Design Collaboration Between OEMs and Electronics Suppliers Design Collaboration Between Dr. Julian Weber March 12, 2008 Page 1 OEMs and Electronics Suppliers.
Dr. Julian Weber, BMW Group IEEE EMC Society Advances in Automotive EMC Test and Design International Center for Automotive Research Clemson University March 12, 2008 Design Collaboration Between OEMs and Design Collaboration Between OEMs Electronics Suppliers Dr. Julian Weber March 12, 2008 and Electronics Suppliers. Page 2 Agenda.
Partnering with the BMW Group
International Co-operation
Supplier Management
AUTOSAR – Standard System Architecture
Ensuring EMC Conformance
Mutual Expectations Design Collaboration Between OEMs and Design Collaboration Between OEMs Electronics Suppliers Dr. Julian Weber March 12, 2008 and Electronics Suppliers. Page 3 Agenda.
Partnering with the BMW Group
International Co-operation
Supplier Management
AUTOSAR – Standard System Architecture
Ensuring EMC Conformance
Mutual Expectations Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Models of Co-operation. Page 4
Cooper- ation Innovations partners External - Engine partners Suppliers - JV - Electronics - ... - Chemistry Integration - Information/ partners communication “Integrated - ... systems” System Industrialization of Tier 1 sourcing concept partners innovations Tier 2 Small technology companies Tier 3
Focus: Pre-development, Focus: Concept development basic development in a product line Source: EM Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Categories of Suppliers. Page 5
1. Core Suppliers Best-in-class in innovation, product development and process control Long-term relationships or common market interests with BMW Ongoing delivery of product and process innovations
2. Concept Suppliers Focus on innovation potential and project management experience Selection based on concept completeness and ability to deliver
3. Series Development Suppliers Responsible for the successful implementation of existing concepts
4. Market Suppliers Responsible for standard parts Priority on cost leadership Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Categories of Engineering Service Providers. Page 6
External Service incl. Integration Volume E.S. Self-provided Service
Single Contract Integration Package Derivative / SE-Partner SE-Supplier Complete - e.g. Rear lights e.g. Vehicle- Axles, placing Cockpit, Door Panel e.g. X3 Development and Production
Single Contract Package Placing Engineering Development Service (EDL) Services e.g. e.g. e.g. Part design, Chassis Suspension, Passive Safety scheduling, Steering Module, simulation
Development Body Packages
Single Tasks Complex Packages
Complete Intra-CoC Cross-COC Vehicle Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Partner Nomination. Page 7
SOP
Strategy Initial Phase Early Phase Series Development Production
Strategic Partner / Innovation Model
Sourcing Development Partner / Strategies Classic Model
Market Supplier / Competition Model
! use entire spectrum !
Caption: Nomination Development Delivery Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Supplier Integration: Nomination Process. Page 8
Possible repeated ‘Dual request’ request for all suppliers Decision-making group/ Contract sent on the basis of alternative circular template complete signed requirements and agreed ‘Ready for request’ Spec. New ‘ready for Formal Specification ‘Dual request’ offer series dvlpmt’ supplier received decision Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Innovation Management. Page 9
Maximum „Effective New Projects „Idea Density“ Selection and Management“ Products external internal
BMW Group Pre-development Suppliers Development Prioritization in Potential Research Automotive Suppliers Local Purchasing Non- automotive Branches International Purchasing
Research Institutes Virtual Innovation Innovation Agency Councils
Start-Ups Scouting .... Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Future Trends: Tightening of the Market. Page 10
Number of independently operating companies Comments Balanced market allocation expected (Mega Supplier) Modified placing/demand of Number of OEMs: complete packages / suppliers modules for supplier New “quality” demanded from supplier -Extended product- and performance spectrum Number -New concepts of OEMs -Additional resources -Supraregional business connection Continuous value added strategy for suppliers as well
Source: Mercer Management Consulting 2004 Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Future Trends: New Ways of Collaboration. Page 11
Pre- Series Component Module Vehicle Not brand development development manuf. assembly assembly sensitive, external service Brand offering sensitive: OEM (moduls), OEM e.g. Toureg/Cayenne -body, TDI VW/DCX
Not brand sensitive, external service offering engineering services to OEM Not brand sensitive: Assembly of Supplier derivates / variants
- Output OEM: cars - Output OEM: cars, modules, services - Inflexible, hierarchical value-added - Shared advantages for both partners process - New roles in cooperation between OEM - OEM, - Distinct role allocation OEM - supplier - supplier, supplier - OEM supplier Source: Mercer Management Consulting 2004 Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Future Trends: Changes in Internal Activities. Page 12
Development (increase/decrease) of self-provided services per brand (total).
Increase of 4.5 billion €
Change in % related to actual self- provided services
Decrease of 30.2 billion €
Source: Mercer Management Consulting 2004 Design Collaboration Between OEMs and Partnering with the BMW Group. Electronics Suppliers Dr. Julian Weber March 12, 2008 Future Trends: Shifts in the Value-added Process. Page 13
supplier supplier Chassis
Drive- train
Engine units
Body structure
Body exterior
Interior
Electrics/ electronics
Source: Mercer Management Consulting 2004 Design Collaboration Between OEMs and Design Collaboration Between OEMs Electronics Suppliers Dr. Julian Weber March 12, 2008 and Electronics Suppliers. Page 14 Agenda.
Partnering with the BMW Group
International Co-operation
Supplier Management
AUTOSAR – Standard System Architecture
Ensuring EMC Conformance
Mutual Expectations Design Collaboration Between OEMs and International Co-operation. Electronics Suppliers Dr. Julian Weber March 12, 2008 BMW Group International Production Network. Page 15
British locations: German Oxford locations: Hams Hall Berlin Leipzig Goodwood Dingolfing Regensburg Spartanburg Swindon Eisenach Wackersdorf Landshut Munich
Kaliningrad
Shenyang/Brilliance Steyr Graz/Magna Cairo Hanoi Rayong Jakarta
Kuala Lumpur
Rosslyn Curitiba/Chrysler
Production plants CKD assembly plants JV / Contract Production Design Collaboration Between OEMs and International Co-operation. Electronics Suppliers Dr. Julian Weber March 12, 2008 BMW Group Development Network. Page 16
BMW Group Car IT BMW Group Forschungs- und Innovationszentrum (FIZ) BMW M BMW Motorrad BMW Motorsport BMW Group Forschung und Technik
BMW Group Designworks Engineering and Emission Test Center BMW Group BMW Group Technology Office Palo Alto Technology Office Tokyo Design Collaboration Between OEMs and International Co-operation. Electronics Suppliers Dr. Julian Weber March 12, 2008 BMW Group International Purchasing Network. Page 17
BMW France S.A. Paris
BMW (UK) Manufacturing Ltd , BMW Italia S.p.A. Oxford Milano BMW Iberica S.A. BMW Manufacturing Corp., Madrid Spartanburg Wentech GmbH BMW AG, Munich Consulting Office, Budapest Fatec Consulting Office, Istanbul JV BMW Brilliance China, Shenyang BMW Motoren GmbH Steyr BMW China Trading BMW Thailand Ltd., Peking Rayong BMW de Mexico S.A. de C.V., Mexico City
BMW Asia Pte. Ltd., BMW Japan Corp., Singapore Tokyo
BMW South Africa, Rosslyn
Operative Purchasing Function International Purchasing Office (IPO) Design Collaboration Between OEMs and International Co-operation. Electronics Suppliers Dr. Julian Weber March 12, 2008 Highest Growth Rates in Asia & Eastern Europe. Page 18
Mio. 90 Total Market : + 38% 80
70
Asia 60 +88%
50
40 +22% America 30
20 +56% Eastern Europe 10 Western +5% Europe
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018
Data Source: Global Insight 2006 Design Collaboration Between OEMs and International Co-operation. Electronics Suppliers Dr. Julian Weber March 12, 2008 Wages. Page 19
Average Direct Wages per Region in 2006 [€ per Hour]
30,0 26,6 EUR/ Hour25,0 + 8.0
20,0 18,6
15,0
s 10,0 -16.7
5,0 4,0 3,8 2,5 1,9 1,0 0,8 Direct Wage Direct 0,0 Germany USA Poland Turkey North Mexico China India Africa Source: BMW Group Design Collaboration Between OEMs and International Co-operation. Electronics Suppliers Dr. Julian Weber March 12, 2008 US$ / Euro Exchange Rate. Page 20
Source: OnVista 2008 Design Collaboration Between OEMs and International Co-operation. Electronics Suppliers Dr. Julian Weber March 12, 2008 The Particular Importance of NAFTA Sourcing for the Page 21 BMW Group.
Global Sourcing Utilization of Global Market Potentials
Asia Eastern … NAFTA Europe
NAFTA is biggest automotive market Focus on NAFTA US$ exposure Sourcing BMW’s (Financial Risk) US sales growth Volume growth Plant Spartanburg Design Collaboration Between OEMs and Design Collaboration Between OEMs Electronics Suppliers Dr. Julian Weber March 12, 2008 and Electronics Suppliers. Page 22 Agenda.
Partnering with the BMW Group
International Co-operation
Supplier Management
AUTOSAR – Standard System Architecture
Ensuring EMC Conformance
Mutual Expectations Design Collaboration Between OEMs and Supplier Management. Electronics Suppliers Dr. Julian Weber March 12, 2008 Areas of Supplier Development. Page 23
Process Results Focus Design Supplier Support Project Supplier Spanning Expertise (Sustainability) Continuous Improvement Project Project Support Specific Process (Speed) Benchmark. Project Assessment
Early Phase Development Series Before Nomination Design Collaboration Between OEMs and Supplier Management. Electronics Suppliers Dr. Julian Weber March 12, 2008 Supplier Development Activities. Page 24
Process Design: Fundamental Improvement of supplier performance in all business processes
Supplier Expertise: Comprehensive technical and commercial appraisal of supplier
Process Benchmarking: Qualitative and comparative supplier appraisal with rating
Supplier Support: Essential boost in supplier performance for every deficient business process, as basis for a stable, long-term, performance contribution Design Collaboration Between OEMs and Supplier Management. Electronics Suppliers Dr. Julian Weber March 12, 2008 Supplier Development Activities (cont.). Page 25
Project Support: Project specific and disturbance related need for improvement of supplier performance by means of process optimization
Project Assessment: Project specific, extensive qualitative project and risk assessment with LOP driven monitoring of corrective actions enabling problem resolution
Continuous Improvement: Project specific procured part cost saving using building blocks: productivity, product value analysis, process value analysis and concept redesign Design Collaboration Between OEMs and Design Collaboration Between OEMs Electronics Suppliers Dr. Julian Weber March 12, 2008 and Electronics Suppliers. Page 26 Agenda.
Partnering with the BMW Group
International Co-operation
Supplier Management
AUTOSAR – Standard System Architecture
Ensuring EMC Conformance
Mutual Expectations Design Collaboration Between OEMs and AUTOSAR – Standard System Architecture. Electronics Suppliers Dr. Julian Weber March 12, 2008 What AUTOSAR is. Page 27
AUTOSAR is an open standards organization created by OEMs and electronics suppliers. Primary Goal of AUTOSAR is to provide an open standard for automotive architecture for developing vehicular software, user interfaces and management.
Consumer Complexity Reusability Exchangeability Quality Electronics Design Collaboration Between OEMs and AUTOSAR – Standard System Architecture. Electronics Suppliers Dr. Julian Weber March 12, 2008 Vision. Page 28
The Vision of AUTOSAR is … … improved complexity management of highly integrated E/E architectures through increased reuse and exchangeability of SW modules between OEMs and suppliers. Design Collaboration Between OEMs and AUTOSAR – Standard System Architecture. Electronics Suppliers Dr. Julian Weber March 12, 2008 Benefits. Page 29
OEM overlapping reuse of software modules which are irrelevant to competition Functions of competitive nature can be developed OEM separately Focus on innovation/ functions Standardized certification
Reduction of version proliferation Development partitioning among suppliers Supplier Increase of efficiency in functional development New business models possible
Common interfaces with development processes Tool provider Seamless, manageable, task optimized (time dependent) tool landscape
Transparent and defined New market entrant interfaces enable new An industry business models standard is established. Design Collaboration Between OEMs and AUTOSAR – Standard System Architecture. Electronics Suppliers Dr. Julian Weber March 12, 2008 Use Case ‘Front Light Management’. Page 30 Switch event Light Request Front-Light Manager Headlight SW-Component Application check_switch () switch_event (event) request_light (type, mode) set_light n Software switch_event request_light get_keyposition ( ) (type, mode) (event) (type, mode) set_light (type, mode) AUTOSAR set_current (...) ... set_dboard(type,mode) Interface
AUTOSAR RTE
AUTOSAR AUTOSAR set_current Interface Interface (...) AUTOSAR get_keyposition ( ) Interface set_dboard (type,mode) ECU ECU HW independent Abstraction Abstraction HW dependent Services HW dependent Services Operating Services (NVRAM, timer, (e.g. State- (NVRAM, timer, Systems Software Machines, Standard fault memory, fault memory, etc.) Subscribing) etc.)
Complex standardized interface Device Driver standardized standardized Interface Interface SPAL DIO PWM COM Driver
Microcontroller Abstraction ECU-Hardware
Note: this slide only shows the principal signal flow. It is otherwise based on an outdated architecture Design Collaboration Between OEMs and AUTOSAR – Standard System Architecture. Electronics Suppliers Dr. Julian Weber March 12, 2008 Exchange of type of front light. Page 31 Switch event Light Request Front-Light Manager XenonHeadlight light SW-Component Application check_switch () switch_event (event) request_light (type, mode) set_light n Software switch_event request_light get_keyposition ( ) (type, mode) (event) (type, mode) set_light (type, mode) AUTOSAR ... set_dboard(type,mode) set_current (...) Interface
AUTOSAR RTE
AUTOSAR AUTOSAR AUTOSAR set_light(...) get_keyposition ( ) Interface Interface Interface AUTOSAR Interface set_dboard ECU HeadlightECU (type,mode) HW independent Abstraction Abstraction HW dependent HW dependent Services Services Services Operating (e.g. State- (NVRAM, timer, Systems Software (NVRAM, timer, Standard fault memory, Machines, fault memory, etc.) Subscribing) etc.)
Complex standardized interface Device Driver standardized standardized Interface Interface
SPAL DIO PWMDIO COM Driver
Microcontroller Abstraction ECU-Hardware
Note: this slide only shows the principal signal flow. It is otherwise based on an outdated architecture Design Collaboration Between OEMs and AUTOSAR – Standard System Architecture. Electronics Suppliers Dr. Julian Weber March 12, 2008 AUTOSAR Core Partners and Members. Page 32 10 Core Partner 48 Associate Member
48 Premium Member
General Generic Standard Tools and Semi- OEM Tier 1 Software Services conductors
Up-to-date status see: www.autosar.org Design Collaboration Between OEMs and Design Collaboration Between OEMs Electronics Suppliers Dr. Julian Weber March 12, 2008 and Electronics Suppliers. Page 33 Agenda.
Partnering with the BMW Group
International Co-operation
Supplier Management
AUTOSAR – Standard System Architecture
Ensuring EMC Conformance
Mutual Expectations Design Collaboration Between OEMs and Ensuring EMC Conformance. Electronics Suppliers Dr. Julian Weber March 12, 2008 BMW Group Standard GS 95002 - 2004. Page 35
The BMW Group Standard GS 95002 Electromagnetic Compatibility (EMC), Requirements and Tests establishes the ` requirements, ` test methods and ` test procedures to ensure electromagnetic compatibility in BMW motor vehicles.
The current version GS 95002 : 2004 refers to national and international standards. BMW is a member in most EMC related standardization committees. Design Collaboration Between OEMs and Ensuring EMC Conformance. Electronics Suppliers Dr. Julian Weber March 12, 2008 EMC Test Specification According to GS 95002. Page 36
Specification of Component EMC Tests: 1. For each component, BMW selects the required tests (from GS 95002). 2. For each required test, the supplier submits an EMC Test Plan that includes: ` A description of the EUT ` The EUT configuration during the test ` Failure criteria for the EUT ` A block diagram of the actual test set-up Design Collaboration Between OEMs and Ensuring EMC Conformance. Electronics Suppliers Dr. Julian Weber March 12, 2008 EMC Component Testing. Page 37
EMC component tests are carried through by the supplier according to BMW GS 95002.
Test Methods: Measurement of emissions Immunity test Test of immunity to electrostatic discharge Attenuation of audio frequencies of audio devices with speaker output and gain control Design Collaboration Between OEMs and Ensuring EMC Conformance. Electronics Suppliers Dr. Julian Weber March 12, 2008 EMC Component Test Documentation. Page 38
After successfully testing the component, the supplier provides a test report to BMW.
Component EMC Test Report: ` Results ` Test information ` Details of test procedures used ` Build level of the EUT ` Detailed description of the actual set-up for each test to ensure reproducibility of performed investigations Design Collaboration Between OEMs and Ensuring EMC Conformance. Electronics Suppliers Dr. Julian Weber March 12, 2008 Complete Vehicle EMC-Testing. Page 39
Approximately 2000 h of EMC testing for new vehicles Late test vehicle availability - debugging very expensive Test Methods: Emission measurement with on-board antenna in an anechoic chamber Radiated susceptibility testing in an anechoic chamber Immunity to interference from on-board radio systems; field intensities of 80 V/m Immunity to electrostatic discharge Quiescent current test under influence of an electromagnetic field
Source: Dr. Friedrich Haslinger BMW Group Design Collaboration Between OEMs and Ensuring EMC Conformance. Electronics Suppliers Dr. Julian Weber March 12, 2008 BMW Group Anechoic Chamber. Page 40
Room Size: 29m x 17m x 12m (95ft x 56ft x 39ft) Antenna System: Electronically controlled positioning Bandwidth 100 kHz - 18 GHZ max. Power 10000W HF Dynamometer: 4x 90kW Design Collaboration Between OEMs and Ensuring EMC Conformance. Electronics Suppliers Dr. Julian Weber March 12, 2008 Process Overview. Page 41
Component / System
Redesign Supplier
Lab Tests ok Lab Tests not ok
Vehicle Vehicle Tests ok. Tests not ok. Redesign OEM
Vehicle Vehicle cannot be sign off signed off Design Collaboration Between OEMs and Design Collaboration Between OEMs Electronics Suppliers Dr. Julian Weber March 12, 2008 and Electronics Suppliers. Page 42 Agenda.
Partnering with the BMW Group
International Co-operation
Supplier Management
AUTOSAR – Standard System Architecture
Ensuring EMC Conformance
Mutual Expectations Design Collaboration Between OEMs and Mutual Expectations. Electronics Suppliers Dr. Julian Weber March 12, 2008 BMW Group from the Supplier‘s Point of View. Page 43
„Which customer is most attractive to do business with?“ 1.6
1.4 BMW
1.2
1.0
0.8
0.6
0.4
0.2
0
-0.2
-0.4
-0.6 GME SEAT Ford -0.8 Fiat Source: OEM-Supplier Relationship Survey 2005 Automotive News Europe/SupplierBusiness.com
Source: Automotive News 2005 Design Collaboration Between OEMs and Mutual Expectations. Electronics Suppliers Dr. Julian Weber March 12, 2008 Important Supplier Assets – Today and Tomorrow. Page 44
Price Quality competitiveness Innovativeness Product Cost Flexibility competence transparency Internationality Image / size Project management / n-tier-management Teamwork Process capability competence Current Importance
low high low Integration capability
low high Future Importance Design Collaboration Between OEMs and Mutual Expectations. Electronics Suppliers Dr. Julian Weber March 12, 2008 What BMW Expects from their Partners. Page 45
Performance Criteria
Innovative and competitive solutions Solid financial basis Premium quality Price competitiveness Environmental and social responsibility …
Business Philosophy Long-term orientation Transparency and openness Risk sharing “Benzin im Blut” Design Collaboration Between OEMs and Electronics Suppliers Dr. Julian Weber March 12, 2008 Page 46
Thank you very much for your attention!