easier to maintain, easier to support and also
ensure that the assembly process of that machine
goes forward flawlessly.
Sal Spada: We are seeing the emergence, within
PLM, of a concurrent design or a systems engineering
approach where different engineering disciplines can
work together on a single model. This increases
efficiency since each discipline can take into account
the impact of another engineering discipline on its own
design.
Contact mag: Would you say that Dassault
Systèmes’ PLM offering is well positioned to
provide the right tools for this industry and if so,
how?
Dick Slansky: The Dassault Systèmes PLM solutions
provide an integrated development platform that
is certainly going to help IE companies collaborate
and increase their agility. Dassault Systèmes has the
technology and the solutions that can help equipment
OEMs to make the cultural change they need
because the benefits will make a case for users to
adopt integrated development platforms. Equipment
manufacturers will be able to build more complex
machines, validate them virtually before physical
commissioning and bring them to market faster. This
will bring significant overall benefits.
The manufacturing process, for example, has
everything to gain by adopting a solution like DELMIA
for virtual simulation. In certain industries, such as
automotive, DELMIA is used extensively to virtually
simulate commissioning before physical
commissioning. These same tools can be applied in
the same way to the machine tool industry and
machinery. Although some of the packaging machine
tool OEMs are a bit reluctant to adopt these
technologies, as customers come forward with more
requirements – faster,
more throughput, more
Virtually simulating the way the
complexity – they’re
machine will function before it is
going to be challenged
to adopt their design
manufactured considerably reduces
processes to meet these
overall costs since modifications
requirements. This is
can be made early on.
where simulation and
virtual commissioning
Dick Slansky
will become very useful.
Another advantage is Dassault Systèmes’ systems
engineering approach, which enables its customers
to adopt a multi-disciplinary approach to design. All
data, whether it is mechanical, electrical or software
automation, is integrated in a single model, a single
source of the truth that each discipline can use to
do his/her own design work. This is based on the
ENOVIA V6 collaborative platform, which works
across all engineering disciplines and organizations
and unites all data in one single repository for efficient
management of the manufacturing BOM, revisions
and intellectual property.
Senior Analyst
ARC Advisory Group
In the area of energy consumption,
the mechatronic design tools
provided by Dassault Systèmes
can help machine builders improve
the overall energy efficiency of
their machinery. Thanks to multidisciplinary collaborative design,
equipment OEMs can make critical
choices up front, thus improving
the quality of their designs and
making their machines lighter and
stronger, for reduced energy
consumption.
Contact mag | Industrial Equipment Special Edition
5
05/04/11 12:24
OVERVIEW
Dick Slansky
Senior Analyst
ARC Advisory Group
PLM in the Industrial
Equipment Industry
Dick Slansky is Senior Analyst at
ARC Advisory Group, a leading
research and advisory firm for
industry and infrastructure, and Sal
Spada is Research Director, Discrete
Automation. Contact mag spoke with
them about the challenges facing
the Industrial Equipment (IE) Industry
and the role PLM can play in
meeting these challenges.
Contact mag: What are the
major trends you see in the
IE Industry?
Dick Slansky: One of the main
challenges is maintaining a
reasonable margin as customers
ask for more functionality from
equipment, leaving a lot of machine
builders in a bind. They have very
little to squeeze out of the
machine in terms of cost and so
what they try to do is lower the cost
of design to get it to market faster.
The recent global recession
also dramatically reduced the
demand for standard machinery in favor of specialty
machinery that better meets customers’ new
requirements. This can be higher machine utilization,
the ability to handle a wider range of parts, and much
higher productivity rates. Machine builders had to
adapt to these changes and look for ways to satisfy
these new demands without driving up costs.
4
Sal Spada: As more and more machine builders ship
globally they are faced with another challenge adhering to safety and regulatory requirements. They
don’t want to over-design to meet the worst case
requirements because this would eliminate their cost
advantage. So what they do is have multiple designs
that enable them to minimize their costs while satisfying
the regulatory and safety requirements of each
customer.
Another challenge is that many Industrial Equipment
manufacturers have not yet made the cultural change
from having individual design teams work separately
to implementing cross-disciplinary collaboration
and information sharing. Usually, a design is initiated
by a mechanical designer and then passed over to
the electrical designer, followed by the automation
software developer, creating an iterative process
that can increase development time considerably.
The IE Industry needs to replace this sequential
way of working with one that approaches the design
process as a whole, as an integrated system.
Sal Spada
Research Director
Discrete Automation
ARC Advisory Group
Contact mag: Why is PLM relevant to the
Industrial Equipment Industry?
Dick Slansky: Virtually simulating the way the machine
will function before it is manufactured considerably
reduces development costs since design changes
based on multi-engineering discipline constraints can
be made in an early concept design phase. As a result,
the product can be brought to market faster. With
respect to safety issues, simulation can also help
identify possible hazard points well in advance before
the design is complete. It is a powerful way to show
customers before the machine is built how it meets
their safety requirements.
Maintaining a machine can also be simplified thanks to
many of the simulation tools available in PLM.
Simulation can be used up front to design a machine
to be easier to maintain, easier to support and also
ensure that the assembly process of that machine
goes forward flawlessly.
Sal Spada: We are seeing the emergence, within
PLM, of a concurrent design or a systems engineering
approach where different engineering disciplines can
work together on a single model. This increases
efficiency since each discipline can take into account
the impact of another engineering discipline on its own
design.
Contact mag: Would you say that Dassault
Systèmes’ PLM offering is well positioned to
provide the right tools for this industry and if so,
how?
Dick Slansky: The Dassault Systèmes PLM solutions
provide an integrated development platform that
is certainly going to help IE companies collaborate
and increase their agility. Dassault Systèmes has the
technology and the solutions that can help equipment
OEMs to make the cultural change they need
because the benefits will make a case for users to
adopt integrated development platforms. Equipment
manufacturers will be able to build more complex
machines, validate them virtually before physical
commissioning and bring them to market faster. This
will bring significant overall benefits.
The manufacturing process, for example, has
everything to gain by adopting a solution like DELMIA
for virtual simulation. In certain industries, such as
automotive, DELMIA is used extensively to virtually
simulate commissioning before physical
commissioning. These same tools can be applied in
the same way to the machine tool industry and
machinery. Although some of the packaging machine
tool OEMs are a bit reluctant to adopt these
technologies, as customers come forward with more
requirements – faster,
more throughput, more
Virtually simulating the way the
complexity – they’re
machine will function before it is
going to be challenged
to adopt their design
manufactured considerably reduces
processes to meet these
overall costs since modifications
requirements. This is
can be made early on.
where simulation and
virtual commissioning
Dick Slansky
will become very useful.
Another advantage is Dassault Systèmes’ systems
engineering approach, which enables its customers
to adopt a multi-disciplinary approach to design. All
data, whether it is mechanical, electrical or software
automation, is integrated in a single model, a single
source of the truth that each discipline can use to
do his/her own design work. This is based on the
ENOVIA V6 collaborative platform, which works
across all engineering disciplines and organizations
and unites all data in one single repository for efficient
management of the manufacturing BOM, revisions
and intellectual property.
Senior Analyst
ARC Advisory Group
In the area of energy consumption,
the mechatronic design tools
provided by Dassault Systèmes
can help machine builders improve
the overall energy efficiency of
their machinery. Thanks to multidisciplinary collaborative design,
equipment OEMs can make critical
choices up front, thus improving
the quality of their designs and
making their machines lighter and
stronger, for reduced energy
consumption.
5
05/04/11 12:24
OVERVIEW
]
By Dominic Anne
PLM solutions power
industrial equipment
manufacturers
Design and manufacturing of modern industrial
products is inherently complex. As product variation
increases and suppliers assume greater design and
manufacturing responsibility, estimating total production
costs becomes more difficult. Yet companies must
meet customer demands and protect profit margins –
especially difficult challenges in a slow economy.
P
roduct Lifecycle Management (PLM) is a
proven strategy for thriving in tough markets,
making companies more effective, innovative
and successful around the globe. Better yet, powerful
Dassault Systèmes (DS) PLM
solutions – including CATIA for
virtual product design, DELMIA
for virtual production, ENOVIA
for global collaborative lifecycle
management, SIMULIA for
virtual testing, 3DVIA for online
lifelike experience, and Exalead
for structured and unstructured
data search – are now available
to companies of all sizes.
Simulation of human
tasks with DELMIA V6
6
With PLM solutions, companies can be more
successful at all stages of the industrial equipment
industry: bidding, design and engineering,
manufacturing and assembly, and implementation
and maintenance.
IMPROVED BIDDING
The best bid addresses customer requirements, ensures
product quality and protects profit margins by anticipating
and addressing key challenges more effectively than the
competition. The more detailed your bid, the more
confidence customers have in your promise.
The DS PLM solution for Industrial Equipment helps
to quickly create and manage more concept variants
by reusing intellectual property. Templates and
catalogs make CAD data, bills of material (BOMs),
and simulation results readily available for developing
and comparing multiple configurations quickly,
accurately and inexpensively, and helps ensure
accurate pricing. Communication using lifelike
animated 3D models quickly demonstrates that a
product meets customer expectations and can be
produced as bid.
PLM also improves collaboration, helping to refine
concepts faster with fewer late-cycle glitches. The
bottom line: faster, more detailed concept modeling
empowered by fully informed stakeholders with realtime access to product development information.
PLM allows companies to standardize methods, react
to global demand and accurately assess requirements
and costs before bidding, delivering more confidence
in a project’s manufacturability and profitability.
Image courtesy of Tetra Pak
DESIGN EXCELLENCE
Product complexity can contribute to design
inconsistencies, delays and poor quality that erode
margins and customer satisfaction. DS PLM facilitates
design and engineering collaboration and task
coordination, increasing the accuracy of new designs
or product variants. Intelligent design templates help
standardize parts to better leverage purchasing
power.
DS PLM facilitates
design and engineering
collaboration and task
coordination, increasing
the accuracy of new
designs or product
variants.
Decreased design time
and complexity improve
manufacturability,
profitability and the
ability to meet the
safety and regulatory
requirements of each
customer, no matter
where they are in the
world. DS PLM also
efficiently handles the
large assemblies typical of the industrial equipment
industry, with powerful kinematics to detect clashes,
tolerancing to help lower the price of components,
and fully integrated, industry-specific solutions from
hundreds of software development partners to meet
specialized needs.
DS PLM provides an integrated system for design,
analysis and manufacturing to support smooth
transitions from 2D to 3D, and from design to analysis
With PLM solutions, companies can be
more successful competing at all stages
of the industrial equipment industry:
bidding, design and engineering,
manufacturing and assembly, and
implementation and maintenance.
and tooling. The DS
simulation portfolio
encompasses finite
element methods
and advanced non-linear analysis. By enabling
collaboration between designers and analysis
engineers, DS PLM accelerates performance-based
design decisions and reduces the need for costly
and time-consuming physical prototypes and testing.
And with strong systems engineering tools, systems
engineers can design, collaborate across multidiscipline teams, and validate their model-based
embedded systems applications, including control
software, electrical / electronic systems, tubing
and piping equipment, to reduce overall design time
and errors.
A DS PLM configuration management capability
enables industrial equipment companies to easily
manage alternate designs or build new designs on the
data from previous projects. Coupled with workflow
and shared catalogs, configuration management
enables clear communication of changes and reduces
the risk of late-cycle errors.
And DS PLM’s strengths in extended enterprise
business process governance for product portfolio
management and program/project management
bring the power of PLM to the entire enterprise,
making sure the whole organization has the
information it needs to remain agile and competitive.
»
7
05/04/11 12:24
OVERVIEW
]
By Dominic Anne
PLM solutions power
industrial equipment
manufacturers
Design and manufacturing of modern industrial
products is inherently complex. As product variation
increases and suppliers assume greater design and
manufacturing responsibility, estimating total production
costs becomes more difficult. Yet companies must
meet customer demands and protect profit margins –
especially difficult challenges in a slow economy.
P
roduct Lifecycle Management (PLM) is a
proven strategy for thriving in tough markets,
making companies more effective, innovative
and successful around the globe. Better yet, powerful
Dassault Systèmes (DS) PLM
solutions – including CATIA for
virtual product design, DELMIA
for virtual production, ENOVIA
for global collaborative lifecycle
management, SIMULIA for
virtual testing, 3DVIA for online
lifelike experience, and Exalead
for structured and unstructured
data search – are now available
to companies of all sizes.
Simulation of human
tasks with DELMIA V6
6
With PLM solutions, companies can be more
successful at all stages of the industrial equipment
industry: bidding, design and engineering,
manufacturing and assembly, and implementation
and maintenance.
IMPROVED BIDDING
The best bid addresses customer requirements, ensures
product quality and protects profit margins by anticipating
and addressing key challenges more effectively than the
competition. The more detailed your bid, the more
confidence customers have in your promise.
The DS PLM solution for Industrial Equipment helps
to quickly create and manage more concept variants
by reusing intellectual property. Templates and
catalogs make CAD data, bills of material (BOMs),
and simulation results readily available for developing
and comparing multiple configurations quickly,
accurately and inexpensively, and helps ensure
accurate pricing. Communication using lifelike
animated 3D models quickly demonstrates that a
product meets customer expectations and can be
produced as bid.
PLM also improves collaboration, helping to refine
concepts faster with fewer late-cycle glitches. The
bottom line: faster, more detailed concept modeling
empowered by fully informed stakeholders with realtime access to product development information.
PLM allows companies to standardize methods, react
to global demand and accurately assess requirements
and costs before bidding, delivering more confidence
in a project’s manufacturability and profitability.
Image courtesy of Tetra Pak
DESIGN EXCELLENCE
Product complexity can contribute to design
inconsistencies, delays and poor quality that erode
margins and customer satisfaction. DS PLM facilitates
design and engineering collaboration and task
coordination, increasing the accuracy of new designs
or product variants. Intelligent design templates help
standardize parts to better leverage purchasing
power.
DS PLM facilitates
design and engineering
collaboration and task
coordination, increasing
the accuracy of new
designs or product
variants.
Decreased design time
and complexity improve
manufacturability,
profitability and the
ability to meet the
safety and regulatory
requirements of each
customer, no matter
where they are in the
world. DS PLM also
efficiently handles the
large assemblies typical of the industrial equipment
industry, with powerful kinematics to detect clashes,
tolerancing to help lower the price of components,
and fully integrated, industry-specific solutions from
hundreds of software development partners to meet
specialized needs.
DS PLM provides an integrated system for design,
analysis and manufacturing to support smooth
transitions from 2D to 3D, and from design to analysis
With PLM solutions, companies can be
more successful competing at all stages
of the industrial equipment industry:
bidding, design and engineering,
manufacturing and assembly, and
implementation and maintenance.
and tooling. The DS
simulation portfolio
encompasses finite
element methods
and advanced non-linear analysis. By enabling
collaboration between designers and analysis
engineers, DS PLM accelerates performance-based
design decisions and reduces the need for costly
and time-consuming physical prototypes and testing.
And with strong systems engineering tools, systems
engineers can design, collaborate across multidiscipline teams, and validate their model-based
embedded systems applications, including control
software, electrical / electronic systems, tubing
and piping equipment, to reduce overall design time
and errors.
A DS PLM configuration management capability
enables industrial equipment companies to easily
manage alternate designs or build new designs on the
data from previous projects. Coupled with workflow
and shared catalogs, configuration management
enables clear communication of changes and reduces
the risk of late-cycle errors.
And DS PLM’s strengths in extended enterprise
business process governance for product portfolio
management and program/project management
bring the power of PLM to the entire enterprise,
making sure the whole organization has the
information it needs to remain agile and competitive.
»
7
05/04/11 12:24
industrial machinery
Steam-powered turbines now generate some 80 percent of the
world’s electricity and are expected to do so well into the future.
But given the changing face of energy markets and economic and
environmental pressures for greater efficiency and reduced CO2 emissions,
steam turbine performance is being scrutinized under a design and optimization
microscope. For manufacturers and power plant operators alike, the goal is to
squeeze maximum wattage out of the available energy source.
Digital manufacturing helps detect and eliminate
mechanical collisions, optimize machine cycles and
maximize resource utilization. DELMIA Automation
bridges the gap between mechanical and automation
engineering, allowing users to leverage virtual models
and explore “what if?” scenarios. DS PLM significantly
reduces product launch time by facilitating testing,
validation, and debugging of systems before physical
commissioning.
LIFETIME VALUE
Customers want to maximize return on investment for
the full life of a product. A turnkey solution that
includes product, installation, operational and
maintenance services ensures ongoing market
success and a long-term flow of revenues.
Assembly line for assembly of cylinder head for diesel engine. Courtesy of TH-Tools
The fully integrated DS PLM environment supports
Design-for-Maintainability, optimizing design,
installation, operation and maintenance processes.
Designing with maintenance in mind also minimizes
the cost of service after the sale and the support time
involved in warranty work.
DIGITAL MANUFACTURING
During manufacturing planning, innumerable elements
must be stringently coordinated and executed to stay
on time and budget. Interconnected activities
throughout manufacturing facilities must be carefully
coordinated to achieve the safest, fastest, and most
optimal sequence.
Design models can be leveraged to directly create
3D-based product documentation that illustrates
detailed operational and maintenance processes.
Easy-to-follow instructions minimize training time and
can be communicated entirely in 3D, eliminating text
and the high cost of foreign-language translations.
Functionality to identify spare or
alternate parts early in the
The fully integrated DS PLM environment supports Design- development cycle helps ensure
for-Manufacturing to concurrently optimize design critical parts are always on hand.
and manufacturing processes to reduce or eliminate costly All of these capabilities increase
value-add, helping to ensure
clashes that otherwise might go undetected until installation. your
repeat business.
Design-for-Manufacturing to concurrently optimize
design and manufacturing processes. Planning,
scheduling, sequencing, Quality Analysis (Q/A)
simulation, and virtual commissioning of digital
manufacturing can be defined to reduce or eliminate
costly clashes that otherwise might go undetected
until installation.
8
Success demands the ability to
deliver new and innovative strategies. PLM solutions
from Dassault Systèmes enable rapid implementation,
higher margins and faster return on investment.
For more information:
www.3ds.com/industrial-equipment
Fast-starts help squeeze watts
Alstom Power utilizes Abaqus FEA
Winning the wattage race
Modern steam turbines are exposed to greater
stresses than earlier versions. The faster you can
get a turbine up to operating conditions, the more
energy you can produce. These rapid start-ups put
tremendous thermal stresses on a turbine as the
temperature is raised by several hundred degrees in
less than an hour. In the past, power providers took
their time during start-ups—a typical start-up might
have taken over four hours—and as a result,
stresses were much lower. Today’s power plant
operators do not have this luxury, and need to
Steam turbine rotor
shave start-up time to maximize energy production
and efficiency.
Due to variable operating conditions, transient
events have become common. Unscheduled
operations such as double-shifts or
load following operation are also the
norm. “Steam turbines need to be
able to start-up rapidly, react to load
Steam-powered
changes in a quick and predictable
turbines now
way, and tolerate the stresses
generate
inherent in these operating
some 80% of
conditions,” said Andreas Ehrsam,
the world’s
project manager at Alstom Power
electricity and
in Switzerland. “These are key
are expected to
technological challenges for modern
do so well into
power plants and for our engineering
the future.
team.” In the future, the challenges
will only increase. According to
Ehrsam, “The target for hot start-up of nextgeneration Combined Cycle Power Plants (CCPP)
steam turbines is well below 30 minutes.” With 100
years of experience designing and building steam
turbines, and having supplied major equipment
for 25% of the world’s existing electric power
generation plants, it’s easy to see why Alstom
80%
»
9
05/04/11 12:24
Steam-powered turbines now generate some 80 percent of the
world’s electricity and are expected to do so well into the future.
But given the changing face of energy markets and economic and
environmental pressures for greater efficiency and reduced CO2 emissions,
steam turbine performance is being scrutinized under a design and optimization
microscope. For manufacturers and power plant operators alike, the goal is to
squeeze maximum wattage out of the available energy source.
Digital manufacturing helps detect and eliminate
mechanical collisions, optimize machine cycles and
maximize resource utilization. DELMIA Automation
bridges the gap between mechanical and automation
engineering, allowing users to leverage virtual models
and explore “what if?” scenarios. DS PLM significantly
reduces product launch time by facilitating testing,
validation, and debugging of systems before physical
commissioning.
LIFETIME VALUE
Customers want to maximize return on investment for
the full life of a product. A turnkey solution that
includes product, installation, operational and
maintenance services ensures ongoing market
success and a long-term flow of revenues.
Assembly line for assembly of cylinder head for diesel engine. Courtesy of TH-Tools
Design-for-Maintainability, optimizing design,
installation, operation and maintenance processes.
Designing with maintenance in mind also minimizes
the cost of service after the sale and the support time
involved in warranty work.
DIGITAL MANUFACTURING
During manufacturing planning, innumerable elements
must be stringently coordinated and executed to stay
on time and budget. Interconnected activities
throughout manufacturing facilities must be carefully
coordinated to achieve the safest, fastest, and most
optimal sequence.
Design models can be leveraged to directly create
3D-based product documentation that illustrates
detailed operational and maintenance processes.
Easy-to-follow instructions minimize training time and
can be communicated entirely in 3D, eliminating text
and the high cost of foreign-language translations.
Functionality to identify spare or
alternate parts early in the
The fully integrated DS PLM environment supports Design- development cycle helps ensure
for-Manufacturing to concurrently optimize design critical parts are always on hand.
and manufacturing processes to reduce or eliminate costly All of these capabilities increase
value-add, helping to ensure
clashes that otherwise might go undetected until installation. your
repeat business.
Design-for-Manufacturing to concurrently optimize
design and manufacturing processes. Planning,
scheduling, sequencing, Quality Analysis (Q/A)
simulation, and virtual commissioning of digital
manufacturing can be defined to reduce or eliminate
costly clashes that otherwise might go undetected
until installation.
8
Success demands the ability to
deliver new and innovative strategies. PLM solutions
from Dassault Systèmes enable rapid implementation,
higher margins and faster return on investment.
www.3ds.com/industrial-equipment
Fast-starts help squeeze watts
Alstom Power utilizes Abaqus FEA
Winning the wattage race
Modern steam turbines are exposed to greater
stresses than earlier versions. The faster you can
get a turbine up to operating conditions, the more
energy you can produce. These rapid start-ups put
tremendous thermal stresses on a turbine as the
temperature is raised by several hundred degrees in
less than an hour. In the past, power providers took
their time during start-ups—a typical start-up might
have taken over four hours—and as a result,
stresses were much lower. Today’s power plant
operators do not have this luxury, and need to
Steam turbine rotor
shave start-up time to maximize energy production
and efficiency.
Due to variable operating conditions, transient
events have become common. Unscheduled
operations such as double-shifts or
load following operation are also the
norm. “Steam turbines need to be
able to start-up rapidly, react to load
Steam-powered
changes in a quick and predictable
turbines now
way, and tolerate the stresses
generate
inherent in these operating
some 80% of
conditions,” said Andreas Ehrsam,
the world’s
project manager at Alstom Power
electricity and
in Switzerland. “These are key
are expected to
technological challenges for modern
do so well into
power plants and for our engineering
the future.
team.” In the future, the challenges
will only increase. According to
Ehrsam, “The target for hot start-up of nextgeneration Combined Cycle Power Plants (CCPP)
steam turbines is well below 30 minutes.” With 100
years of experience designing and building steam
turbines, and having supplied major equipment
for 25% of the world’s existing electric power
generation plants, it’s easy to see why Alstom
80%
»
9
05/04/11 12:24
(Fig.1) Rotor model non-stationary
temperature profile at 60 minutes start-up.
(Fig.2) Rotor model with steady-state temperature
profile at base load. Images courtesy of Alstom
(Fig.1)
simulation, basing it on a set of
predefined process parameters. In
a second step, they would
perform a finite element analysis
to verify these thermal boundary
conditions. This sequential
approach required numerous iterations—a
tedious manual process—to arrive at the optimal
process parameters.
(Fig.2)
Power is continuously looking for ways to improve
turbine performance and maximize power
production.
Alstom Power has been
optimizing steam turbine
start-up processes for years.
They use Abaqus FEA from
SIMULIA because of its
powerful thermo-mechanical
simulation capabilities.
In simplified terms, the
rotor in a steam turbine
is composed of rows of
rotating blades that
capture the energy from
high-velocity steam
jetted from stationary
nozzles between the
rows. During transient
events in the operation of
a steam turbine, thermal stresses occur, causing
high fatigue loading—and these stresses are
especially prevalent in thick-walled components. At
the same time, turbines experience gradual creep
loading as a result of general operation at high
temperatures. Combining creep and fatigue loading
over time puts stresses on the turbine, eventually
leading to crack initiation and growth that can limit
turbine lifespan.
Automating a start-up simulation
Alstom Power has been optimizing steam turbine
start-up processes for years. They use Abaqus FEA
from SIMULIA, the Dassault Systémes brand for
realistic simulation, because of its powerful thermomechanical simulation capabilities. Prior to this,
early optimization analysis at Alstom Power was
based on finite difference codes and simplified
component models. Moving to FEA, Alstom
engineers would first derive the transient thermal
boundary conditions for the whole start-up
10
With the demand for increased operational flexibility
and more accurate modeling, Ehrsam’s engineering
team looked to the automation capabilities in
Abaqus to bypass the time-consuming iterative
simulation process. To automate the optimization,
the group developed a design tool that interlinked
Abaqus with Alstom’s in-house thermodynamic
code using Python, the programming language of
the Abaqus kernel scripting interface. This solution,
according to Ehrsam, “allowed direct and easy
communication between our proprietary code and
Abaqus/CAE.” The result was a tool that determined
optimal transient thermal boundary conditions
based on real-time thermal stresses and automated
the search for optimal process parameters through
the use of a feedback control algorithm. “Use of this
tool eliminated the need for the high number of
manual iterations that were previously required,”
added Ehrsam. “As a result, the process became
much more efficient.”
The automated simulation happens in the following
way: Abaqus calls a subroutine to apply the thermal
boundary condition to the model of the turbine
The use of this design tool eliminated the need
for the high number of manual iterations that
were previously required. As a result, the process
became much more efficient.
Andreas Ehrsam, project manager
Alstom Power Switzerland
rotor. Then it queries the Alstom thermodynamic
program for the thermal boundary condition for the
first time-step. With this input, Abaqus completes
the thermo-mechanical analysis. To calculate the
thermal boundary condition for the next time-step,
Abaqus extracts the actual stresses at critical
locations from its output database, calls the control
algorithm to determine the optimal mass flow,
queries the Alstom code for the thermal boundary
conditions based on this information, and finally
performs the thermo-mechanical analysis.
This computational loop is repeated for each
time-step—from 10 to 60 seconds depending
on the application—comparing the computed
stresses at critical
A typical time for a start-up locations with the
optimization using the material stress
previous manual method limits, while making
sure that the mass
was about 10 man-days. flow approaches,
With the new tool, this was but does not
reduced 50%, to only five. exceed, the stress
limits.
Automation trumps iteration
To put the tool to work, Alstom Power chose to
simulate a steam turbine rotor during a typical
60 minute start-up. They used Abaqus for a number
of steps: for preprocessing; for the creation and
meshing of 2D models of simple parts such as
axisymmetric rotor models; and for optimization
automation using Python scripts. More complex 3D
models were created in CATIA V5 and, depending
on the application, imported into Abaqus using the
CATIA V5 Associative Interface for Abaqus or the
CATIA V5 Import feature. The team then used
Abaqus to mesh the model and perform the finite
element analysis of the rotor. The time step for
mass flow control and automation was set to 60
seconds.
To start the simulation, Ehrsam’s group modeled
the initial temperature profile of the component
before start-up. First, the turbine was accelerated to
nominal speed for grid synchronization. Then,
throughout the 60 minute start-up, the team
optimized the loading gradient so the maximum
stress in the hottest section of the rotor was kept
just below the material stress limit of the rotor
materials (see Figure 1 page 10), until steady-state
temperature profile at base load was reached
(see Figure 2 page 10). Running on a standard
engineering PC, this automated optimization took
approximately 16 minutes. Although the earlier
manual calculations each took only about a third of
this run time, they consumed significantly more
set-up time because they were based on estimates
that had to be changed manually from run to run.
“As a result of the automated process, we were
able to determine the fastest start-up parameters
and process without exceeding stress limits,”
said Ehrsam. This led to a change in the design of
the rotor grooves based on global deformation
and heat flows. “Comparing the sequential
versus automated method,” Ehrsam said, “we
demonstrated time-savings and improvements in
accuracy using the automated tool.” A typical time
for a start-up optimization using the previous
manual method was about 10 man-days. With
the new tool, this was reduced 50%, to only five.
The Alstom Power team validated the automated
analysis against the previous process and found
good agreement between results data.
“In the world of power generation, small changes
in efficiency can save millions of dollars a year in
fuel cost,” said Ehrsam. With savings on this scale,
using simulation and optimization together to
squeeze maximum wattage out of turbines will
become increasingly important to power producers
in the future.
Detail of a lowpressure steam
turbine rotor
www.alstom.com
www.simulia.com
11
05/04/11 12:24
(Fig.1) Rotor model non-stationary
temperature profile at 60 minutes start-up.
(Fig.2) Rotor model with steady-state temperature
profile at base load. Images courtesy of Alstom
(Fig.1)
simulation, basing it on a set of
predefined process parameters. In
a second step, they would
perform a finite element analysis
to verify these thermal boundary
conditions. This sequential
approach required numerous iterations—a
tedious manual process—to arrive at the optimal
process parameters.
(Fig.2)
Power is continuously looking for ways to improve
turbine performance and maximize power
production.
Alstom Power has been
optimizing steam turbine
start-up processes for years.
They use Abaqus FEA from
SIMULIA because of its
powerful thermo-mechanical
simulation capabilities.
In simplified terms, the
rotor in a steam turbine
is composed of rows of
rotating blades that
capture the energy from
high-velocity steam
jetted from stationary
nozzles between the
rows. During transient
events in the operation of
a steam turbine, thermal stresses occur, causing
high fatigue loading—and these stresses are
especially prevalent in thick-walled components. At
the same time, turbines experience gradual creep
loading as a result of general operation at high
temperatures. Combining creep and fatigue loading
over time puts stresses on the turbine, eventually
leading to crack initiation and growth that can limit
turbine lifespan.
Automating a start-up simulation
Alstom Power has been optimizing steam turbine
start-up processes for years. They use Abaqus FEA
from SIMULIA, the Dassault Systémes brand for
realistic simulation, because of its powerful thermomechanical simulation capabilities. Prior to this,
early optimization analysis at Alstom Power was
based on finite difference codes and simplified
component models. Moving to FEA, Alstom
engineers would first derive the transient thermal
boundary conditions for the whole start-up
10
With the demand for increased operational flexibility
and more accurate modeling, Ehrsam’s engineering
team looked to the automation capabilities in
Abaqus to bypass the time-consuming iterative
simulation process. To automate the optimization,
the group developed a design tool that interlinked
Abaqus with Alstom’s in-house thermodynamic
code using Python, the programming language of
the Abaqus kernel scripting interface. This solution,
according to Ehrsam, “allowed direct and easy
communication between our proprietary code and
Abaqus/CAE.” The result was a tool that determined
optimal transient thermal boundary conditions
based on real-time thermal stresses and automated
the search for optimal process parameters through
the use of a feedback control algorithm. “Use of this
tool eliminated the need for the high number of
manual iterations that were previously required,”
added Ehrsam. “As a result, the process became
much more efficient.”
The automated simulation happens in the following
way: Abaqus calls a subroutine to apply the thermal
boundary condition to the model of the turbine
The use of this design tool eliminated the need
for the high number of manual iterations that
were previously required. As a result, the process
became much more efficient.
Andreas Ehrsam, project manager
Alstom Power Switzerland
rotor. Then it queries the Alstom thermodynamic
program for the thermal boundary condition for the
first time-step. With this input, Abaqus completes
the thermo-mechanical analysis. To calculate the
thermal boundary condition for the next time-step,
Abaqus extracts the actual stresses at critical
locations from its output database, calls the control
algorithm to determine the optimal mass flow,
queries the Alstom code for the thermal boundary
conditions based on this information, and finally
performs the thermo-mechanical analysis.
This computational loop is repeated for each
time-step—from 10 to 60 seconds depending
on the application—comparing the computed
stresses at critical
A typical time for a start-up locations with the
optimization using the material stress
previous manual method limits, while making
sure that the mass
was about 10 man-days. flow approaches,
With the new tool, this was but does not
reduced 50%, to only five. exceed, the stress
limits.
Automation trumps iteration
To put the tool to work, Alstom Power chose to
simulate a steam turbine rotor during a typical
60 minute start-up. They used Abaqus for a number
of steps: for preprocessing; for the creation and
meshing of 2D models of simple parts such as
axisymmetric rotor models; and for optimization
automation using Python scripts. More complex 3D
models were created in CATIA V5 and, depending
on the application, imported into Abaqus using the
CATIA V5 Associative Interface for Abaqus or the
CATIA V5 Import feature. The team then used
Abaqus to mesh the model and perform the finite
element analysis of the rotor. The time step for
mass flow control and automation was set to 60
seconds.
To start the simulation, Ehrsam’s group modeled
the initial temperature profile of the component
before start-up. First, the turbine was accelerated to
nominal speed for grid synchronization. Then,
throughout the 60 minute start-up, the team
optimized the loading gradient so the maximum
stress in the hottest section of the rotor was kept
just below the material stress limit of the rotor
materials (see Figure 1 page 10), until steady-state
temperature profile at base load was reached
(see Figure 2 page 10). Running on a standard
engineering PC, this automated optimization took
approximately 16 minutes. Although the earlier
manual calculations each took only about a third of
this run time, they consumed significantly more
set-up time because they were based on estimates
that had to be changed manually from run to run.
“As a result of the automated process, we were
able to determine the fastest start-up parameters
and process without exceeding stress limits,”
said Ehrsam. This led to a change in the design of
the rotor grooves based on global deformation
and heat flows. “Comparing the sequential
versus automated method,” Ehrsam said, “we
demonstrated time-savings and improvements in
accuracy using the automated tool.” A typical time
for a start-up optimization using the previous
manual method was about 10 man-days. With
the new tool, this was reduced 50%, to only five.
The Alstom Power team validated the automated
analysis against the previous process and found
good agreement between results data.
“In the world of power generation, small changes
in efficiency can save millions of dollars a year in
fuel cost,” said Ehrsam. With savings on this scale,
using simulation and optimization together to
squeeze maximum wattage out of turbines will
become increasingly important to power producers
in the future.
Detail of a lowpressure steam
turbine rotor
www.alstom.com
www.simulia.com
11
05/04/11 12:24
Meyn speeds complex machine design
]
By John Krouse
formerly known as TechniGraphics
Meyn is a global leader in poultry processing systems. It develops high-quality,
high-performance equipment with tens of thousands of mechanical parts that
must work in perfect synchronization to meet specific customer requirements.
This long-time CATIA V5 user – with plans to move to V6 – conveys ideas,
gains insight into product behavior and improves engineering productivity
by leveraging the lifelike precision of its 3D designs.
N
o matter where you are in the world, chances
are good that the chicken on your dinner
table was processed using equipment from
Meyn Food Processing Technology – one of the
world’s top manufacturers of automated poultry
processing systems. The company is headquartered
in the Netherlands, with
The combination of CATIA V6 and customers in over 90
ENOVIA V6 will certainly help Meyn countries and a list of
that includes
continually improve its high product references
the world’s top 25 poultry
quality standards while operating processors.
more efficiently and expanding its
offerings of innovative products – all
decisive competitive advantages.
Douglas Noordhoorn
Manager of Meyn’s IT
Competence Center
Meyn’s
end-to-end
systems consist of all
phases of processing,
from live bird handling
and cut-up to weighing
and packaging. The largest of layouts cover 10,000
square-meter (100,000 square-feet) or more. Some
machines have over 25,000 parts. Meyn’s super-fast
de-boner can process 3,000 legs per hour.
Transitioning from 2D drawings
to 3D models
Meyn has used CATIA V5 since
2004 to design its complex
equipment. It is currently migrating
to the V6 PLM platform, as well as
transitioning from 2D drawings to
designs based on 3D models. According
to Steef Klein, Meyn’s Chief
Information Officer, high-end 3D
functionality was one of the
major reasons in selecting
CATIA over less functional
mid-range packages.
12
“The ability to visualize large assemblies is one of the
greatest advantages of designing in 3D,” said Klein.
“Engineers can study intricate details and how parts fit
together by rotating models and generating exploded
views, cross-sections and transparencies. Working in
3D enables us to obtain a realistic representation of the
product that was impossible with 2D.”
In addition, mechanical simulations can be performed
on the 3D models, analyzing motion paths, part fit,
clearances and interferences. Plans are to leverage
CATIA V6 to broaden such simulation to include
dynamic analysis in determining accelerations, forces,
displacements and deflection of components.
Working smarter and faster
in the virtual world
Designing in 3D with CATIA provides insights into product
behavior and allows engineers to spot
and fix problems, explore design alternatives
and perform what-if studies – all before
expensive prototypes are built.
Such capabilities increase engineering productivity
in generating the huge number of variants required
for Meyn’s configure-to-order approach in which
standard modules are sized and integrated for
each customer’s unique requirements. “Using
CATIA enables our engineers to develop and
manage product variants, check the performance
and optimize design all very quickly,” said Klein.
“The 3D models are unambiguous in conveying
precisely to these outside companies how their
designs fit into the overall system,” added
Noordhoorn.
Managing massive amounts
of design data
Incredibly lifelike PHOTOREALISTIC
rendering with CATIA V6
Lifelike visualizations help avoid
unexpected problems
To further leverage 3D design, Meyn is in the
final stages of transitioning from 2D legacy
systems and ENOVIA SmarTeam to the V6
PLM platform. Multi-site capabilities will allow
Meyn to centralize its huge product database
and software portfolio, enabling CATIA V6 and
related development processes to be
standardized across its worldwide facilities.
Douglas Noordhoorn, Manager of Meyn’s IT
Competence Center, pointed out that 3D
visualization also improves the customer review
process. “When we have fully transitioned
to 3D design using the V6 PLM platform,
we will be able to show customers a realistic
3D representation of their machine and how
it will work before it is built. If design changes
are required, we can simulate these before
building a machine to avoid unexpected
problems.”
Whether for design review or marketing
materials, visualization is an essential part of
presenting products and concepts. CATIA
Rendering delivers all the appropriate tools
for photorealistic rendering. You can
produce photorealistic images with the
integrated mental ray® system or with the
interactive iray technology to obtain quick
results.
This approach will provide companywide access
to features for extracting data from 3D models to
automatically generate BOMs, create 3D CAM
data, as well as manage configure-to-order
product variants and large assemblies. Overall, the
new platform will enable Meyn to address its
biggest challenge: managing the massive number
of change orders across a hybrid mix of 3D
models with 2D legacy drawings and related
product data.
Plans are to expand the sharing of 3D models
with suppliers and co-development partners
in the development of highly specialized
machines, especially those with
advanced mechatronics.
“Quality is one of the main cost drivers in our
business,” explained Noordhoorn. “The
combination of CATIA V6 and ENOVIA V6 will
certainly help Meyn continually improve its
high product quality standards while operating
more efficiently and expanding its offerings of
innovative products – all decisive competitive
advantages.”
CATIA V6 for lifelike modeling
and simulation of systems
behavior
CATIA V6 provides multi-discipline
dynamic behavior modeling and simulation
through a systems engineering approach.
It delivers an extensive suite of multidiscipline libraries that are specifically
designed for advanced modeling of
complex multi-physical systems so you
can realistically model and simulate a
variety of field scenarios and drastically
improve the way complex interacting
systems are engineered.
www.catia.com
www.meyn.com
www.3ds.com/products
13
05/04/11 12:24
Meyn speeds complex machine design
]
By John Krouse
formerly known as TechniGraphics
Meyn is a global leader in poultry processing systems. It develops high-quality,
high-performance equipment with tens of thousands of mechanical parts that
must work in perfect synchronization to meet specific customer requirements.
This long-time CATIA V5 user – with plans to move to V6 – conveys ideas,
gains insight into product behavior and improves engineering productivity
by leveraging the lifelike precision of its 3D designs.
N
o matter where you are in the world, chances
are good that the chicken on your dinner
table was processed using equipment from
Meyn Food Processing Technology – one of the
world’s top manufacturers of automated poultry
processing systems. The company is headquartered
in the Netherlands, with
The combination of CATIA V6 and customers in over 90
ENOVIA V6 will certainly help Meyn countries and a list of
that includes
continually improve its high product references
the world’s top 25 poultry
quality standards while operating processors.
more efficiently and expanding its
offerings of innovative products – all
decisive competitive advantages.
Douglas Noordhoorn
Manager of Meyn’s IT
Competence Center
Meyn’s
end-to-end
systems consist of all
phases of processing,
from live bird handling
and cut-up to weighing
and packaging. The largest of layouts cover 10,000
square-meter (100,000 square-feet) or more. Some
machines have over 25,000 parts. Meyn’s super-fast
de-boner can process 3,000 legs per hour.
Transitioning from 2D drawings
to 3D models
Meyn has used CATIA V5 since
2004 to design its complex
equipment. It is currently migrating
to the V6 PLM platform, as well as
transitioning from 2D drawings to
designs based on 3D models. According
to Steef Klein, Meyn’s Chief
Information Officer, high-end 3D
functionality was one of the
major reasons in selecting
CATIA over less functional
mid-range packages.
12
“The ability to visualize large assemblies is one of the
greatest advantages of designing in 3D,” said Klein.
“Engineers can study intricate details and how parts fit
together by rotating models and generating exploded
views, cross-sections and transparencies. Working in
3D enables us to obtain a realistic representation of the
product that was impossible with 2D.”
In addition, mechanical simulations can be performed
on the 3D models, analyzing motion paths, part fit,
clearances and interferences. Plans are to leverage
CATIA V6 to broaden such simulation to include
dynamic analysis in determining accelerations, forces,
displacements and deflection of components.
Working smarter and faster
in the virtual world
Designing in 3D with CATIA provides insights into product
behavior and allows engineers to spot
and fix problems, explore design alternatives
and perform what-if studies – all before
expensive prototypes are built.
Such capabilities increase engineering productivity
in generating the huge number of variants required
for Meyn’s configure-to-order approach in which
standard modules are sized and integrated for
each customer’s unique requirements. “Using
CATIA enables our engineers to develop and
manage product variants, check the performance
and optimize design all very quickly,” said Klein.
“The 3D models are unambiguous in conveying
precisely to these outside companies how their
designs fit into the overall system,” added
Noordhoorn.
Managing massive amounts
of design data
Incredibly lifelike PHOTOREALISTIC
rendering with CATIA V6
Lifelike visualizations help avoid
unexpected problems
To further leverage 3D design, Meyn is in the
final stages of transitioning from 2D legacy
systems and ENOVIA SmarTeam to the V6
PLM platform. Multi-site capabilities will allow
Meyn to centralize its huge product database
and software portfolio, enabling CATIA V6 and
related development processes to be
standardized across its worldwide facilities.
Douglas Noordhoorn, Manager of Meyn’s IT
Competence Center, pointed out that 3D
visualization also improves the customer review
process. “When we have fully transitioned
to 3D design using the V6 PLM platform,
we will be able to show customers a realistic
3D representation of their machine and how
it will work before it is built. If design changes
are required, we can simulate these before
building a machine to avoid unexpected
problems.”
Whether for design review or marketing
materials, visualization is an essential part of
presenting products and concepts. CATIA
Rendering delivers all the appropriate tools
for photorealistic rendering. You can
produce photorealistic images with the
integrated mental ray® system or with the
interactive iray technology to obtain quick
results.
This approach will provide companywide access
to features for extracting data from 3D models to
automatically generate BOMs, create 3D CAM
data, as well as manage configure-to-order
product variants and large assemblies. Overall, the
new platform will enable Meyn to address its
biggest challenge: managing the massive number
of change orders across a hybrid mix of 3D
models with 2D legacy drawings and related
product data.
Plans are to expand the sharing of 3D models
with suppliers and co-development partners
in the development of highly specialized
machines, especially those with
advanced mechatronics.
“Quality is one of the main cost drivers in our
business,” explained Noordhoorn. “The
combination of CATIA V6 and ENOVIA V6 will
certainly help Meyn continually improve its
high product quality standards while operating
more efficiently and expanding its offerings of
innovative products – all decisive competitive
advantages.”
CATIA V6 for lifelike modeling
and simulation of systems
behavior
CATIA V6 provides multi-discipline
dynamic behavior modeling and simulation
through a systems engineering approach.
It delivers an extensive suite of multidiscipline libraries that are specifically
designed for advanced modeling of
complex multi-physical systems so you
can realistically model and simulate a
variety of field scenarios and drastically
improve the way complex interacting
systems are engineered.
www.catia.com
www.meyn.com
13
05/04/11 12:24
chuler AG achieves production
S
optimization of press lines with DELMIA
Crossbar-Feeder
Unit for interpress
transfer
Centering station with vision system for part orientation
Schuler AG of Göppingen set a new standard in adaptability for press
lines with their new equipment for the production of large car body
panels. For the first time, production optimization was carried out
with control and process simulation of press lines using DELMIA V5.
A
s the technological and global
market leader in metalforming,
Schuler supplies machines,
production lines, dies, process know-how
and services for the entire metal-working
industry. Their clients include car manufacturers
and their suppliers, as well as companies
in the forging, household equipment and
electrical industry. Schuler is also the market
leader in coin-minting technology and
produces complete wind turbines. The
company employs more than 5,000 people
and is represented by its own facilities and
sales offices in 40 nations around the world.
Schuler Pressen GmbH und Co. KG develops
and manufactures state-of-the-art
mechanical press systems for customers
in the automobile, supplier, electrical and
14
household appliance industries. In 2009,
the world’s first press line with ServoDirect
technology and Crossbar Feeder automation began operation. This press line, which
allows up to six presses, was developed
for the production of large car body panels
at the BMW GROUP.
The production process
makes this one-of-a-kind
facility unique
In order to make the entire forming process
of the new press line more efficient,
decision-makers at Schuler worked with
equipment operator BMW GROUP during
the development of the press line. Together,
they explored opportunities for simulating
production startup with molds and simulating
the transfer of car body parts.
Efficiency calculations quickly revealed
that the economic difference between
optimizing equipment directly versus
through simulation was enormous.
“Simulation reduces the cost of equipment
programming by a factor of five, and
increases production capacity by 5% to
10%,” explained Dietmar Schöllhammer,
process development manager at Schuler
Pressen GmbH und Co. KG.
Schuler and the BMW GROUP had been
using CATIA V5 for many years. DELMIA V5
had long been used for blank feeding at the
Gemmingen location during robot simulation.
In cooperation with BMW GROUP, this solution
is now being used for press simulation in
Göppingen. The catalyst was an appeal
from within the OEM simulation team. The
request was for an integrated solution that
can be linked with the CATIA V5 platform.
Such a solution permits close integration of
mold design and simulation of the production
cycle. A similar solution using CATIA had
already been developed as a product at the
Schuler Group, but a comparison with
DELMIA V5 demonstrated clear performance
advantages. For this reason, DELMIA was
ultimately chosen. The critical objective of
integration into the entire process was
achieved through intensive coordination
with the BMW GROUP development team.
Collision-free movement
and transport
With the new press line, production
optimization first took place through
control and process simulation using DELMIA.
A method plan was established for each
sheet metal part to be produced by the press
line. This described the number of forming
stations, the necessary technical process,
and the different positions necessary to produce
the part. The method plan was followed by
the flow chart, which tests whether the part
positions defined are consistent with the
requirements of the transfer equipment.
Can the parts be transported without a
collision occurring, and at what speed can
they be transferred? All movements and
positions of the parts were examined. Once
these parameters had been determined,
mold design using CATIA could begin.
During method planning, information for
press and transfer was generated early on
and incorporated directly into equipment
simulation and programming using DELMIA V5.
The range of motion, feasibility, movement,
and transfer could be examined in the subsequent simulation—and at a stage where
no concrete mold had been produced—
a significant cost and time factor. At this
phase, corrections could be implemented
with a few mouse clicks.
By implementing DELMIA V5,
all necessary actions and
production steps of a press
line could now be planned
and tested in context at a
work station, resulting potentially in tremendous savings:
simplification of processes,
reduced costs, and minimization of error sources as
well as faster completion.
was close cooperation between BMW
GROUP, Schuler, and Dassault Systèmes
during development of the system. Initial
experiences have been extremely positive.
“Do you know the feeling of looking in
astonishment at a MicroSD card with 16GB
and asking, how do they achieve that?
This describes our feeling, when we evaluate
the performance of the press simulation
using DELMIA V5. You’re constantly asking
Simulation reduces the cost of
equipment programming by a factor
of five, and increases production
capacity by 5% to 10%.
Simple Operation of DELMIA
According to Dietmar Schöllhammer, “We
anticipate maximum acceptance of the
integrated solution once deployed. By
integration, I mean that our equipment is
optimally integrated into the manufacturing
process.” Existing employee skills in both
areas is a considerable factor in the decision
to implement the system.
Introducing DELMIA V5 has proven uncomplicated. At Schuler it was hardly even
noticed that a new system had been
implemented. All operations were largely
familiar from CATIA V5, and the few additional
functions were quickly learned.
At the BMW GROUP, concerns about
complexity of equipment have given way to
enthusiasm, because the potential of the
press line can now be fully exhausted
through surprisingly effective use of the
simulation system. Basis for this success
Dietmar Schöllhammer
Process Development Manager
Schuler Pressen GmbH und Co. KG.
yourself, how do they do that?” marveled
Schöllhammer.
Deployment of DELMIA V5 significantly
simplifies simulation. Equipment functionality
is displayed through the simulation user
interface. Not only is the functionality of
the system easy to understand, operation is
equally simple. This is a great advantage
for users. In addition, the solution allows for
significantly improved cooperation between
Schuler and the OEM during optimization of
equipment operation. With the performance
and elegant user interface, it is “simply
a joy to work with,” Schöllhammer said.
www.schulergroup.com
www.delmia.com
15
05/04/11 12:24
chuler AG achieves production
S
optimization of press lines with DELMIA
Crossbar-Feeder
Unit for interpress
transfer
Centering station with vision system for part orientation
Schuler AG of Göppingen set a new standard in adaptability for press
lines with their new equipment for the production of large car body
panels. For the first time, production optimization was carried out
with control and process simulation of press lines using DELMIA V5.
A
s the technological and global
market leader in metalforming,
Schuler supplies machines,
production lines, dies, process know-how
and services for the entire metal-working
industry. Their clients include car manufacturers
and their suppliers, as well as companies
in the forging, household equipment and
electrical industry. Schuler is also the market
leader in coin-minting technology and
produces complete wind turbines. The
company employs more than 5,000 people
and is represented by its own facilities and
sales offices in 40 nations around the world.
Schuler Pressen GmbH und Co. KG develops
and manufactures state-of-the-art
mechanical press systems for customers
in the automobile, supplier, electrical and
14
household appliance industries. In 2009,
the world’s first press line with ServoDirect
technology and Crossbar Feeder automation began operation. This press line, which
allows up to six presses, was developed
for the production of large car body panels
at the BMW GROUP.
The production process
makes this one-of-a-kind
facility unique
In order to make the entire forming process
of the new press line more efficient,
decision-makers at Schuler worked with
equipment operator BMW GROUP during
the development of the press line. Together,
they explored opportunities for simulating
production startup with molds and simulating
the transfer of car body parts.
Efficiency calculations quickly revealed
that the economic difference between
optimizing equipment directly versus
through simulation was enormous.
“Simulation reduces the cost of equipment
programming by a factor of five, and
increases production capacity by 5% to
10%,” explained Dietmar Schöllhammer,
process development manager at Schuler
Pressen GmbH und Co. KG.
Schuler and the BMW GROUP had been
using CATIA V5 for many years. DELMIA V5
had long been used for blank feeding at the
Gemmingen location during robot simulation.
In cooperation with BMW GROUP, this solution
is now being used for press simulation in
Göppingen. The catalyst was an appeal
from within the OEM simulation team. The
request was for an integrated solution that
can be linked with the CATIA V5 platform.
Such a solution permits close integration of
mold design and simulation of the production
cycle. A similar solution using CATIA had
already been developed as a product at the
Schuler Group, but a comparison with
DELMIA V5 demonstrated clear performance
advantages. For this reason, DELMIA was
ultimately chosen. The critical objective of
integration into the entire process was
achieved through intensive coordination
with the BMW GROUP development team.
Collision-free movement
and transport
With the new press line, production
optimization first took place through
control and process simulation using DELMIA.
A method plan was established for each
sheet metal part to be produced by the press
line. This described the number of forming
stations, the necessary technical process,
and the different positions necessary to produce
the part. The method plan was followed by
the flow chart, which tests whether the part
positions defined are consistent with the
requirements of the transfer equipment.
Can the parts be transported without a
collision occurring, and at what speed can
they be transferred? All movements and
positions of the parts were examined. Once
these parameters had been determined,
mold design using CATIA could begin.
During method planning, information for
press and transfer was generated early on
and incorporated directly into equipment
simulation and programming using DELMIA V5.
The range of motion, feasibility, movement,
and transfer could be examined in the subsequent simulation—and at a stage where
no concrete mold had been produced—
a significant cost and time factor. At this
phase, corrections could be implemented
with a few mouse clicks.
By implementing DELMIA V5,
all necessary actions and
production steps of a press
line could now be planned
and tested in context at a
work station, resulting potentially in tremendous savings:
simplification of processes,
reduced costs, and minimization of error sources as
well as faster completion.
was close cooperation between BMW
GROUP, Schuler, and Dassault Systèmes
during development of the system. Initial
experiences have been extremely positive.
“Do you know the feeling of looking in
astonishment at a MicroSD card with 16GB
and asking, how do they achieve that?
This describes our feeling, when we evaluate
the performance of the press simulation
using DELMIA V5. You’re constantly asking
Simulation reduces the cost of
equipment programming by a factor
of five, and increases production
capacity by 5% to 10%.
Simple Operation of DELMIA
According to Dietmar Schöllhammer, “We
anticipate maximum acceptance of the
integrated solution once deployed. By
integration, I mean that our equipment is
optimally integrated into the manufacturing
process.” Existing employee skills in both
areas is a considerable factor in the decision
to implement the system.
Introducing DELMIA V5 has proven uncomplicated. At Schuler it was hardly even
noticed that a new system had been
implemented. All operations were largely
familiar from CATIA V5, and the few additional
functions were quickly learned.
At the BMW GROUP, concerns about
complexity of equipment have given way to
enthusiasm, because the potential of the
press line can now be fully exhausted
through surprisingly effective use of the
simulation system. Basis for this success
Dietmar Schöllhammer
Process Development Manager
Schuler Pressen GmbH und Co. KG.
yourself, how do they do that?” marveled
Schöllhammer.
Deployment of DELMIA V5 significantly
simplifies simulation. Equipment functionality
is displayed through the simulation user
interface. Not only is the functionality of
the system easy to understand, operation is
equally simple. This is a great advantage
for users. In addition, the solution allows for
significantly improved cooperation between
Schuler and the OEM during optimization of
equipment operation. With the performance
and elegant user interface, it is “simply
a joy to work with,” Schöllhammer said.
www.schulergroup.com
www.delmia.com
15
05/04/11 12:24
TYAZHMASH increases production
by 80% with CATIA and 3DVIA
To maintain its lead in the heavy machinery
market, Russia’s PJSC ‘TYAZHMASH’
had to shorten product development cycle
times. They chose CATIA PLM Express
to support all engineering work and
3DVIA Composer to create all its technical
documentation, helping the company create
technical documentation in half the time.
E
stablished in 1941, Russia’s Public Joint Stock
Company ‘TYAZHMASH’ is a leading manufacturer of world-renowned products for the industrial equipment, energy, and transportation sectors. PJSC
‘TYAZHMASH’ products are used to equip thermal,
hydro and nuclear power plants. They are also used in
large integrated mining plants, open and shaft mines,
blast furnaces, cement and chemical plants, and at
space launch sites. PJSC ‘TYAZHMASH’ can handle
complex orders and has a solid reputation due to the
high quality of its products as well as their durability and
serviceability.
Managing large assemblies
with CATIA PLM Express
In order to maintain its leading position in the heavy
machinery production market, PJSC ‘TYAZHMASH’ had
to shorten design and engineering cycle times and to
model extremely large installations. This limited its choice
of CAD systems to those that support large assemblies
and the interaction between individual components. After
comparing the different solutions available on the market,
PJSC ‘TYAZHMASH’ selected Dassault Systèmes (DS)
Product Lifecycle Management (PLM) solutions CATIA PLM
Express and, more recently, 3DVIA Composer. This choice
was, in part, based on the solutions’ adaptability and
ability to efficiently handle engineering tasks performed
by experts in various fields.
Better quality,
reduced development time
The introduction of DS PLM solutions in the design and
engineering departments provided designers with an
incentive to switch from the drafting table to 3D virtual
applications in only two years. As a result, the company
now enjoys significant time savings when developing
new products and business processes. In addition, using
an in-house measurement and inspection tool from
which parameters are then entered into CATIA, PJSC
‘TYAZHMASH’ has improved assembly quality, ensured
precision and can make verifications for customers,
even on large installations. This significantly accelerated
the production process and improved the quality of its
products.
In order to improve machining quality, PJSC ‘TYAZHMASH’
purchased 5-axis high-speed milling machines and NC
16
CATIA PLM Express enabled us to increase
production volumes by 80% and to decrease
our product rejects by 50%.
D.S. Trifonov
Deputy General Director
Director of hydropower and hydromechanical equipment
PJSC ‘TYAZHMASH’
machines where simulation paths are entirely managed
using CATIA. All parts manufactured by the milling
machines require no additional finishing. Thanks to
CATIA Machining solutions, productivity increased and
PJSC ‘TYAZHMASH’ was able to undertake complicated
projects under extremely tight deadlines, resulting in
an increase in the number of contracts signed with
customers. “I asked our teams to put in place an all-inone and out-of-the-box PLM solution enabling us to
manufacture right the first time. CATIA PLM Express
enabled us to increase production volumes by 80%
and to decrease our product rejects by 50%,” said
D.S. Trifonov, Deputy General Director – Director of
hydropower and hydromechanical equipment, PJSC
‘TYAZHMASH’.
Creating 3D technical documentation
with 3DVIA Composer
During the design and manufacturing processes, a
considerable amount of information, including product
models and related technical information, is accumulated.
Prior to the implementation of 3DVIA Composer, PJSC
‘TYAZHMASH’ struggled to coordinate the assembly
phase and the parts completion phase, resulting in a
waste of resources and loss of time. Inconsistencies
between the designs and associated technical
documentation reduced productivity.
Today, users without any special CAD skills can use
3DVIA Composer to create 3D-presentation materials
using digital models of the designed products,
improving the quality of the documentation. Using
interactive and graphic elements reduces the quantity of
text needed, allowing the company to minimize translation
costs. This is important since PJSC ‘TYAZHMASH’ has
many customers all over the world. “We can now create
our documentation with 3DVIA Composer during
the product design process, improving efficiency,” said
Trifonov. “This enables us to reduce the time spent
on rework and updating documentation when making
design changes. As a matter of fact, 3DVIA Composer
helped reduce the time required to prepare technical
documentation by 50%,” he said.
Increased value and credibility
Using DS PLM solutions has had a positive impact on
PJSC ‘TYAZHMASH’s business image. Demonstrating
PLM solutions to potential local and international
customers has enabled the company to sign over
40% of its contracts with prior booking. ”PLM solutions
significantly increase our company’s value and credibility
among customers,” said Trifonov.
50%
3DVIA Composer helped
reduce the time required
to prepare technical
documentation by 50%.
www.tyazhmash.com/eng
www.3ds.com/catia-plm-express
www.3dviacomposer.com
17
05/04/11 12:24
TYAZHMASH increases production
by 80% with CATIA and 3DVIA
To maintain its lead in the heavy machinery
market, Russia’s PJSC ‘TYAZHMASH’
had to shorten product development cycle
times. They chose CATIA PLM Express
to support all engineering work and
3DVIA Composer to create all its technical
documentation, helping the company create
technical documentation in half the time.
E
stablished in 1941, Russia’s Public Joint Stock
Company ‘TYAZHMASH’ is a leading manufacturer of world-renowned products for the industrial equipment, energy, and transportation sectors. PJSC
‘TYAZHMASH’ products are used to equip thermal,
hydro and nuclear power plants. They are also used in
large integrated mining plants, open and shaft mines,
blast furnaces, cement and chemical plants, and at
space launch sites. PJSC ‘TYAZHMASH’ can handle
complex orders and has a solid reputation due to the
high quality of its products as well as their durability and
serviceability.
Managing large assemblies
with CATIA PLM Express
In order to maintain its leading position in the heavy
machinery production market, PJSC ‘TYAZHMASH’ had
to shorten design and engineering cycle times and to
model extremely large installations. This limited its choice
of CAD systems to those that support large assemblies
and the interaction between individual components. After
comparing the different solutions available on the market,
PJSC ‘TYAZHMASH’ selected Dassault Systèmes (DS)
Product Lifecycle Management (PLM) solutions CATIA PLM
Express and, more recently, 3DVIA Composer. This choice
was, in part, based on the solutions’ adaptability and
ability to efficiently handle engineering tasks performed
by experts in various fields.
Better quality,
reduced development time
The introduction of DS PLM solutions in the design and
engineering departments provided designers with an
incentive to switch from the drafting table to 3D virtual
applications in only two years. As a result, the company
now enjoys significant time savings when developing
new products and business processes. In addition, using
an in-house measurement and inspection tool from
which parameters are then entered into CATIA, PJSC
‘TYAZHMASH’ has improved assembly quality, ensured
precision and can make verifications for customers,
even on large installations. This significantly accelerated
the production process and improved the quality of its
products.
In order to improve machining quality, PJSC ‘TYAZHMASH’
purchased 5-axis high-speed milling machines and NC
16
CATIA PLM Express enabled us to increase
production volumes by 80% and to decrease
our product rejects by 50%.
D.S. Trifonov
Deputy General Director
Director of hydropower and hydromechanical equipment
PJSC ‘TYAZHMASH’
machines where simulation paths are entirely managed
using CATIA. All parts manufactured by the milling
machines require no additional finishing. Thanks to
CATIA Machining solutions, productivity increased and
PJSC ‘TYAZHMASH’ was able to undertake complicated
projects under extremely tight deadlines, resulting in
an increase in the number of contracts signed with
customers. “I asked our teams to put in place an all-inone and out-of-the-box PLM solution enabling us to
manufacture right the first time. CATIA PLM Express
enabled us to increase production volumes by 80%
and to decrease our product rejects by 50%,” said
D.S. Trifonov, Deputy General Director – Director of
hydropower and hydromechanical equipment, PJSC
‘TYAZHMASH’.
Creating 3D technical documentation
with 3DVIA Composer
During the design and manufacturing processes, a
considerable amount of information, including product
models and related technical information, is accumulated.
Prior to the implementation of 3DVIA Composer, PJSC
‘TYAZHMASH’ struggled to coordinate the assembly
phase and the parts completion phase, resulting in a
waste of resources and loss of time. Inconsistencies
between the designs and associated technical
documentation reduced productivity.
Today, users without any special CAD skills can use
3DVIA Composer to create 3D-presentation materials
using digital models of the designed products,
improving the quality of the documentation. Using
interactive and graphic elements reduces the quantity of
text needed, allowing the company to minimize translation
costs. This is important since PJSC ‘TYAZHMASH’ has
many customers all over the world. “We can now create
our documentation with 3DVIA Composer during
the product design process, improving efficiency,” said
Trifonov. “This enables us to reduce the time spent
on rework and updating documentation when making
design changes. As a matter of fact, 3DVIA Composer
helped reduce the time required to prepare technical
documentation by 50%,” he said.
Increased value and credibility
Using DS PLM solutions has had a positive impact on
PJSC ‘TYAZHMASH’s business image. Demonstrating
PLM solutions to potential local and international
customers has enabled the company to sign over
40% of its contracts with prior booking. ”PLM solutions
significantly increase our company’s value and credibility
among customers,” said Trifonov.
50%
3DVIA Composer helped
reduce the time required
to prepare technical
documentation by 50%.
www.tyazhmash.com/eng
www.3ds.com/catia-plm-express
17
05/04/11 12:24
Tetra Pak needed to reduce costs by verifying
that its process solutions work according to customer
specifications before plant start-up. The company
uses Dymola to develop tailored process solutions
for customers and to validate their efficiency through
simulation, thereby enabling it to reduce equipment
configuration and delivery costs and improve
the performance of its equipment.
Tetra Pak optimizes process
solutions with Dymola
Tailored solutions for each customer
The motto, PROTECTS WHAT’S GOOD™ reflects
Tetra Pak’s vision to make food safe and available
everywhere. Optimizing its processing solutions is
vital as Tetra Pak wants to avoid production
downtime and inefficiencies for its customers. This
is why the company’s Processing Systems’ division,
which develops customized processing solutions
for food industry customers who pack their
products in Tetra Pak or third-party packaging,
must verify the viability of its solutions before a
production unit is shipped to the customer. “We
simulate what we are going to supply to be sure
it will function optimally,” said Tomas Skoglund,
Research Project Senior Manager, Tetra Pak.
“Each solution we supply to customers is unique in
some respects. We build them on a standardized
platform but since the specifications vary from
customer to customer, it’s valuable to be able to
verify and validate the entire configuration with
simulation.” Skoglund’s team even tests entirely
new concepts with simulation to verify that they
work well.
were designed, to use them for simulation,” he said.
“We are able to split the work between modeling
and simulation engineers, each with their respective
know-how. This means that simulation can be
performed by a much wider group of users.”
Optimum processing with Dymola
Hardware-in-the-loop,
realistic virtual testing
Tetra Pak chose Dymola, Dassault Systèmes’ multiengineering modeling and simulation solutions
based on the open Modelica modeling language, to
optimize equipment configuration. “We chose Dymola
because it is based on the powerful open objectoriented Modelica language, and because of its
user-friendly graphical user interface,” said Skoglund.
Trend toward desktop simulation
with Dymola
Tetra Pak is putting greater emphasis on desktop
design and simulation of new alternative designs
and technologies. “We are beginning to replace
workshop testing with desktop testing using
simulation, which costs less,” said Skoglund. “We
use Dymola to verify and optimize a process,
particularly when we are designing completely new
solutions or a new way of processing something,”
said Skoglund. “It’s an efficient way to validate
function and optimize the different options.”
Skoglund finds it easy to build models with Dymola,
splitting the work between engineers with modeling
skills and those with simulation skills. “If you build
models correctly you can have someone else, who
doesn’t have to be familiar with the way the models
18
Tetra Pak
Tetra Pak recently developed a Dymola-based
solution for hardware-in-the-loop (HIL) simulation
for the food processing industry. Normally, food
processing units are functionally tested by running
them with water before they are shipped to the
customer. This is carried out to ensure the high
quality of the equipment but cannot be done before
the machine is manufactured, increasing delays
before delivery. To enable shorter delivery time at
a lower cost, an alternative to functional testing is
to run a real-time HIL simulation where the real
Programmable Logic Controller (PLC) system is
connected and operated with the process model.
Since the process model enables simulation with
real fluids and not just water, the HIL simulation
can be more realistic. Furthermore, water tests
often cannot be performed on special equipment,
such as centrifugal separators, due to practical
considerations. However, this limitation seldom
exists in simulations. In addition, simulations also
enable Tetra Pak to virtually monitor any dynamic
variable (pressure, flow rates or temperature) in
the system without the need for sensors, which
can be of great help to quickly understand and
resolve issues.
Training operators:
a future for simulation
Tetra Pak is the world’s leading
food processing and packaging
solutions company. Working closely
with its customers and suppliers,
Tetra Pak provides safe, innovative
and environmentally sound
products that each day meet the
needs of hundreds of millions of
people around the world. Tetra Pak
has over 20,000 employees and
operations in more than 170
countries.
Skoglund considers simulation as
the future for operator training. “I see
a trend where we will use simulation
to train operators who are going
to run a plant,” Skoglund said.
“Customers can train new staff
without disturbing production.
We have been talking to them about
simulation and they are quite keen on getting
their staff up to speed in this way before installation
and commissioning.”
www.tetrapak.com
www.dymola.com
19
05/04/11 12:24
Tetra Pak needed to reduce costs by verifying
that its process solutions work according to customer
specifications before plant start-up. The company
uses Dymola to develop tailored process solutions
for customers and to validate their efficiency through
simulation, thereby enabling it to reduce equipment
configuration and delivery costs and improve
the performance of its equipment.
Tetra Pak optimizes process
solutions with Dymola
Tailored solutions for each customer
The motto, PROTECTS WHAT’S GOOD™ reflects
Tetra Pak’s vision to make food safe and available
everywhere. Optimizing its processing solutions is
vital as Tetra Pak wants to avoid production
downtime and inefficiencies for its customers. This
is why the company’s Processing Systems’ division,
which develops customized processing solutions
for food industry customers who pack their
products in Tetra Pak or third-party packaging,
must verify the viability of its solutions before a
production unit is shipped to the customer. “We
simulate what we are going to supply to be sure
it will function optimally,” said Tomas Skoglund,
Research Project Senior Manager, Tetra Pak.
“Each solution we supply to customers is unique in
some respects. We build them on a standardized
platform but since the specifications vary from
customer to customer, it’s valuable to be able to
verify and validate the entire configuration with
simulation.” Skoglund’s team even tests entirely
new concepts with simulation to verify that they
work well.
were designed, to use them for simulation,” he said.
“We are able to split the work between modeling
and simulation engineers, each with their respective
know-how. This means that simulation can be
performed by a much wider group of users.”
Optimum processing with Dymola
Hardware-in-the-loop,
realistic virtual testing
Tetra Pak chose Dymola, Dassault Systèmes’ multiengineering modeling and simulation solutions
based on the open Modelica modeling language, to
optimize equipment configuration. “We chose Dymola
because it is based on the powerful open objectoriented Modelica language, and because of its
user-friendly graphical user interface,” said Skoglund.
Trend toward desktop simulation
with Dymola
Tetra Pak is putting greater emphasis on desktop
design and simulation of new alternative designs
and technologies. “We are beginning to replace
workshop testing with desktop testing using
simulation, which costs less,” said Skoglund. “We
use Dymola to verify and optimize a process,
particularly when we are designing completely new
solutions or a new way of processing something,”
said Skoglund. “It’s an efficient way to validate
function and optimize the different options.”
Skoglund finds it easy to build models with Dymola,
splitting the work between engineers with modeling
skills and those with simulation skills. “If you build
models correctly you can have someone else, who
doesn’t have to be familiar with the way the models
18
Tetra Pak
Tetra Pak recently developed a Dymola-based
solution for hardware-in-the-loop (HIL) simulation
for the food processing industry. Normally, food
processing units are functionally tested by running
them with water before they are shipped to the
customer. This is carried out to ensure the high
quality of the equipment but cannot be done before
the machine is manufactured, increasing delays
before delivery. To enable shorter delivery time at
a lower cost, an alternative to functional testing is
to run a real-time HIL simulation where the real
Programmable Logic Controller (PLC) system is
connected and operated with the process model.
Since the process model enables simulation with
real fluids and not just water, the HIL simulation
can be more realistic. Furthermore, water tests
often cannot be performed on special equipment,
such as centrifugal separators, due to practical
considerations. However, this limitation seldom
exists in simulations. In addition, simulations also
enable Tetra Pak to virtually monitor any dynamic
variable (pressure, flow rates or temperature) in
the system without the need for sensors, which
can be of great help to quickly understand and
resolve issues.
Training operators:
a future for simulation
Tetra Pak is the world’s leading
food processing and packaging
solutions company. Working closely
with its customers and suppliers,
Tetra Pak provides safe, innovative
and environmentally sound
products that each day meet the
needs of hundreds of millions of
people around the world. Tetra Pak
has over 20,000 employees and
operations in more than 170
countries.
Skoglund considers simulation as
the future for operator training. “I see
a trend where we will use simulation
to train operators who are going
to run a plant,” Skoglund said.
“Customers can train new staff
without disturbing production.
We have been talking to them about
simulation and they are quite keen on getting
their staff up to speed in this way before installation
and commissioning.”
www.tetrapak.com
www.dymola.com
19
05/04/11 12:24
ENOVIA SmarTeam totally in control of our business.
It’s a wonderful product, but it’s important to know that
we have the support we need because we are so
dependent on it.”
Langen Packaging Inc. of Ontario,
Canada, manufactures highly
customized, durable machinery
used to package products that
range from food and durable
goods to cosmetics, paper,
pharmaceuticals and more.
Langen Packaging customizes products
with ENOVIA SmarTeam and Microsoft
T
o build made-to-order equipment, Langen
Packaging needed a robust data engine to
help it start fast and go the distance for its
customers. Starting fast means responding quickly to
new customer requests with accurate quotes and
proposals that build off existing designs, while going
the distance requires the ability
to provide long-term service.
ENOVIA SmarTeam gives us the
This involves maintaining –
ability to retain and track the kind
sometimes over a span of 20
years or more – updated
of customer information that gives
knowledge of a machine’s
us a competitive advantage.
evolving configuration in the field.
Mirek Tokarz
Director of Technology Development
Langen Packaging
20
a project are organized and stored together for future
reference.
What’s more, the flexibility and commonality of the
Microsoft platform has enabled Langen Packaging to
continually expand the use of ENOVIA SmarTeam into
new areas of the business. “SQL Server® 2005 does
what it is supposed to without us really having to
worry about its maintenance,” explains Mirek Tokarz,
Director of Technology Development. “It just works.
Because of its wide use by so many companies, it
also is easier to find support expertise when compared
to other database platforms.”
ENOVIA SmarTeam, coupled
with the Microsoft platform and
Windows® operating system,
answers Langen Packaging’s
needs. By replacing years of custom solution
development with out-of-the box functionality, the
company is now poised for growth.
Langen Packaging has even integrated ENOVIA
SmarTeam with Microsoft Outlook® 2003, which
allows it to capture project-critical emails. Those
emails, including attachments, can be stored and
linked directly to projects, saving time and making
associated documents readily accessible for future
use and quick searches.
Adding value with Microsoft
and Windows
After-sale service easier with strong
BOM tracking
Because ENOVIA SmarTeam operates on the Microsoft
platform, information from a broad range of sources,
including Microsoft® Office applications such as Word
and Excel, can be stored together with product
designs and proposals. This helps ensure all details of
With ENOVIA SmarTeam, Langen Packaging is well
equipped to handle changes in the field. “If our
Aftermarket group needs to introduce changes to a
piece of equipment in the field, their starting base is a
clean bill of material (BOM),” Tokarz explains. “This
BOM can be revised and released back to
manufacturing, and when the cycle is done, we are left
with a revision of the BOM that represents what’s in
the field.”
When a customer calls asking for a spare part or help
with a repair in the field, Langen Packaging’s customer
support teams can access the relevant BOMs and
documents in ENOVIA SmarTeam. With a few simple
clicks they can launch the latest drawing in the viewer,
allowing them to provide customer support on the
machine as it has been maintained and updated over
the years.
Tokarz believes ENOVIA SmarTeam gives Langen
Packaging an advantage over its competitors. “Our
customers know we understand them as a client and
know what their business is all about, even down to
details such as their requirements for a machine a year
ago,” he says. “ENOVIA SmarTeam gives us the ability
to retain and track that kind of customer information
and that gives us a competitive advantage.”
AscendBridge support makes good
choice better
With ENOVIA SmarTeam and AscendBridge, Langen
has freed up significant staff resources that once
supported its legacy system. “Over the years, we had
developed many different databases and maintaining
them created unwanted overhead,” Tokarz says.
“Replacing them with a commercial product that can
easily be supported by
AscendBridge improves our
Storing and managing a large
flexibility and makes us less
dependent on our internal
range of materials in ENOVIA
expertise.”
A bright future
SmarTeam ensures easy
access to the most relevant
and up-to-date information
throughout the company.
Langen Packaging constantly
identifies new ways to use
ENOVIA SmarTeam. The
company’s future plans
include expanding the use of ENOVIA SmarTeam to
the Marketing department, which maintains a large
library of videos, photographs, brochures and technical
literature about Langen Packaging’s products.
Storing and managing all of those materials in ENOVIA
SmarTeam will ensure easy access to the most relevant
and up-to-date information throughout the company.
Tokarz says Langen Packaging is also assessing the
ENOVIA SmarTeam Community Workspace module to
provide its customers with Internet access to their own
assemblies and BOMs. He envisions customers using
the same solution for RFQs, and leveraging
it to give vendors access to
product drawings
or to bid on
requirements for
manufacturing
parts.
Tokarz’s satisfaction with Langen’s choice of ENOVIA
SmarTeam has only been enhanced by the level of
support Langen gets from its local Dassault Systèmes
partner AscendBridge.
“AscendBridge’s proximity and responsiveness have
proven to be a tremendous advantage,” he says.
“When we call on AscendBridge, we have someone
brilliant sitting in our building, helping us out, within a
few hours. That is very important because we have put
www.langeninc.com
www.ascendbridge.com
21
05/04/11 12:24
ENOVIA SmarTeam totally in control of our business.
It’s a wonderful product, but it’s important to know that
we have the support we need because we are so
dependent on it.”
Langen Packaging Inc. of Ontario,
Canada, manufactures highly
customized, durable machinery
used to package products that
range from food and durable
goods to cosmetics, paper,
pharmaceuticals and more.
Langen Packaging customizes products
with ENOVIA SmarTeam and Microsoft
T
o build made-to-order equipment, Langen
Packaging needed a robust data engine to
help it start fast and go the distance for its
customers. Starting fast means responding quickly to
new customer requests with accurate quotes and
proposals that build off existing designs, while going
the distance requires the ability
to provide long-term service.
ENOVIA SmarTeam gives us the
This involves maintaining –
ability to retain and track the kind
sometimes over a span of 20
years or more – updated
of customer information that gives
knowledge of a machine’s
us a competitive advantage.
evolving configuration in the field.
Mirek Tokarz
Director of Technology Development
Langen Packaging
20
a project are organized and stored together for future
reference.
What’s more, the flexibility and commonality of the
Microsoft platform has enabled Langen Packaging to
continually expand the use of ENOVIA SmarTeam into
new areas of the business. “SQL Server® 2005 does
what it is supposed to without us really having to
worry about its maintenance,” explains Mirek Tokarz,
Director of Technology Development. “It just works.
Because of its wide use by so many companies, it
also is easier to find support expertise when compared
to other database platforms.”
ENOVIA SmarTeam, coupled
with the Microsoft platform and
Windows® operating system,
answers Langen Packaging’s
needs. By replacing years of custom solution
development with out-of-the box functionality, the
company is now poised for growth.
Langen Packaging has even integrated ENOVIA
SmarTeam with Microsoft Outlook® 2003, which
allows it to capture project-critical emails. Those
emails, including attachments, can be stored and
linked directly to projects, saving time and making
associated documents readily accessible for future
use and quick searches.
Adding value with Microsoft
and Windows
After-sale service easier with strong
BOM tracking
Because ENOVIA SmarTeam operates on the Microsoft
platform, information from a broad range of sources,
including Microsoft® Office applications such as Word
and Excel, can be stored together with product
designs and proposals. This helps ensure all details of
With ENOVIA SmarTeam, Langen Packaging is well
equipped to handle changes in the field. “If our
Aftermarket group needs to introduce changes to a
piece of equipment in the field, their starting base is a
clean bill of material (BOM),” Tokarz explains. “This
BOM can be revised and released back to
manufacturing, and when the cycle is done, we are left
with a revision of the BOM that represents what’s in
the field.”
When a customer calls asking for a spare part or help
with a repair in the field, Langen Packaging’s customer
support teams can access the relevant BOMs and
documents in ENOVIA SmarTeam. With a few simple
clicks they can launch the latest drawing in the viewer,
allowing them to provide customer support on the
machine as it has been maintained and updated over
the years.
Tokarz believes ENOVIA SmarTeam gives Langen
Packaging an advantage over its competitors. “Our
customers know we understand them as a client and
know what their business is all about, even down to
details such as their requirements for a machine a year
ago,” he says. “ENOVIA SmarTeam gives us the ability
to retain and track that kind of customer information
and that gives us a competitive advantage.”
AscendBridge support makes good
choice better
With ENOVIA SmarTeam and AscendBridge, Langen
has freed up significant staff resources that once
supported its legacy system. “Over the years, we had
developed many different databases and maintaining
them created unwanted overhead,” Tokarz says.
“Replacing them with a commercial product that can
easily be supported by
AscendBridge improves our
Storing and managing a large
flexibility and makes us less
dependent on our internal
range of materials in ENOVIA
expertise.”
A bright future
SmarTeam ensures easy
access to the most relevant
and up-to-date information
throughout the company.
Langen Packaging constantly
identifies new ways to use
ENOVIA SmarTeam. The
company’s future plans
include expanding the use of ENOVIA SmarTeam to
the Marketing department, which maintains a large
library of videos, photographs, brochures and technical
literature about Langen Packaging’s products.
Storing and managing all of those materials in ENOVIA
SmarTeam will ensure easy access to the most relevant
and up-to-date information throughout the company.
Tokarz says Langen Packaging is also assessing the
ENOVIA SmarTeam Community Workspace module to
provide its customers with Internet access to their own
assemblies and BOMs. He envisions customers using
the same solution for RFQs, and leveraging
it to give vendors access to
product drawings
or to bid on
requirements for
manufacturing
parts.
Tokarz’s satisfaction with Langen’s choice of ENOVIA
SmarTeam has only been enhanced by the level of
support Langen gets from its local Dassault Systèmes
partner AscendBridge.
“AscendBridge’s proximity and responsiveness have
proven to be a tremendous advantage,” he says.
“When we call on AscendBridge, we have someone
brilliant sitting in our building, helping us out, within a
few hours. That is very important because we have put
www.langeninc.com
21
05/04/11 12:24
TOOLING
Tool & Design Solutions:
]
Pressing ahead
By Nick Lerner
Designing and simulating automotive press tools is both
an art and a science, and success requires a perfect
match of knowledge, expertise and technology.
Tool & Design Solutions, a leading South-African
company, deploys Dassault Systèmes methodologies to
retain and enhance its leading position in the industry.
T
ool & Design Solutions (TDS), based in the
heart of the South-African automotive
industry at Port Elizabeth, has become the
premier supplier of press-tool design in the region.
With more than 20 years’ experience, company
founder and design engineer
Peter Feltham develops
CATIA is the key to
tooling designs and solutions
developing and delivering for an enviable list of local and
optimized design intent. international automotive tierone and tier-two customers.
Initial Impact
Die face compensation based
on simulation springback
results using CATIA realistic
shape optimization
Having trained at General Motors and worked at
Comau, Feltham understands the auto industry’s
need for extreme accuracy, materials control and
process minimization. Feltham explained how this is
achieved: “CATIA Mechanical Shape Optimization
(HCX) is used to model press tool designs using
digital 3D and specialized forming simulation
software. Using Dassault Systèmes technology in
this way, it is possible to reduce the number of tools
and processes needed to press a panel.
This can take up to 30% of time and cost
out of the equation. The rewards of this
working methodology are consequently
significant.”
“The use of new materials and
specialized steels in the
automotive industry increases
complexity.
Hardness,
resistance and springback
have to be accurately
simulated and factored
22
Progression tool design
into the eventual design. Errors are potentially very
costly, with a single press tool worth as much as
20 cars on the forecourt.”
Feltham continued: “CATIA HCX is an ideal tool to
use for this work since it incorporates shape optimizing
features, advanced surfacing and morphing tools
and the facility to easily manipulate press tool
shapes. It is also excellent for sharing visual data
with customers, who are then able to fully visualize
the design and its operation. Their iterated inputs
can be accommodated quickly and easily, ensuring
fully informed sign off.”
Springback
CATIA’s surface-definition technology is fundamental
to the work at TDS, and because CATIA has
become the automotive industry standard design/
development platform, accuracy is ensured. Feltham
commented: “CATIA has become the standard
industry tool because it has no limitations and it
enables design intent to be retained from concept
through to engineering, manufacture – and beyond.
The system’s intelligence means that there is no
shape you can’t make. The system’s Shape
Optimizer allows for accurate adjustment for
compensation of springback, and because this
can be seen graphically, customers can make
better-informed planning choices with a greater
range of engineering options.”
Feltham added: “Timing is crucial in this industry,
and a poorly designed tool or an unnecessary extra
process can add expensively to overall delay and
unforeseen engineering costs. CATIA helps avoid
these problems before they even start, and it is
an excellent tool to deliver the knowledge, skills
and design experience that I have developed
over the years.”
Under Pressure
Dassault Systèmes portfolio of PLM software
(including CATIA) is represented in South-Africa by
CDC, an authorized Dassault Systèmes partner. By
working with Tool and Design Solutions since its
inception, CDC has helped to ensure that Dassault
Systèmes technology is used to its best technical
and commercial advantage. The system was initially
installed by CDC, who also provides training and
support to maintain the software - and its operators
- at the forefront of technological advantage. CDC
acts as an interface with Dassault Systèmes and is
able to understand the newest developments and
advise on their suitability and implementation.
Feltham added, “Despite a retraction of the automotive
business, we have never been so busy. This can be
explained by the efficiencies that CATIA brings to
the automotive industry and the great savings that
can be delivered if the right simulation technology is
deployed. In lean times, companies look harder to
reduce waste, and so require better methodologies
to eliminate it from their processes. 3D digital
simulation allows designs, and the processes
through which they will be put, to be thoroughly
optimized in a way that is not possible with any
other system. Because CATIA is so well able to deal
with the subtleties of press tool design, customers
bring us their most difficult problems, certain that a
better solution is discoverable. In all cases, CATIA
delivers the best result at lower cost and within a
quicker time.”
“The work that CDC and TDS have achieved
together has helped South-African industry to take
a step forward. By showing the benefits of 3D digital
working to other industrial users in the region and
explaining the advantages of Dassault Systèmes
technology, TDS has accelerated progress and
increased overall expertise in the region. As the
economy picks up and demand improves, the
methods that enhance productivity and reduce
waste will persist, and this brings the further benefit
of improved quality. The confidence to make better
engineering and commercial decisions, the
availability of finer tolerances, and getting it right on
the screen with simulation so that it’s right in the
factory, are no longer merely on the wish-list but are
available now, bringing terrific advantage to those
who choose to exploit what is available to today’s
industry.”
www.tooldesign.co.za
www.cdcza.co.za
www.catia.com
L&RH part positions optimized
by laying the flanges out
accurately for this draw die
23
05/04/11 12:24
TOOLING
Tool & Design Solutions:
]
Pressing ahead
By Nick Lerner
Designing and simulating automotive press tools is both
an art and a science, and success requires a perfect
match of knowledge, expertise and technology.
Tool & Design Solutions, a leading South-African
company, deploys Dassault Systèmes methodologies to
retain and enhance its leading position in the industry.
T
ool & Design Solutions (TDS), based in the
heart of the South-African automotive
industry at Port Elizabeth, has become the
premier supplier of press-tool design in the region.
With more than 20 years’ experience, company
founder and design engineer
Peter Feltham develops
CATIA is the key to
tooling designs and solutions
developing and delivering for an enviable list of local and
optimized design intent. international automotive tierone and tier-two customers.
Initial Impact
Die face compensation based
on simulation springback
results using CATIA realistic
shape optimization
Having trained at General Motors and worked at
Comau, Feltham understands the auto industry’s
need for extreme accuracy, materials control and
process minimization. Feltham explained how this is
achieved: “CATIA Mechanical Shape Optimization
(HCX) is used to model press tool designs using
digital 3D and specialized forming simulation
software. Using Dassault Systèmes technology in
this way, it is possible to reduce the number of tools
and processes needed to press a panel.
This can take up to 30% of time and cost
out of the equation. The rewards of this
working methodology are consequently
significant.”
“The use of new materials and
specialized steels in the
automotive industry increases
complexity.
Hardness,
resistance and springback
have to be accurately
simulated and factored
22
Progression tool design
into the eventual design. Errors are potentially very
costly, with a single press tool worth as much as
20 cars on the forecourt.”
Feltham continued: “CATIA HCX is an ideal tool to
use for this work since it incorporates shape optimizing
features, advanced surfacing and morphing tools
and the facility to easily manipulate press tool
shapes. It is also excellent for sharing visual data
with customers, who are then able to fully visualize
the design and its operation. Their iterated inputs
can be accommodated quickly and easily, ensuring
fully informed sign off.”
Springback
CATIA’s surface-definition technology is fundamental
to the work at TDS, and because CATIA has
become the automotive industry standard design/
development platform, accuracy is ensured. Feltham
commented: “CATIA has become the standard
industry tool because it has no limitations and it
enables design intent to be retained from concept
through to engineering, manufacture – and beyond.
The system’s intelligence means that there is no
shape you can’t make. The system’s Shape
Optimizer allows for accurate adjustment for
compensation of springback, and because this
can be seen graphically, customers can make
better-informed planning choices with a greater
range of engineering options.”
Feltham added: “Timing is crucial in this industry,
and a poorly designed tool or an unnecessary extra
process can add expensively to overall delay and
unforeseen engineering costs. CATIA helps avoid
these problems before they even start, and it is
an excellent tool to deliver the knowledge, skills
and design experience that I have developed
over the years.”
Under Pressure
Dassault Systèmes portfolio of PLM software
(including CATIA) is represented in South-Africa by
CDC, an authorized Dassault Systèmes partner. By
working with Tool and Design Solutions since its
inception, CDC has helped to ensure that Dassault
Systèmes technology is used to its best technical
and commercial advantage. The system was initially
installed by CDC, who also provides training and
support to maintain the software - and its operators
- at the forefront of technological advantage. CDC
acts as an interface with Dassault Systèmes and is
able to understand the newest developments and
advise on their suitability and implementation.
Feltham added, “Despite a retraction of the automotive
business, we have never been so busy. This can be
explained by the efficiencies that CATIA brings to
the automotive industry and the great savings that
can be delivered if the right simulation technology is
deployed. In lean times, companies look harder to
reduce waste, and so require better methodologies
to eliminate it from their processes. 3D digital
simulation allows designs, and the processes
through which they will be put, to be thoroughly
optimized in a way that is not possible with any
other system. Because CATIA is so well able to deal
with the subtleties of press tool design, customers
bring us their most difficult problems, certain that a
better solution is discoverable. In all cases, CATIA
delivers the best result at lower cost and within a
quicker time.”
“The work that CDC and TDS have achieved
together has helped South-African industry to take
a step forward. By showing the benefits of 3D digital
working to other industrial users in the region and
explaining the advantages of Dassault Systèmes
technology, TDS has accelerated progress and
increased overall expertise in the region. As the
economy picks up and demand improves, the
methods that enhance productivity and reduce
waste will persist, and this brings the further benefit
of improved quality. The confidence to make better
engineering and commercial decisions, the
availability of finer tolerances, and getting it right on
the screen with simulation so that it’s right in the
factory, are no longer merely on the wish-list but are
available now, bringing terrific advantage to those
who choose to exploit what is available to today’s
industry.”
www.tooldesign.co.za
www.cdcza.co.za
www.catia.com
L&RH part positions optimized
by laying the flanges out
accurately for this draw die
23
05/04/11 12:24
TOOLING
oncours Mold slices cycle times 30%
C
Concours Mold adopted the CATIA for Mold
solution to make complex molds more quickly
and accurately by eliminating repetitive, sequential
processes and validating design functionality in
the virtual stage. Concours Mold reduced the
overall time required to generate molds by 30%
and validates designs virtually before production,
facilitating more complex projects.
“CATIA also offers other advantages over specialpurpose tools, such as its ability to visualize the design
as a rendered solid model.”
Left: Concours Mold specializes in
producing complex molds with thousands
of parts, such as this CATIA model for
the interior of a fascia mold, which forms
an automobile’s front body-skin panel.
Above: The same mold when closed.
W
ith sales of about US $50 million, Concours
Mold of Windsor, Canada, is the fourthlargest moldmaker in North America and
moving up fast. Concours Mold produces large,
complex injection molds used in the production of
automotive components such as fascias, the body-skin
panels at the front of a car. Such molds can feature
thousands of parts, so seeing how the components
operate together is critical to detecting interferences early.
Blazing new mold-making trail with CATIA
24
we were doing part of the design in one software and
part in another,” remembers Luigi Nicoletti, engineering
manager for Concours Mold.
Concours Mold found a better way when it switched
to the CATIA for Mold solution, which performs both
major design functions in the same package, saving
time and eliminating the challenges created by nonconcurrent engineering. As part of CATIA PLM Express,
CATIA for Mold also features ENOVIA SmarTeam data
management capabilities built into every seat.
Today, Concours Mold designers read the customer
geometry, design the mold surfaces and produce the
mold design as solid models within the CATIA PLM
Express environment. The product design is associated
to the mold surfaces, which in turn are associated to
the mold design. As design changes arrive from the
customer, both mold surfaces and product designs
update in parallel, allowing mold design, manufacturing
and assembly to proceed simultaneously for fast designto-prototype production.
Concours Mold designers have leveraged CATIA’s
template-based design approach to capture and apply
consistent, verified company standards to every design.
Concours Mold then customizes these templates to
create variations that reflect the unique requirements of
specific customers. Typical customer standards might
dictate variables such as screw and drill hole sizes and
clearances. By using the customer-specific templates,
Concours Mold quickly and easily ensures that every
project conforms to both its own best practices and
that customer’s unique standards.
Working with 3D solid models also makes it easy to
share designs with customers at any stage in the
process. This helps to identify and correct errors that
otherwise might go unnoticed until manufacturing.
Faster responses win more business
Traditionally, mold makers have used CAD software
to read customer design files and generate mold
surface geometry, then translated the data into
specialized niche software packages to create the mold
design. This required data translation and data checking,
adding delays, increasing the potential for errors, and
requiring new translations with each new design
change from the customer.
Templates ensure consistency, quality
By capturing and leveraging its knowledge in
reusable templates, Concours Mold responds to
customer orders more quickly. When it wins a bid,
designers only need to enter a few refinements to
that customer’s intelligent templates to update the bid
design to the final specification. This reduces delivery
times, helps the company win short-cycle projects, and
ensures high levels of customer satisfaction.
Niche tools also made it difficult to visualize an up-todate design. “We couldn’t see how all the parts fit
together so we could validate the design, because
“With CATIA Knowledgeware templates that are fully
and easily configured, we now have more powerful
capabilities and embedded design standards we just
didn’t get with the previous application,” Nicoletti said.
“As we gain more experience and continue to develop
the templates, we expect to keep reducing our time to
market,” Nicoletti said. For example, the company
“Using CATIA allowed us in our very first attempt to
reduce the number of hours required to design a mold
by 30%, and it costs about the same as far less powerful
tools,” Nicoletti said. “Plus, we knew the design would
work because we had validated it virtually.”
CATIA enables our engineers and our customers
to visualize the proposed mold design in 3D and
present validation or concerns long before we
start building the mold.
Luigi Nicoletti
Engineering Manager, Concours Mold
plans to integrate its design and manufacturing operations
by producing CNC programs directly from intelligent
CATIA templates. “This should automate our process
and reduce manufacturing costs, which account
for 55% of the total cost of a mold,” Nicoletti said.
“And when we implement the ENOVIA SmarTeam
functionality built into CATIA PLM
Express, we will be able to reuse
intellectual property from previous
projects to save even more time
AscendBridge Solutions Inc. is a Canadaand deliver more accurate quotes.”
based engineering consulting, technology
services, and PLM solutions provider to the North American market. Committed to
Nicoletti credits AscendBridge,
delivering process-centric design software,
its Dassault Systèmes Business
product data management, digital
Partner, with helping Concours Mold
manufacturing solutions and proprietary
make a successful transition to
programs, AscendBridge works with its
its all-CATIA strategy. “Ascendclients to increase their competitiveness,
Bridge laid down the foundation
productivity and bottom line. With deep
industry knowledge, Dassault Systèmes
for our successful implementation,”
certified resources and a proven track record,
Nicoletti said. “Their crew mentored
AscendBridge can provide the right people,
our best mold designers to teach
skills and technologies to clients to improve
them how to create templates that
their performance. AscendBridge’s offering
embed best practices and design
includes integrated PLM solutions standards. We agreed upfront on
for product development (CATIA®, DELMIA®,
the objectives and timeline of the
ENOVIA®).
implementation, and AscendBridge
Focus on AscendBridge
surpassed them all.”
www.concoursmold.com
www.catia.com
25
05/04/11 12:24
TOOLING
oncours Mold slices cycle times 30%
C
Concours Mold adopted the CATIA for Mold
solution to make complex molds more quickly
and accurately by eliminating repetitive, sequential
processes and validating design functionality in
the virtual stage. Concours Mold reduced the
overall time required to generate molds by 30%
and validates designs virtually before production,
facilitating more complex projects.
“CATIA also offers other advantages over specialpurpose tools, such as its ability to visualize the design
as a rendered solid model.”
Left: Concours Mold specializes in
producing complex molds with thousands
of parts, such as this CATIA model for
the interior of a fascia mold, which forms
an automobile’s front body-skin panel.
Above: The same mold when closed.
W
ith sales of about US $50 million, Concours
Mold of Windsor, Canada, is the fourthlargest moldmaker in North America and
moving up fast. Concours Mold produces large,
complex injection molds used in the production of
automotive components such as fascias, the body-skin
panels at the front of a car. Such molds can feature
thousands of parts, so seeing how the components
operate together is critical to detecting interferences early.
Blazing new mold-making trail with CATIA
24
we were doing part of the design in one software and
part in another,” remembers Luigi Nicoletti, engineering
manager for Concours Mold.
Concours Mold found a better way when it switched
to the CATIA for Mold solution, which performs both
major design functions in the same package, saving
time and eliminating the challenges created by nonconcurrent engineering. As part of CATIA PLM Express,
CATIA for Mold also features ENOVIA SmarTeam data
management capabilities built into every seat.
Today, Concours Mold designers read the customer
geometry, design the mold surfaces and produce the
mold design as solid models within the CATIA PLM
Express environment. The product design is associated
to the mold surfaces, which in turn are associated to
the mold design. As design changes arrive from the
customer, both mold surfaces and product designs
update in parallel, allowing mold design, manufacturing
and assembly to proceed simultaneously for fast designto-prototype production.
Concours Mold designers have leveraged CATIA’s
template-based design approach to capture and apply
consistent, verified company standards to every design.
Concours Mold then customizes these templates to
create variations that reflect the unique requirements of
specific customers. Typical customer standards might
dictate variables such as screw and drill hole sizes and
clearances. By using the customer-specific templates,
Concours Mold quickly and easily ensures that every
project conforms to both its own best practices and
that customer’s unique standards.
Working with 3D solid models also makes it easy to
share designs with customers at any stage in the
process. This helps to identify and correct errors that
otherwise might go unnoticed until manufacturing.
Faster responses win more business
Traditionally, mold makers have used CAD software
to read customer design files and generate mold
surface geometry, then translated the data into
specialized niche software packages to create the mold
design. This required data translation and data checking,
adding delays, increasing the potential for errors, and
requiring new translations with each new design
change from the customer.
Templates ensure consistency, quality
By capturing and leveraging its knowledge in
reusable templates, Concours Mold responds to
customer orders more quickly. When it wins a bid,
designers only need to enter a few refinements to
that customer’s intelligent templates to update the bid
design to the final specification. This reduces delivery
times, helps the company win short-cycle projects, and
ensures high levels of customer satisfaction.
Niche tools also made it difficult to visualize an up-todate design. “We couldn’t see how all the parts fit
together so we could validate the design, because
“With CATIA Knowledgeware templates that are fully
and easily configured, we now have more powerful
capabilities and embedded design standards we just
didn’t get with the previous application,” Nicoletti said.
“As we gain more experience and continue to develop
the templates, we expect to keep reducing our time to
market,” Nicoletti said. For example, the company
“Using CATIA allowed us in our very first attempt to
reduce the number of hours required to design a mold
by 30%, and it costs about the same as far less powerful
tools,” Nicoletti said. “Plus, we knew the design would
work because we had validated it virtually.”
CATIA enables our engineers and our customers
to visualize the proposed mold design in 3D and
present validation or concerns long before we
start building the mold.
Luigi Nicoletti
Engineering Manager, Concours Mold
plans to integrate its design and manufacturing operations
by producing CNC programs directly from intelligent
CATIA templates. “This should automate our process
and reduce manufacturing costs, which account
for 55% of the total cost of a mold,” Nicoletti said.
“And when we implement the ENOVIA SmarTeam
functionality built into CATIA PLM
Express, we will be able to reuse
intellectual property from previous
projects to save even more time
AscendBridge Solutions Inc. is a Canadaand deliver more accurate quotes.”
based engineering consulting, technology
services, and PLM solutions provider to the North American market. Committed to
Nicoletti credits AscendBridge,
delivering process-centric design software,
its Dassault Systèmes Business
product data management, digital
Partner, with helping Concours Mold
manufacturing solutions and proprietary
make a successful transition to
programs, AscendBridge works with its
its all-CATIA strategy. “Ascendclients to increase their competitiveness,
Bridge laid down the foundation
productivity and bottom line. With deep
industry knowledge, Dassault Systèmes
for our successful implementation,”
certified resources and a proven track record,
Nicoletti said. “Their crew mentored
AscendBridge can provide the right people,
our best mold designers to teach
skills and technologies to clients to improve
them how to create templates that
their performance. AscendBridge’s offering
embed best practices and design
includes integrated PLM solutions standards. We agreed upfront on
for product development (CATIA®, DELMIA®,
the objectives and timeline of the
ENOVIA®).
implementation, and AscendBridge
Focus on AscendBridge
surpassed them all.”
www.concoursmold.com
www.catia.com
25
05/04/11 12:24
Manufacturing process
An advanced factory of the future and manufacturing
research centre explores, develops and implements
optimized production procedures for industry using
Dassault Systèmes PLM solutions to bring technical,
environmental and commercial benefits.
]
Catia model developed
by AMRC
By Nick Lerner
AMRC: A fine example
to manufacturing industry
T
he University of Sheffield’s Advanced
Manufacturing Research Centre (AMRC) with
Boeing explores the use of new tools and
techniques for advanced manufacturing for its industryleading partners. With over 90 staff and availability
of the remarkable Rolls-Royce Factory of the Future,
the AMRC develops and consults on introducing
optimized equipment and processes for industry.
We can quickly realize and
implement the most beneficial
whole system adjustments
at our industrial partners’ sites,
without the disruption that
this would entail were it
done in-house.
Rob Carroll
AMRC Project Manager
26
Techniques are refined in the
Factory of the Future using
on-site advanced machine
tools and Dassault Systèmes
CATIA, DELMIA and 3DVIA
technology. Solutions are
found for industry that industry
itself often does not have
the time, expertise or capability
to develop.
Making Introductions
Rab Scott, Head of IT at AMRC,
explained the organization’s
work: “Industrial partners come to us with problems
because we have the culture, capability, capacity and
commitment to investigate and resolve them. A recent
example for a major aerospace undercarriage tier
one supplier helped them to win a valuable contract.
This was achieved using CATIA to digitally examine
potential production methodologies, and accurately
calculate production times. Having helped win the
contract, AMRC subsequently helped implement
the new methodology for the aerospace supplier
with great success.”
Scott continued, “Customers often present us with a
blank canvas on which we create a methodology
using our experience and tools. The best solution
may involve a complete mindset change involving
assessment, optimization of processes and the
appliance of best practices. We have achieved up
to 95% process-time reduction, which are initially
proved out in the Factory of the Future then transitioned
to industry.”
Blank Canvas
AMRC uses DELMIA QUEST to digitally plan optimized
factory layouts that calibrate and iterate process flow,
health and safety, best use of capital equipment and
robot simulation. Ben Kitcher, Technical Lead, Factory
Planning, at AMRC explained its usage : “There are
always efficiencies to be made in any process because
technology, materials and techniques move on. We
use DELMIA to develop continual improvement, which
is transferred to industry once the strategy and tactics
have been fully proven both digitally and physically.”
Rob Carroll, AMRC Project Manager added, “CATIA
is used at AMRC to create digital prismatic parts, thin
wall five-axis forms and large aerospace assemblies.
We utilise CATIA to improve machining process
strategy by optimizing tool paths. Dynamic profiles
of machines can be improved so that they cut
and create surfaces faster. This is done using
accelerometers and other equipment to find spindle
speeds that reduce vibration and stabilize the
machine. This allows tools to operate at maximum
speed, optimum cut depth and greatest overall
efficiency. Having done this work at AMRC we can
quickly realize and implement the most beneficial
whole system adjustments at our industrial partners’
sites, without the disruption that this would entail
were it done in-house.”
Using Dassault Systèmes PLM, AMRC is able to
investigate theoretical, virtual and physical production
scenarios by digitally modelling systems and processes.
In many cases this saves industry the cost of buying
new equipment because existing facilities can be
made to work a lot more efficiently through better
understanding their functionality and making appropriate
modifications to it.
Composed Presentation
AMRC makes great use of Dassault Systèmes 3DVIA
Composer, finding its facility to develop training and other
scenarios of very high value to its work. Scott described
the benefit of its use: “3DVIA Composer enables us to
look at single parts and assemblies in context and to
consider in 3D their assembly procedure and its
optimization. It also allows us to find design faults that
could adversely affect other operations and to correct
them before the damage is done. 3DVIA Composer’s
manipulation capability allows us to design for assembly
and maintenance as well as providing very high levels
of digital communication interactivity in 3D.”
best use and development. Applied trains AMRC
staff, runs seminars and troubleshoots as well as
advising on new software and the value of its
implementation. Scott commented: “It is sometimes
difficult to stay up to date with all the latest advances
and developments in PLM, but with Applied on
the team we know that software to improve our
facilities will be properly evaluated for its suitability
and potential benefits.”
AMRC is an exemplar of best engineering practice,
providing experienced guidance to major global
enterprises. They are strong advocates of Dassault
Systèmes PLM, and through close involvement have
been influential on PLM developments by providing
valuable feedback based on the deep knowledge
that has developed from working with their industrial
partners.
www.amrc.co.uk
www.appliedgroup.co.uk
DELMIA Quest production
cell simulation
This is possible because 3DVIA Composer is able to
provide secure but accessible 3D digital models in a
format that allows stakeholders to manipulate and
mark them up. In this role it greatly helps with training,
simulated manipulation and moving views from single
parts to final assembly.
Instrumental in the development of AMRC has been
the involvement of Dassault Systèmes’ partner
Applied PLM Solutions. Applied introduced and has
provided training and support for AMRC‘s Dassault
Systèmes PLM installation and also consults on its
27
05/04/11 12:24
An advanced factory of the future and manufacturing
research centre explores, develops and implements
optimized production procedures for industry using
Dassault Systèmes PLM solutions to bring technical,
environmental and commercial benefits.
]
Catia model developed
by AMRC
By Nick Lerner
AMRC: A fine example
to manufacturing industry
T
he University of Sheffield’s Advanced
Manufacturing Research Centre (AMRC) with
Boeing explores the use of new tools and
techniques for advanced manufacturing for its industryleading partners. With over 90 staff and availability
of the remarkable Rolls-Royce Factory of the Future,
the AMRC develops and consults on introducing
optimized equipment and processes for industry.
We can quickly realize and
implement the most beneficial
whole system adjustments
at our industrial partners’ sites,
without the disruption that
this would entail were it
done in-house.
Rob Carroll
AMRC Project Manager
26
Techniques are refined in the
Factory of the Future using
on-site advanced machine
tools and Dassault Systèmes
CATIA, DELMIA and 3DVIA
technology. Solutions are
found for industry that industry
itself often does not have
the time, expertise or capability
to develop.
Making Introductions
Rab Scott, Head of IT at AMRC,
explained the organization’s
work: “Industrial partners come to us with problems
because we have the culture, capability, capacity and
commitment to investigate and resolve them. A recent
example for a major aerospace undercarriage tier
one supplier helped them to win a valuable contract.
This was achieved using CATIA to digitally examine
potential production methodologies, and accurately
calculate production times. Having helped win the
contract, AMRC subsequently helped implement
the new methodology for the aerospace supplier
with great success.”
Scott continued, “Customers often present us with a
blank canvas on which we create a methodology
using our experience and tools. The best solution
may involve a complete mindset change involving
assessment, optimization of processes and the
appliance of best practices. We have achieved up
to 95% process-time reduction, which are initially
proved out in the Factory of the Future then transitioned
to industry.”
Blank Canvas
AMRC uses DELMIA QUEST to digitally plan optimized
factory layouts that calibrate and iterate process flow,
health and safety, best use of capital equipment and
robot simulation. Ben Kitcher, Technical Lead, Factory
Planning, at AMRC explained its usage : “There are
always efficiencies to be made in any process because
technology, materials and techniques move on. We
use DELMIA to develop continual improvement, which
is transferred to industry once the strategy and tactics
have been fully proven both digitally and physically.”
Rob Carroll, AMRC Project Manager added, “CATIA
is used at AMRC to create digital prismatic parts, thin
wall five-axis forms and large aerospace assemblies.
We utilise CATIA to improve machining process
strategy by optimizing tool paths. Dynamic profiles
of machines can be improved so that they cut
and create surfaces faster. This is done using
accelerometers and other equipment to find spindle
speeds that reduce vibration and stabilize the
machine. This allows tools to operate at maximum
speed, optimum cut depth and greatest overall
efficiency. Having done this work at AMRC we can
quickly realize and implement the most beneficial
whole system adjustments at our industrial partners’
sites, without the disruption that this would entail
were it done in-house.”
Using Dassault Systèmes PLM, AMRC is able to
investigate theoretical, virtual and physical production
scenarios by digitally modelling systems and processes.
In many cases this saves industry the cost of buying
new equipment because existing facilities can be
made to work a lot more efficiently through better
understanding their functionality and making appropriate
modifications to it.
Composed Presentation
AMRC makes great use of Dassault Systèmes 3DVIA
Composer, finding its facility to develop training and other
scenarios of very high value to its work. Scott described
the benefit of its use: “3DVIA Composer enables us to
look at single parts and assemblies in context and to
consider in 3D their assembly procedure and its
optimization. It also allows us to find design faults that
could adversely affect other operations and to correct
them before the damage is done. 3DVIA Composer’s
manipulation capability allows us to design for assembly
and maintenance as well as providing very high levels
of digital communication interactivity in 3D.”
best use and development. Applied trains AMRC
staff, runs seminars and troubleshoots as well as
advising on new software and the value of its
implementation. Scott commented: “It is sometimes
difficult to stay up to date with all the latest advances
and developments in PLM, but with Applied on
the team we know that software to improve our
facilities will be properly evaluated for its suitability
and potential benefits.”
AMRC is an exemplar of best engineering practice,
providing experienced guidance to major global
enterprises. They are strong advocates of Dassault
Systèmes PLM, and through close involvement have
been influential on PLM developments by providing
valuable feedback based on the deep knowledge
that has developed from working with their industrial
partners.
www.amrc.co.uk
www.appliedgroup.co.uk
DELMIA Quest production
cell simulation
This is possible because 3DVIA Composer is able to
provide secure but accessible 3D digital models in a
format that allows stakeholders to manipulate and
mark them up. In this role it greatly helps with training,
simulated manipulation and moving views from single
parts to final assembly.
Instrumental in the development of AMRC has been
the involvement of Dassault Systèmes’ partner
Applied PLM Solutions. Applied introduced and has
provided training and support for AMRC‘s Dassault
Systèmes PLM installation and also consults on its
27
05/04/11 12:24
Virtual representation of
robot inspection in DELMIA
Robot inspects and welds
sandwich cone structure
FORCE Technology simulates
inspection devices with DELMIA
Cycle Time Performance
Plant maintenance often requires operators to shut down a plant during inspection and repairs.
Shortening downtime reduces the costs inherent with production interruption. FORCE Technology
uses simulation to pre-test its inspection devices in a virtual environment to ensure that its
equipment is designed to perform right the first time.
P
eriodic testing for wear and potential
damage is a requirement that all plants must
respect. Non-destructive testing makes
it possible to examine the condition or the quality
of an object without damaging it.
Used preventively and to improve
safety, non-destructive testing helps
avoid interruptions and breakdowns
in production, and can often be
Specialists in non-destructive testing of structures,
performed without production
products and materials, FORCE Technology has
interruptions.
more than 60 years of experience inspecting power
plants, pressure tanks, bridges, pipeline systems,
It is used in many different businesses
storage tanks and ships around the world. In
and industries, including energy,
addition to performing inspections, FORCE
Technology designs and builds the equipment used
offshore, construction, chemical and
to carry out these inspections. Based in Brøndby,
petrochemical. While some checks
Denmark, FORCE Technology operates subsidiaries
can be done during plant operation
in Sweden, Norway, USA and Russia and has more
(such as inspecting a pipe’s exterior)
than 1,000 highly skilled employees worldwide.
others may require shutting down the
plant, which can be extremely costly.
FORCE Technology in brief
28
Inspection experts
for the heavy industry
Built on a solid foundation with more than 60 years of
experience, FORCE Technology focuses on product
and concept development, design, production
optimization and operation, and maintenance of
industrial facilities.
Since downtime in any plant is expensive, FORCE
Technology needs to verify beforehand that its
devices work right the first time. There is no time
to modify a device once in operation. “We need to go
in and get the job done quickly so that the plant can
start up as soon as possible,” explained Christian
Brandt Lauritzen, project manager, FORCE Technology.
“It simply has to work right the first time.”
Virtual simulation
for a custom-made device
FORCE Technology relies on CATIA PLM Express
and DELMIA Cycle Time Performance to design and
test special-design equipment before it is manufactured.
“We do a feasibility study to see how big the device
or manipulator can be, how we get it in and how
we get it out,” Lauritzen said. “We receive from the
customer the geometry of the pipe or object to
inspect and import this data into CATIA PLM Express.
We then design the manipulator and use DELMIA
to virtually simulate it in operation.” Each manipulator
is unique and tailored to a customer situation, which
is why physical prototypes are not created. “It’s
a one-of-a-kind production,” he added.
Optimal performance of a device
With the help of DELMIA, FORCE Technology equipment
can be designed to obtain the best possible results
during an inspection. In effect, simulation with
DELMIA helps FORCE Technology optimize the
nominal cycle time of a manipulator as well as its
performance, eliminate collisions during the simulation
phase, and implement design changes early and
quickly. “In the past, we could not see problems
before the machine was built,” Laurizen said.
“But with DELMIA, we foresee the problems early
and can correct the design, confident that when it
will be built, it will not generate errors. Ramp-up time
is faster thanks to DELMIA.”
Sales success rate has gone up
3D DELMIA animations of the proposed solution help
FORCE Technology’s sales force communicate more
effectively, replacing documents and words with
a visual experience. “It helps build customer
confidence,” Lauritzen said.
Manipulators are expensive equipment and
customers need to know that FORCE Technology
can handle the job. And the 3DXML Player, currently
used by the sales force to communicate with one
another, will soon be extended to production to show
how a manipulator should be assembled. “This will
promote better collaboration between the design
and production departments,” Lauritzen commented.
Adaptable nozzle
inspection system
“Before, we opted for one-of-a-kind components for
each project, but over the years we have been using
more and more standard components, which we can
equip with different tooling depending on what needs
to be inspected,” Lauritzen said. “We are creating a
database that contains all our standard components
and their associated specifications so that everyone
will know which components to use. Thanks to
ENOVIA SmarTeam, the data will be readily available
to them.”
With DELMIA, we foresee the
Collaborating on the same
problems early and can correct
model is another short-term
the design, confident that when it
goal for FORCE Technology.
“We already had cases
will be built, it will not generate
where one developer was
errors. Ramp-up time is faster.
working on a model and
another was working on the
Christian Brandt Lauritzen
same model, which resulted
Project Manager
in conflicting data problems,” Lauritzen explained. “We
FORCE Technology
definitely want to have more people collaborating
on the same model simultaneously; this will be
possible with ENOVIA SmarTeam”.
www.force.dk
www.delmia.com
From one-of-a-kind to standard
reusable components
CATIA PLM Express, with its integrated ENOVIA
SmarTeam capabilities, is important to FORCE
Technology since production has increased over the
years and a more standard data structure is necessary.
29
05/04/11 12:24
Virtual representation of
robot inspection in DELMIA
FORCE Technology simulates
inspection devices with DELMIA
Cycle Time Performance
Plant maintenance often requires operators to shut down a plant during inspection and repairs.
Shortening downtime reduces the costs inherent with production interruption. FORCE Technology
uses simulation to pre-test its inspection devices in a virtual environment to ensure that its
equipment is designed to perform right the first time.
P
eriodic testing for wear and potential
damage is a requirement that all plants must
respect. Non-destructive testing makes
it possible to examine the condition or the quality
of an object without damaging it.
Used preventively and to improve
safety, non-destructive testing helps
avoid interruptions and breakdowns
in production, and can often be
Specialists in non-destructive testing of structures,
performed without production
products and materials, FORCE Technology has
interruptions.
more than 60 years of experience inspecting power
plants, pressure tanks, bridges, pipeline systems,
It is used in many different businesses
storage tanks and ships around the world. In
and industries, including energy,
addition to performing inspections, FORCE
Technology designs and builds the equipment used
offshore, construction, chemical and
to carry out these inspections. Based in Brøndby,
petrochemical. While some checks
Denmark, FORCE Technology operates subsidiaries
can be done during plant operation
in Sweden, Norway, USA and Russia and has more
(such as inspecting a pipe’s exterior)
than 1,000 highly skilled employees worldwide.
others may require shutting down the
plant, which can be extremely costly.
FORCE Technology in brief
28
Inspection experts
for the heavy industry
Built on a solid foundation with more than 60 years of
experience, FORCE Technology focuses on product
and concept development, design, production
optimization and operation, and maintenance of
industrial facilities.
Since downtime in any plant is expensive, FORCE
Technology needs to verify beforehand that its
devices work right the first time. There is no time
to modify a device once in operation. “We need to go
in and get the job done quickly so that the plant can
start up as soon as possible,” explained Christian
Brandt Lauritzen, project manager, FORCE Technology.
“It simply has to work right the first time.”
Virtual simulation
for a custom-made device
FORCE Technology relies on CATIA PLM Express
and DELMIA Cycle Time Performance to design and
test special-design equipment before it is manufactured.
“We do a feasibility study to see how big the device
or manipulator can be, how we get it in and how
we get it out,” Lauritzen said. “We receive from the
customer the geometry of the pipe or object to
inspect and import this data into CATIA PLM Express.
We then design the manipulator and use DELMIA
to virtually simulate it in operation.” Each manipulator
is unique and tailored to a customer situation, which
is why physical prototypes are not created. “It’s
a one-of-a-kind production,” he added.
Optimal performance of a device
With the help of DELMIA, FORCE Technology equipment
can be designed to obtain the best possible results
during an inspection. In effect, simulation with
DELMIA helps FORCE Technology optimize the
nominal cycle time of a manipulator as well as its
performance, eliminate collisions during the simulation
phase, and implement design changes early and
quickly. “In the past, we could not see problems
before the machine was built,” Laurizen said.
“But with DELMIA, we foresee the problems early
and can correct the design, confident that when it
will be built, it will not generate errors. Ramp-up time
is faster thanks to DELMIA.”
Sales success rate has gone up
3D DELMIA animations of the proposed solution help
FORCE Technology’s sales force communicate more
effectively, replacing documents and words with
a visual experience. “It helps build customer
confidence,” Lauritzen said.
Manipulators are expensive equipment and
customers need to know that FORCE Technology
can handle the job. And the 3DXML Player, currently
used by the sales force to communicate with one
another, will soon be extended to production to show
how a manipulator should be assembled. “This will
promote better collaboration between the design
and production departments,” Lauritzen commented.
Adaptable nozzle
inspection system
“Before, we opted for one-of-a-kind components for
each project, but over the years we have been using
more and more standard components, which we can
equip with different tooling depending on what needs
to be inspected,” Lauritzen said. “We are creating a
database that contains all our standard components
and their associated specifications so that everyone
will know which components to use. Thanks to
ENOVIA SmarTeam, the data will be readily available
to them.”
With DELMIA, we foresee the
Collaborating on the same
problems early and can correct
model is another short-term
the design, confident that when it
goal for FORCE Technology.
“We already had cases
will be built, it will not generate
where one developer was
errors. Ramp-up time is faster.
working on a model and
another was working on the
Christian Brandt Lauritzen
same model, which resulted
Project Manager
in conflicting data problems,” Lauritzen explained. “We
FORCE Technology
definitely want to have more people collaborating
on the same model simultaneously; this will be
possible with ENOVIA SmarTeam”.
www.force.dk
www.delmia.com
From one-of-a-kind to standard
reusable components
CATIA PLM Express, with its integrated ENOVIA
SmarTeam capabilities, is important to FORCE
Technology since production has increased over the
years and a more standard data structure is necessary.
29
05/04/11 12:24
Taira Promote:
Next-generation online i-manuals
i-manual view of a plant system
Taira Promote, a technical content creator for
automotive, machinery and other engineering
products, is redefining the concept of manuals
with its i-manuals online visual media. Created
with 3DVIA Virtools and 3DVIA Composer,
i-manuals leverage 3D design data and are
a user-friendly and unique way to benefit
from realistic and interactive content.
C
make any changes and to enable interactive
communication between the creator and the end
user. To achieve these objectives, Taira Promote
set up a system where data provided by its clients
is stored in a database so that the online visual
manuals can be created efficiently. A user can easily
download necessary data from the database and
use it in 3DVIA Virtools and 3DVIA Composer to
create manuals, disassembly instructions, factory
assembly instructions and training materials.
i-manuals contain advanced visual elements that
improve user understanding over traditional online
manuals that mainly use text and still images. Taira
Promote has developed its i-manuals using 3DVIA
Virtools and 3DVIA Composer, based on 3D design
data. “By combining the 3DVIA Virtools 3D data
handling functions with its strong programming
capabilities, we have been able to create a new
type of interactive manual that enables quick and
intelligent responses to user needs,” said Tomoyasu
Taira, Managing Director, Taira Promote.
Design changes no longer an issue
Intuitive data handling
In the past, CAD model formats had to be
converted with various tools in order to be used
for animation creation with CG software. If the
conversion tools were not available for a particular
system, the 3D CAD data could not be used.
As a result, many people had to be involved during
the creation process and various intermediate
formats had to be used. This multi-step process
increased the chance for errors as well as the
overall processing time for modifications when
there were design changes. “By using 3DVIA
Virtools and 3DVIA Composer, a lot of mistakes can
be avoided since digital CAD data can be directly
incorporated by the system,” said Takahiro Kano,
Director, Engineering Division, Taira Promote. “Text
can be added for explanations, along with crosssection and interior structure views, to quickly
create a user-friendly online visual manual.”
“With 3DVIA Composer, we can manage the
geometrical data and the animation scenarios
separately, making file management easy while
having the flexibility to handle design changes.
Customers are also happy because data can be
used “in an intuitive manner,” commented Kano.
Using intelligent diagrams to
significantly improve repair work
i-manuals are used for truck wiring repair and
maintenance work at Hino Motors, Ltd. Conventional
wiring diagrams do not indicate clearly where wires
are placed in the vehicle, making it difficult to know
where to connect a certain connector pin. Using the
power of 3D navigation with i-manuals, users are
now able to use the online system to see enhanced
visualization of the wiring diagram in both 2D and
3D, just by entering truck model codes. Users can
manipulate and rotate the wiring diagrams so that
they can see the diagrams from any angle, helping
to improve the comprehension of the complex
wiring system.
The i-manuals product fulfills three Taira Promote
objectives: to enable a comprehensive understanding
at a glance, to utilize design data without having to
30
Using the power of 3D navigation with
i-manuals, users can manipulate and
rotate the wiring diagrams so that they
can see the diagrams from any angle,
helping to improve the comprehension
of the complex wiring system.
ompanies that are looking for ways to
accelerate the learning speed of their
employees can implement online visual
manuals that accurately represent technical and
complex information to facilitate comprehension. By
incorporating visual elements such as illustrations,
lightweight 3D design data, real-time rendering and
CG animation into a new online visual format called
‘i-manuals’, Taira Promote has earned itself a solid
reputation in the user documentation market.
“3DVIA Virtools is fascinating because of its strong
simulation technology, programming functions and
API,” Kano said. “Its compatability with CATIA and
other Dassault Systèmes products supports our
i-manuals concept of utilizing design data without
making any changes. With 3DVIA, we can also
set up links to external equipment. For example,
by connecting a wrench equipped with a torque
sensor, it is possible to check whether the worker
is following the instructions and tightening the bolt
with the correct torque.”
“In the future, we wish to leverage the scalability of
3DVIA Virtools by promoting better exchange with
other systems. With a vehicle diagnostic machine,
for example, we can provide automatic visualization
of the area needing repair so that the user can order
parts instantly,” concluded Kano.
Hino Motors, Ltd.’s wiring diagram
of a truck. Drawings are available
in both 2D and 3D, while interactive
operation offers a precise wire
connection view.
For more information: www.3dvia.com
Taira Promote in brief
Japan’s Taira Promote Co., Ltd. specializes in the creation of technical media including
training, instruction manuals, and presentation
materials. Taira Promote was founded in 1964
and has since grown to a 103-employee company that creates online visual manuals to provide users with greater learning efficiency
thanks to their interactivity and visual appeal.
31
05/04/11 12:24
Taira Promote:
Next-generation online i-manuals
Taira Promote, a technical content creator for
automotive, machinery and other engineering
products, is redefining the concept of manuals
with its i-manuals online visual media. Created
with 3DVIA Virtools and 3DVIA Composer,
i-manuals leverage 3D design data and are
a user-friendly and unique way to benefit
from realistic and interactive content.
C
make any changes and to enable interactive
communication between the creator and the end
user. To achieve these objectives, Taira Promote
set up a system where data provided by its clients
is stored in a database so that the online visual
manuals can be created efficiently. A user can easily
download necessary data from the database and
use it in 3DVIA Virtools and 3DVIA Composer to
create manuals, disassembly instructions, factory
assembly instructions and training materials.
i-manuals contain advanced visual elements that
improve user understanding over traditional online
manuals that mainly use text and still images. Taira
Promote has developed its i-manuals using 3DVIA
Virtools and 3DVIA Composer, based on 3D design
data. “By combining the 3DVIA Virtools 3D data
handling functions with its strong programming
capabilities, we have been able to create a new
type of interactive manual that enables quick and
intelligent responses to user needs,” said Tomoyasu
Taira, Managing Director, Taira Promote.
Design changes no longer an issue
Intuitive data handling
In the past, CAD model formats had to be
converted with various tools in order to be used
for animation creation with CG software. If the
conversion tools were not available for a particular
system, the 3D CAD data could not be used.
As a result, many people had to be involved during
the creation process and various intermediate
formats had to be used. This multi-step process
increased the chance for errors as well as the
overall processing time for modifications when
there were design changes. “By using 3DVIA
Virtools and 3DVIA Composer, a lot of mistakes can
be avoided since digital CAD data can be directly
incorporated by the system,” said Takahiro Kano,
Director, Engineering Division, Taira Promote. “Text
can be added for explanations, along with crosssection and interior structure views, to quickly
create a user-friendly online visual manual.”
“With 3DVIA Composer, we can manage the
geometrical data and the animation scenarios
separately, making file management easy while
having the flexibility to handle design changes.
Customers are also happy because data can be
used “in an intuitive manner,” commented Kano.
Using intelligent diagrams to
significantly improve repair work
i-manuals are used for truck wiring repair and
maintenance work at Hino Motors, Ltd. Conventional
wiring diagrams do not indicate clearly where wires
are placed in the vehicle, making it difficult to know
where to connect a certain connector pin. Using the
power of 3D navigation with i-manuals, users are
now able to use the online system to see enhanced
visualization of the wiring diagram in both 2D and
3D, just by entering truck model codes. Users can
manipulate and rotate the wiring diagrams so that
they can see the diagrams from any angle, helping
to improve the comprehension of the complex
wiring system.
The i-manuals product fulfills three Taira Promote
objectives: to enable a comprehensive understanding
at a glance, to utilize design data without having to
30
Using the power of 3D navigation with
i-manuals, users can manipulate and
rotate the wiring diagrams so that they
can see the diagrams from any angle,
helping to improve the comprehension
of the complex wiring system.
ompanies that are looking for ways to
accelerate the learning speed of their
employees can implement online visual
manuals that accurately represent technical and
complex information to facilitate comprehension. By
incorporating visual elements such as illustrations,
lightweight 3D design data, real-time rendering and
CG animation into a new online visual format called
‘i-manuals’, Taira Promote has earned itself a solid
reputation in the user documentation market.
“3DVIA Virtools is fascinating because of its strong
simulation technology, programming functions and
API,” Kano said. “Its compatability with CATIA and
other Dassault Systèmes products supports our
i-manuals concept of utilizing design data without
making any changes. With 3DVIA, we can also
set up links to external equipment. For example,
by connecting a wrench equipped with a torque
sensor, it is possible to check whether the worker
is following the instructions and tightening the bolt
with the correct torque.”
“In the future, we wish to leverage the scalability of
3DVIA Virtools by promoting better exchange with
other systems. With a vehicle diagnostic machine,
for example, we can provide automatic visualization
of the area needing repair so that the user can order
parts instantly,” concluded Kano.
Hino Motors, Ltd.’s wiring diagram
of a truck. Drawings are available
in both 2D and 3D, while interactive
operation offers a precise wire
connection view.
For more information: www.3dvia.com
Taira Promote in brief
Japan’s Taira Promote Co., Ltd. specializes in the creation of technical media including
training, instruction manuals, and presentation
materials. Taira Promote was founded in 1964
and has since grown to a 103-employee company that creates online visual manuals to provide users with greater learning efficiency
thanks to their interactivity and visual appeal.
31
05/04/11 12:24
To promote collaboration and innovation and maximize the use
of its manufacturing equipment assets, industrial equipment
maker Enquip chose Dassault Systèmes’ CATIA and ENOVIA.
The company has standardized manufacturing processes,
reduced overall manufacturing costs, and realized significant
gains in productivity, thereby shortening product delivery times.
Enquip improves manufacturing performance
Miller Formless
makes short work
of service manuals
with 3DVIA Composer
B
With nearly four decades of experience, Miller Formless knows that when it comes to working
with concrete, saving time is extremely important. The company, based in McHenry, Illinois, has
been manufacturing concrete slip-form paving equipment for road, curb, barrier, and sidewalk
construction since 1970. That’s why the company recently purchased 3DVIA Composer to create
content for its parts and service manuals and develop 3D interactive assembly instructions more
efficiently and cost-effectively.
We purchased 3DVIA Composer because of the
interface with SolidWorks, which is so smooth
and seamless; it works extremely well.
Jim Szamlewski
Vice President of Manufacturing and
Engineering, Miller Formless Company
P
rior to 3DVIA Composer, technical
illustrators at Miller Formless
Company relied on a competitive
solution that was difficult to use and time
consuming.
“The interface between that tool and our
CAD system was very cumbersome,” says
Jim Szamlewski, vice president of
Manufacturing and Engineering. “We
purchased 3DVIA Composer because of the
interface with SolidWorks, which is so
32
smooth and seamless; it
works extremely well.”
Before adopting 3DVIA
Composer, technical
illustrators at Miller
Formless had to wait for
engineers to convert their
design data into STEP
format before they could
begin working with it in their former technical
illustration tool. Now, with 3DVIA Composer,
technical illustrators can easily pull their
SolidWorks CAD data directly into 3DVIA
Composer in a single step. This saves time
for both the technical illustrators and the
engineers, who can now focus on design
rather than on providing data for
documentation.
“With 3DVIA Composer, the 3D data is
easily accessible to the technical illustrator,
mobile equipment
and so is the bill of material information,”
Szamlewski said. “With 3DVIA Composer,
the bill of material information is available
automatically.”
But speed and efficiency aren’t the only
benefits Miller Formless realized when it
moved to 3DVIA Composer. The solution is
also fast and easy to learn and fun to use.
Just two weeks after installing the software,
technical illustrators at Miller Formless were
generating content using 3DVIA Composer
and enjoying improved productivity. “Our
technical illustrators are actually excited
about having this product to do their job,”
Szamlewski said. ”This has translated into
even more productivity for the company”.
www.millerformless.com
www.3dmojo.com
razilian company Enquip, located in
the southeastern state of Rio de
Janeiro, develops and manufactures
industrial equipment for use in cargo handling
solutions and products, including hydraulic
winches and electric or pneumatic telescopic
cranes used in the energy, shipbuilding and
construction industries. Certified ISO 9001,
Enquip has invested in technology solutions
with an eye toward sustainable development.
In its efforts to optimize manufacturing
processes and use of existing hardware and
machines, Enquip faced a key challenge –
how to expand and improve management of
its engineering data, a function that was
previously limited due to integration and
programming issues with production
equipment. In 2009, Enquip chose CATIA
and ENOVIA SmarTeam to improve its
technology in the areas of product design,
finite element simulations, kinematics
analysis, and parametric detailing in
production. Enquip required an integrated
PLM solution that was robust, came with
technical support, and was easy to integrate
into existing software solutions. The
implementation and rollout of these solutions
was done by Dassault Systèmes and
Tecmes, its business partner in Brazil.
improvement in overall manufacturing
performance and a significant step forward
in the quality of our products, all resulting
in the improved use of our machines,” said
Marcello Pecci, Plant Manager, Enquip. The
optimization of CNC programs has also
resulted in better use of machine resources
and a more dedicated and trimmed
production cycle.
Performance improves by 30%
By integrating all manufacturing processes
into a single workflow, the company now has
a “best practices” model that protects its
intellectual property and allows Enquip to
reuse successful manufacturing processes in
other areas. The Dassault Systèmes’ PLM
solution also allows Enquip to quickly alter
product designs throughout manufacturing in
order to comply with any last-minute market
changes or industry requirements.
With the Dassault Systèmes PLM solution,
Enquip now manages the development of
manufacturing equipment virtually, but also
validates manufacturing operations first using
simulation to test the operation of the
machines and the processes beforehand.
“With CATIA and ENOVIA, we noticed a 30%
Optimized use of resources
With an accurate design plan, which was
tested virtually, Enquip made better use of its
raw materials and avoided environmental
waste. Complex geometrical models that
before required a great deal of programming
time became easier to execute. As a result,
the machining cycle per part produced was
cut significantly. The time savings translate
into increased resources that can be
invested in the development of new
products. “The results attained were
exceptional and exceeded expectations,”
said Pecci. “The new PLM rollout was a
success and it positively impacted the entire
organization.”
www.enquip.com.br
33
05/04/11 12:24
To promote collaboration and innovation and maximize the use
of its manufacturing equipment assets, industrial equipment
maker Enquip chose Dassault Systèmes’ CATIA and ENOVIA.
The company has standardized manufacturing processes,
reduced overall manufacturing costs, and realized significant
gains in productivity, thereby shortening product delivery times.
Enquip improves manufacturing performance
Miller Formless
makes short work
of service manuals
with 3DVIA Composer
B
With nearly four decades of experience, Miller Formless knows that when it comes to working
with concrete, saving time is extremely important. The company, based in McHenry, Illinois, has
been manufacturing concrete slip-form paving equipment for road, curb, barrier, and sidewalk
construction since 1970. That’s why the company recently purchased 3DVIA Composer to create
content for its parts and service manuals and develop 3D interactive assembly instructions more
efficiently and cost-effectively.
We purchased 3DVIA Composer because of the
interface with SolidWorks, which is so smooth
and seamless; it works extremely well.
Jim Szamlewski
Vice President of Manufacturing and
Engineering, Miller Formless Company
P
rior to 3DVIA Composer, technical
illustrators at Miller Formless
Company relied on a competitive
solution that was difficult to use and time
consuming.
“The interface between that tool and our
CAD system was very cumbersome,” says
Jim Szamlewski, vice president of
Manufacturing and Engineering. “We
purchased 3DVIA Composer because of the
interface with SolidWorks, which is so
32
smooth and seamless; it
works extremely well.”
Before adopting 3DVIA
Composer, technical
illustrators at Miller
Formless had to wait for
engineers to convert their
design data into STEP
format before they could
begin working with it in their former technical
illustration tool. Now, with 3DVIA Composer,
technical illustrators can easily pull their
SolidWorks CAD data directly into 3DVIA
Composer in a single step. This saves time
for both the technical illustrators and the
engineers, who can now focus on design
rather than on providing data for
documentation.
“With 3DVIA Composer, the 3D data is
easily accessible to the technical illustrator,
mobile equipment
and so is the bill of material information,”
Szamlewski said. “With 3DVIA Composer,
the bill of material information is available
automatically.”
But speed and efficiency aren’t the only
benefits Miller Formless realized when it
moved to 3DVIA Composer. The solution is
also fast and easy to learn and fun to use.
Just two weeks after installing the software,
technical illustrators at Miller Formless were
generating content using 3DVIA Composer
and enjoying improved productivity. “Our
technical illustrators are actually excited
about having this product to do their job,”
Szamlewski said. ”This has translated into
even more productivity for the company”.
www.millerformless.com
www.3dmojo.com
razilian company Enquip, located in
the southeastern state of Rio de
Janeiro, develops and manufactures
industrial equipment for use in cargo handling
solutions and products, including hydraulic
winches and electric or pneumatic telescopic
cranes used in the energy, shipbuilding and
construction industries. Certified ISO 9001,
Enquip has invested in technology solutions
with an eye toward sustainable development.
In its efforts to optimize manufacturing
processes and use of existing hardware and
machines, Enquip faced a key challenge –
how to expand and improve management of
its engineering data, a function that was
previously limited due to integration and
programming issues with production
equipment. In 2009, Enquip chose CATIA
and ENOVIA SmarTeam to improve its
technology in the areas of product design,
finite element simulations, kinematics
analysis, and parametric detailing in
production. Enquip required an integrated
PLM solution that was robust, came with
technical support, and was easy to integrate
into existing software solutions. The
implementation and rollout of these solutions
was done by Dassault Systèmes and
Tecmes, its business partner in Brazil.
improvement in overall manufacturing
performance and a significant step forward
in the quality of our products, all resulting
in the improved use of our machines,” said
Marcello Pecci, Plant Manager, Enquip. The
optimization of CNC programs has also
resulted in better use of machine resources
and a more dedicated and trimmed
production cycle.
Performance improves by 30%
By integrating all manufacturing processes
into a single workflow, the company now has
a “best practices” model that protects its
intellectual property and allows Enquip to
reuse successful manufacturing processes in
other areas. The Dassault Systèmes’ PLM
solution also allows Enquip to quickly alter
product designs throughout manufacturing in
order to comply with any last-minute market
changes or industry requirements.
With the Dassault Systèmes PLM solution,
Enquip now manages the development of
manufacturing equipment virtually, but also
validates manufacturing operations first using
simulation to test the operation of the
machines and the processes beforehand.
“With CATIA and ENOVIA, we noticed a 30%
Optimized use of resources
With an accurate design plan, which was
tested virtually, Enquip made better use of its
raw materials and avoided environmental
waste. Complex geometrical models that
before required a great deal of programming
time became easier to execute. As a result,
the machining cycle per part produced was
cut significantly. The time savings translate
into increased resources that can be
invested in the development of new
products. “The results attained were
exceptional and exceeded expectations,”
said Pecci. “The new PLM rollout was a
success and it positively impacted the entire
organization.”
www.enquip.com.br
33
05/04/11 12:24
mobile equipment
Maschio Gaspardo: CATIA and
ENOVIA SmarTeam take to the field
A global organization, a wide and varied product range, and models
consisting of up to five thousand parts: with CATIA and ENOVIA SmarTeam,
Maschio Gaspardo S.p.A. has found an ideal solution to handle
complex design, production and post-sales operations.
Close to the market
Italian Maschio Gaspardo SpA designs, manufactures
and sells agricultural machinery and equipment all
over the world: harrows, sowing machines, rotary
cutters for different types of land and cultivations. The
key values of the Veneto-based company (the
headquarters are divided between Campodarsego,
near Padua, and Morsano al Tagliamento, near
Pordenone) are an extensive product range from
small to huge equipment, and a distribution network
with direct subsidiaries all around the world. This
network has proved to be a success factor in an
industry that Massimo Crozzoli, IT Director Corporate,
compares to Easter egg production in terms of
seasonality and risk concentration. “Despite
unceasing attempts to balance crop production in the
different hemispheres, this business is still strongly
concentrated in the first four months of the year. At
spring, giant machines start tilling huge plots for
businessmen who generate all of their revenues in a
few weeks. In these conditions, any inconvenience,
breakdown or failure generates sheer costs; that’s
why it is essential to be close to customers, to provide
them with service and spare parts as quickly as possible.”
First in the third dimension
In the early 1990s’, Maschio Gaspardo was the first
company in Italy (together with Fincantieri) to
choose 3D as the common language for its
organization. “At that time, concepts like integration,
collaboration and networking were starting to
emerge,” Crozzoli remembers, “and in this respect,
a key area is the department where products are
created. We were looking for a solution to integrate
the engineering department with the rest of the
company, and we chose Dassault Systèmes’
CATIA, which had just announced its porting on
the Microsoft platform. We decided to leverage
the integration with the Microsoft world to support
and streamline the integration of the technical
department with other areas; it was a bold choice
back then, because Windows, networking and
CATIA itself were leading-edge technologies
with some margins of risk. But it was a decision
that has brought great results, also thanks to the
excellent support we have got from DS engineers.”
Three dimensions, three benefits
“An immediate benefit we noticed was
implementation and model construction speed,”
says Crozzoli. “CATIA is a highly visual product that
immediately shows whether a design is going in
the right direction, while before that we had to build
a physical product. The second success factor
was the quick learning curve; with CATIA, an
engineer with basic mechanical design skills is up
and running in a very short time, allowing the
company to save on training and to invest these
resources elsewhere.”
The third key benefit of CATIA became apparent
after the database had been populated with a
significant number of projects. “CATIA is excellent
for co-engineering as a result of two key elements:
On one hand, Windows provides for integration
across the entire company; on the other, the
software is conceived to work with a high level of
distribution and collaboration.”
34
ENOVIA SmarTeam keep track of the changes
and all the versions
A crop of information
The equipment manufactured by Gaspardo can be
very complex, including mechanical, electrical,
hydraulic and pneumatic parts, sheet metal, cabling,
automation, and load-bearing frames requiring
structural analysis. Models, including up to 5,000
parts, are completely managed with CATIA and some
specific modules for sheet metal, cabling and
structural analysis. With large, complex models and a
huge number of machines manufactured each year,
you can easily imagine the quantity of data the
company has accumulated across 15 years of 3D
design.
Maschio
Gaspardo model
For this reason, according to Crozzoli, the
implementation of ENOVIA SmarTeam by Dassault
Systèmes was a momentous step forward. “Product
data management software tracks all modifications
and versions, keeps a well-ordered repository of
huge quantities of files, streamlines searches and,
as a result, minimizes redundancies and the risk
to re-design existing parts, while maximizing
the re-use and re-purposing of our intellectual
property.”
www.maschionet.com
www.catia.com
www.enovia.com
35
05/04/11 12:24
mobile equipment
Maschio Gaspardo: CATIA and
ENOVIA SmarTeam take to the field
A global organization, a wide and varied product range, and models
consisting of up to five thousand parts: with CATIA and ENOVIA SmarTeam,
Maschio Gaspardo S.p.A. has found an ideal solution to handle
complex design, production and post-sales operations.
Close to the market
Italian Maschio Gaspardo SpA designs, manufactures
and sells agricultural machinery and equipment all
over the world: harrows, sowing machines, rotary
cutters for different types of land and cultivations. The
key values of the Veneto-based company (the
headquarters are divided between Campodarsego,
near Padua, and Morsano al Tagliamento, near
Pordenone) are an extensive product range from
small to huge equipment, and a distribution network
with direct subsidiaries all around the world. This
network has proved to be a success factor in an
industry that Massimo Crozzoli, IT Director Corporate,
compares to Easter egg production in terms of
seasonality and risk concentration. “Despite
unceasing attempts to balance crop production in the
different hemispheres, this business is still strongly
concentrated in the first four months of the year. At
spring, giant machines start tilling huge plots for
businessmen who generate all of their revenues in a
few weeks. In these conditions, any inconvenience,
breakdown or failure generates sheer costs; that’s
why it is essential to be close to customers, to provide
them with service and spare parts as quickly as possible.”
First in the third dimension
In the early 1990s’, Maschio Gaspardo was the first
company in Italy (together with Fincantieri) to
choose 3D as the common language for its
organization. “At that time, concepts like integration,
collaboration and networking were starting to
emerge,” Crozzoli remembers, “and in this respect,
a key area is the department where products are
created. We were looking for a solution to integrate
the engineering department with the rest of the
company, and we chose Dassault Systèmes’
CATIA, which had just announced its porting on
the Microsoft platform. We decided to leverage
the integration with the Microsoft world to support
and streamline the integration of the technical
department with other areas; it was a bold choice
back then, because Windows, networking and
CATIA itself were leading-edge technologies
with some margins of risk. But it was a decision
that has brought great results, also thanks to the
excellent support we have got from DS engineers.”
Three dimensions, three benefits
“An immediate benefit we noticed was
implementation and model construction speed,”
says Crozzoli. “CATIA is a highly visual product that
immediately shows whether a design is going in
the right direction, while before that we had to build
a physical product. The second success factor
was the quick learning curve; with CATIA, an
engineer with basic mechanical design skills is up
and running in a very short time, allowing the
company to save on training and to invest these
resources elsewhere.”
The third key benefit of CATIA became apparent
after the database had been populated with a
significant number of projects. “CATIA is excellent
for co-engineering as a result of two key elements:
On one hand, Windows provides for integration
across the entire company; on the other, the
software is conceived to work with a high level of
distribution and collaboration.”
34
ENOVIA SmarTeam keep track of the changes
and all the versions
A crop of information
The equipment manufactured by Gaspardo can be
very complex, including mechanical, electrical,
hydraulic and pneumatic parts, sheet metal, cabling,
automation, and load-bearing frames requiring
structural analysis. Models, including up to 5,000
parts, are completely managed with CATIA and some
specific modules for sheet metal, cabling and
structural analysis. With large, complex models and a
huge number of machines manufactured each year,
you can easily imagine the quantity of data the
company has accumulated across 15 years of 3D
design.
Maschio
Gaspardo model
For this reason, according to Crozzoli, the
implementation of ENOVIA SmarTeam by Dassault
Systèmes was a momentous step forward. “Product
data management software tracks all modifications
and versions, keeps a well-ordered repository of
huge quantities of files, streamlines searches and,
as a result, minimizes redundancies and the risk
to re-design existing parts, while maximizing
the re-use and re-purposing of our intellectual
property.”
www.maschionet.com
www.catia.com
www.enovia.com
35
05/04/11 12:24
mobile equipment
All of our data is in one place, eliminating islands of information
that were previously dispersed in different databases, and which
were not in sync with each other or necessarily up to date.
Leif Sundin, Applications and Process Development, MacGregor
ENOVIA V6 – SAP integration
MacGregor Cranes thinks
PLM with ENOVIA V6
In order to deal with a sharp rise in orders and to take advantage of after-sales service opportunities,
MacGregor Cranes needed to increase efficiencies and streamline processes. ENOVIA V6 helps
improve data management and provide employees and partners with secure access to information,
resulting in better collaboration, workflow management, and role-based access.
M
acGregor Cranes produces a wide variety
of cranes, some of which can lift up to
450 tons. “We propose both standard
cranes with predefined configurations and tailormade cranes based on customer specifications,”
said Leif Sundin, applications and process
development specialist, MacGregor. “Our emphasis
on product quality makes MacGregor cranes the
Rolls Royce of cranes.”
A sharp rise in orders
In 2007, MacGregor Cranes experienced tremendous
growth in customer demand for its cranes, resulting
in a sharp increase in orders. Sundin said, “This
jump was partially
MacGregor in brief due to the fact that
ship owners who
MacGregor Cranes is the world’s leading marine cargo
had
been holding
crane supplier with 33% of world market share. MacGregor
back on replacing
is a brand of Cargotec Corporation, a global leader for
aging ships were
cargo handling solutions. The MacGregor Cranes business
ready to make
line is part of the group’s Merchant Ship Division. Other
the
necessary
MacGregor business lines include Dry Cargo, RoRo (roll-on,
investments.” The
roll-off), and Self Unloaders. The Cranes business
company quickly
line has 155 employees in Sweden, China and Korea,
realized that it
and is headquartered in Örnsköldsvik, Sweden.
would have to
36
improve its customer responsiveness or risk losing
credibility. “The increase put a strain on our way of
working,” said Sundin. “We knew that we would have
to improve our processes if we were to efficiently deal
with the growth we were experiencing at the time.”
Global service network
MacGregor’s cranes have an average lifespan
of 20 years, and the aftermarket for parts and service
is an important growth driver for the company.
“We have a service network that is worldwide, which
distinguishes us from our competitors,” declared
Sundin. “The high potential of this business requires
that we make our service organization more
productive and reactive to customer needs.”
To increase that reactivity, MacGregor wanted
to deliver more information from its new sales
business lines to the after-sales organization, and
to do so in a more streamlined fashion. “We can
increase the efficiency of our service network by
giving it easy access to detailed information on
each customer’s product configuration,” explained
Sundin. “With the BOM being the core of a
product’s definition, giving them access to it would
increase service quality and reactivity.”
A MatrixOne user since 1998 for document
management, MacGregor implemented ENOVIA V6
in 2009 to revamp its business processes and
improve data management. Today, ENOVIA V6 is
integrated with SAP, MacGregor’s ERP system.
ENOVIA V6 enables global access to all product
information and supports MacGregor’s product
development processes from concept engineering
designs to after-sales and services. “ENOVIA V6
and SAP is an excellent combination,” said Sundin.
“Parts are created in the PLM environment and
assigned part numbers and other related information
by SAP.”
Extended access to information
ENOVIA V6 information is accessed by MacGregor’s
employees in Sweden, China and Korea. With
production based in Asia, the company soon plans
to extend this access to its production partners.
“As opposed to sending drawings by email, as
was previously the case, our production partners
can access the system and retrieve the information
they need using a role-based access approach
while preserving the security of our network and
information,” commented Sundin.
Single version of the truth
Sundin sees a number of benefits to using ENOVIA
V6 PLM. “All of our data is in one place, eliminating
islands of information that were previously dispersed
in different databases, and which were not in sync
with each other or necessarily up to date. Users find
it easier to locate the information using the ‘where
used’ functionality and by navigating through the
relationships in the data model.”
MacGregor now thinks PLM
ENOVIA V6 has prompted a mini-cultural revolution
at MacGregor by helping transform the company’s
approach into a PLM way of thinking. “We are
putting more controls in our processes, for example
in how we manage engineering changes,” said
Sundin. “We now have workflows to make sure
that everything is done in the right way and that the
data goes to the right person for processing.
There’s traceability and we can literally visualize our
processes.”
www.macgregor-group.com
www.enovia.com
Focus on Technia
Technia is a world-class supplier of Product Lifecycle Management
(PLM) solutions for the creation and management of product
information throughout the entire
product lifecycle. Technia has about 200 employees and is a part of the Addnode group (listed at the OMX Nordic List, Small Cap).
The company is a strategic partner
to more than 200 Nordic companies
and has offices in Sweden, Finland, Norway and North America.
Technia’s customer list includes: BT Products, Ericsson, Forsmark, GE
Healthcare, Haglöfs, Metso Paper,
Mölnlycke Health Care, Nokia, Orion,
Oticon, Scania, Skanska, Sony
Ericsson and SSAB. For more
information about Technia, please visit www.technia.com
37
05/04/11 12:24
mobile equipment
All of our data is in one place, eliminating islands of information
that were previously dispersed in different databases, and which
were not in sync with each other or necessarily up to date.
Leif Sundin, Applications and Process Development, MacGregor
ENOVIA V6 – SAP integration
MacGregor Cranes thinks
PLM with ENOVIA V6
In order to deal with a sharp rise in orders and to take advantage of after-sales service opportunities,
MacGregor Cranes needed to increase efficiencies and streamline processes. ENOVIA V6 helps
improve data management and provide employees and partners with secure access to information,
resulting in better collaboration, workflow management, and role-based access.
M
acGregor Cranes produces a wide variety
of cranes, some of which can lift up to
450 tons. “We propose both standard
cranes with predefined configurations and tailormade cranes based on customer specifications,”
said Leif Sundin, applications and process
development specialist, MacGregor. “Our emphasis
on product quality makes MacGregor cranes the
Rolls Royce of cranes.”
A sharp rise in orders
In 2007, MacGregor Cranes experienced tremendous
growth in customer demand for its cranes, resulting
in a sharp increase in orders. Sundin said, “This
jump was partially
MacGregor in brief due to the fact that
ship owners who
MacGregor Cranes is the world’s leading marine cargo
had
been holding
crane supplier with 33% of world market share. MacGregor
back on replacing
is a brand of Cargotec Corporation, a global leader for
aging ships were
cargo handling solutions. The MacGregor Cranes business
ready to make
line is part of the group’s Merchant Ship Division. Other
the
necessary
MacGregor business lines include Dry Cargo, RoRo (roll-on,
investments.” The
roll-off), and Self Unloaders. The Cranes business
company quickly
line has 155 employees in Sweden, China and Korea,
realized that it
and is headquartered in Örnsköldsvik, Sweden.
would have to
36
improve its customer responsiveness or risk losing
credibility. “The increase put a strain on our way of
working,” said Sundin. “We knew that we would have
to improve our processes if we were to efficiently deal
with the growth we were experiencing at the time.”
Global service network
MacGregor’s cranes have an average lifespan
of 20 years, and the aftermarket for parts and service
is an important growth driver for the company.
“We have a service network that is worldwide, which
distinguishes us from our competitors,” declared
Sundin. “The high potential of this business requires
that we make our service organization more
productive and reactive to customer needs.”
To increase that reactivity, MacGregor wanted
to deliver more information from its new sales
business lines to the after-sales organization, and
to do so in a more streamlined fashion. “We can
increase the efficiency of our service network by
giving it easy access to detailed information on
each customer’s product configuration,” explained
Sundin. “With the BOM being the core of a
product’s definition, giving them access to it would
increase service quality and reactivity.”
A MatrixOne user since 1998 for document
management, MacGregor implemented ENOVIA V6
in 2009 to revamp its business processes and
improve data management. Today, ENOVIA V6 is
integrated with SAP, MacGregor’s ERP system.
ENOVIA V6 enables global access to all product
information and supports MacGregor’s product
development processes from concept engineering
designs to after-sales and services. “ENOVIA V6
and SAP is an excellent combination,” said Sundin.
“Parts are created in the PLM environment and
assigned part numbers and other related information
by SAP.”
Extended access to information
ENOVIA V6 information is accessed by MacGregor’s
employees in Sweden, China and Korea. With
production based in Asia, the company soon plans
to extend this access to its production partners.
“As opposed to sending drawings by email, as
was previously the case, our production partners
can access the system and retrieve the information
they need using a role-based access approach
while preserving the security of our network and
information,” commented Sundin.
Single version of the truth
Sundin sees a number of benefits to using ENOVIA
V6 PLM. “All of our data is in one place, eliminating
islands of information that were previously dispersed
in different databases, and which were not in sync
with each other or necessarily up to date. Users find
it easier to locate the information using the ‘where
used’ functionality and by navigating through the
relationships in the data model.”
MacGregor now thinks PLM
ENOVIA V6 has prompted a mini-cultural revolution
at MacGregor by helping transform the company’s
approach into a PLM way of thinking. “We are
putting more controls in our processes, for example
in how we manage engineering changes,” said
Sundin. “We now have workflows to make sure
that everything is done in the right way and that the
data goes to the right person for processing.
There’s traceability and we can literally visualize our
processes.”
www.macgregor-group.com
www.enovia.com
Focus on Technia
Technia is a world-class supplier of Product Lifecycle Management
(PLM) solutions for the creation and management of product
information throughout the entire
product lifecycle. Technia has about 200 employees and is a part of the Addnode group (listed at the OMX Nordic List, Small Cap).
The company is a strategic partner
to more than 200 Nordic companies
and has offices in Sweden, Finland, Norway and North America.
Technia’s customer list includes: BT Products, Ericsson, Forsmark, GE
Healthcare, Haglöfs, Metso Paper,
Mölnlycke Health Care, Nokia, Orion,
Oticon, Scania, Skanska, Sony
Ericsson and SSAB. For more
information about Technia, please visit www.technia.com
37
05/04/11 12:24
Contactmag
development. Dassault Systèmes PLM
solutions enable collaboration between diverse design groups and support
systems integration - even across the extended enterprise. Take the essential
step to meet customers’ requirements even more effectively and achieve
Industrial
Equipment
PLM powers the Industrial
Special
edition
Equipment Industry
top line benefits.
05/04/11 12:24

Industrial Equipment

Transcription

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