Transdisciplinary : Crossing Boundaries 585 M. Borsato et al. (Eds.) © 2016 The authors and IOS Press. This article is published online with Open Access by IOS Press and distributed under the terms of the Creative Commons Attribution Non-Commercial License 4.0 (CC BY-NC 4.0). doi:10.3233/978-1-61499-703-0-585 Using Process Models for Supporting Early Digital

Juliana SCHMIDT a,1, Milton BORSATOa, Edmar HINCKELa Fabio MACCARIb, Paulo STORRERa and Eduardo ONOFREa aFederal University of Technology, Paraná, Brazil bCNH Industrial Latin America, Brazil

Abstract. In the present scenario of search for quality and competitiveness, many companies use digital to analyze performance, manufacturability, maintainability and other characteristics of products. Virtual prototyping, or DMU (Digital Mockup), consists of an environment where one can check products and processes, exchange information and make decisions, from the conceptual stage through detailing. However, by restriction time or lack of appropriate guidelines, many of these activities are postponed or neglected. The present work aims to define a sequence of DMU analysis activities, applicable to different industries, able to reduce rework and assist architects and in identifying inconsistencies in digital mockups. Modeled in BPMN (Business Process Model and Notation) standard, the process proposed herein provides analysis in areas such as assembly, security, ergonomics, manufacturing, operation and maintenance. To verify the process applicability and consistency, the context of an agriculture equipment manufacturing company was considered. In this study, aligned with the principles of DSR ( Research), it was necessary to identify the flow of activities involved (i.e. product architects and designers) as well as their needs and constraints. The evaluation of process performance was done through questionnaires submitted to stakeholders. From the application of the proposed solution, it is possible to reduce the number of reworks and identify problems in early stages of product development, thus contributing to improvement of quality indicators and competitiveness of enterprises.

Keywords. PDP, BPMN, DMU, Digital Mockup.

Introduction

Virtual Prototypes have been used to reduce the number of physical prototypes during product validation [1]. Such prototypes, called Digital Mockup (DMU), are 3D models that represent the product, allowing to simulate scenarios according to considered restrictions (e.g. kinematics, dynamics, ergonomic), or can be used for various purposes and steps of the Product Development Process (PDP) [2]. When the need for a change in the product is identified, the engineer may make this change before physical prototypes. However, if some activity on the DMU is neglected (e.g. a critical constraint not analyzed in advance), chances are there will be future design rework. Therefore, for DMU to be effective, it is necessary to follow best practices along the PDP through standardized guidelines and approaches such as DFX (Design for X), thus enabling considerations of several restrictions related to products, as well as interactions with stakeholders [3, 4]. Therefore, the need for a standard language to represent the process with the activities related to the DMU is remarkable.

1 Juliana Schmidt. [[email protected]] 586 J. Schmidt et al. / Using Business Process Models for Supporting Early Digital Mockup

The Business Process Model and Notation (BPMN) standard has been proposed in the literature as a standard representation and communication between stakeholders [5- 7]. In this sense, this work aims to model a process with a sequence of activities related to DMU within the PDP in order to guide and inform designers and other stakeholders in the implementation of its activities through the BPMN standard. For the implementation of the study, in line with the principles of Design Science Research (DSR), the following sequence was performed: (a) identification of the problem and motivation; (b) definition of goals and solutions; (c) design and development; (d) demonstration; and (e) evaluation. The study considered the scenario of a multinational segment of agricultural machinery where it is intended to reduce rework due to neglected activities related to DMU. The present paper is organized as follows: Section 1 of this paper presents a brief literature review on DMU, applied in the PDP, as well as a theoretical overview on DFX and the BPMN standard. Section 2 describes the methodological aspects of the present research, applied to the proposed process. Sections 3 and 4 bring the results of the study and the evaluation of the proposed process. Finally, Section 5 presents final considerations.

1. Theoretical Background

This section presents the basics concepts used for developing the proposed process and a brief literature review on the main applications of BPMN standard in the context of PDP and DMU. BPMN is both a model and graphical language standard used to describe and specify business processes. The focus of BPMN is to create a pattern of communication between all involved in the processes that take place in or with companies, making the connection between the business and implementation of processes [5, 8]. DMU is a realistic digital representation of the layout of a product and its manufacturing processes by means of Computer Aided Design (CAD) [9, 10]. Through DMU, engineers can use geometric information, functional and kinematic analysis to assist Finite Element Analysis (FEA), Computer Aided Process Planning (CAPP) and other analysis during the PDP (e.g. manufacturability, ergonomics, maintainability) [11]. DFX is a Concurrent Engineering (CE) support approach. The letter X represents a phase of the product life cycle or a process whereby the product will pass (e.g. Assembly Design for focusing the product assembly process, which is a part of the product life cycle) [12]. The goal in DFX is to make designers become aware of the constraints involved in each phase of the product life cycle, through rules and guidelines [13]. The BPMN standard has been used extensively in various types of business, meeting specific goals of each organization, in order to reduce human error and miscommunication between stakeholders [14]. [15] study cases of application of BPMN in major European manufacturing industries, in order to support the consumer, integrate it with the company's business process, and align the PDP with the company's strategy. Currently, BPMN has also been applied as a standard to promote the visibility of processes for software and services, in the scenario of information systems, allowing for automation of decision flows of companies [14]. One of the major concerns of BPMN models are to control the quality of processes in order to add value to the J. Schmidt et al. / Using Business Process Models for Supporting Early Digital Mockup 587 company's strategy. Within this context, this paper considers DMU as a sequence of activities and a PDP sub-process, which needs to be represented in a way that ensures communication and understanding by the authors (i.e. design engineers) in all activities of the process.

2. Methodological Aspects

The work presented in this paper was based on the DSR approach [16]. This approach is related to Design Science and refers to the development of an artifact for meeting a certain goal. Such artifacts can be defined as constructions, models, methods, or instantiations. In this sense, the artifact proposed in this paper is a method characterized by a process modeled based on the BPMN standard. The DSR approach is conducted as a set of stages: (i) problem identification and motivation; (ii) definition of goals and solutions; (iii) design and development; (iv) demonstration; and (v) evaluation, which results in a method approved to be used, suitable to the need presented above. To develop the proposed artifact the above-presented phases are detailed in accordance with activities executed in each of them. In phase Problem Identification and Motivation a strategy based on the analysis of Engineering Change Orders (ECOs) related to a particular product was used. This product was chosen because the number of associated ECOs. With the product defined, all ECOs were collected and classified according to type of problem encountered and the system to which the component to be changed belonged. Thus, it was possible to identify which the most common problems were. In addition, through interviews with design engineers and others involved (e.g. vehicular ), it was possible to identify that designers subjected 3D models of components or assemblies for architecture analysis with no previous evaluation of their digital mockup or, if evaluated, only superficially. Thus, it was found that vehicular architecture activities were performed on demand. Such information afforded to conclude that this behavior generated a large accumulation of activities for architecture analysis which resulted in ECOs in later stages of the PDP. In step Definition of Goals and Solution, it was identified that the use of a defined process could help designers during the evaluation of DMU and thus reduce rework throughout the PDP. Currently, designers are pressured to perform their activities quickly, which often prevent important analysis regarding the model to be realized. Thus, a formalized process, with each step necessary for the evaluation of a digital mockup, could serve as support and guide the during the execution of their activities. In step Design and Development, the activities carried out were: a) identification of activities flow; b) evaluation of the DMU tool used in the company and its features; c) new process definition; and d) identification of the company's PDP steps related to the new process. Through interviews, the activities normally held by the designers were initially identified. From this identification, each activity was documented and it was possible to define the flow of activities that was actually driven by the designers, for each designer performed its activities in a specific sequence. In the evaluation of the DMU tool, features available to the user were evaluated. That was done in order to find possible tool restrictions or utilities that were not being employed by the designers. 588 J. Schmidt et al. / Using Business Process Models for Supporting Early Digital Mockup

With the activities carried out in (a) and (b), it was possible to develop the proposed process, called Early Digital Mockup (EDMU). To develop it, a literature research to identify related work was initially conducted. The EDMU process corresponds to earlier analyses carried out by the designer, on partial digital product mockups. This process presents some activities that help verify possible inconsistencies in 3D models that need to be identified during CAD modelling. Then, the company´s PDP was analyzed for possible associations with respect to the proposed process. In step Demonstration, the new process was first applied in laboratory environment. With the assistance of the DMU tool used in the company, this first evaluation was necessary to verify whether there were inconsistencies in the process. Then the process and a questionnaire was sent to some company designers for appraisal based on certain criteria such as operability, efficiency, generality and ease of use [16]. Each of them completed the questionnaire with suggestions and difficulties, which led to a review of the process. Once this step was finished, the step Evaluation took place, in which the revised process was forwarded again to some company designers so they could use it in practice. The next section presents the proposed process, detailing each associated activity.

3. EDMU process

Based on the PDP suggested by [17], the process proposed in this study is presented in this section. During the modeling of new or revised components, verifications must be conducted at assembly , that is, the interaction of these components with others that belong to the same assembly. Regarding the assemblies modeling, checks must be made based on the relationship between such assembly and others that are in the interface. The sequence of activities is described below and corresponds to: i) Assembly analysis; ii) Security Analysis; iii) Ergonomic Analysis; iv) Manufacturing analysis; v) Operating Conditions Analysis; vi) Maintenance Analysis; and vii) DFX Analysis.

3.1. Assembly Analysis

Before starting the assembly analysis, the first activity of the process corresponds to open the component file and the assembly to which it belongs in the DMU analysis tool (Figure 1). Characterized as a sub-process, assembly analysis has two main activities: Check dynamic interference and Check static interference. Check dynamic interference refers to identifying possible physical interference between components related to the drive mechanisms (e.g. opening the hood) or the assembly during manufacturing. It is recommended to consult information from Manufacturing Engineering regarding the assembly sequence. Check static interference activity is related to the interference between components in their initial positions. It is noteworthy that these activities are associated with tolerances determined in the modeling step. Some features of the DMU analysis tool can assist such checks. If any interference is identified, the designer must return to the modeling stage and make the necessary changes.

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Figure 1. Assembly analysis representation.

3.2. Security Analysis

The second activity, showed in Figure 2, is related to the verification of factors that affect security. This check corresponds to identifying whether the technical functions specified to the component or assembly are met reliably and if it is possible to ensure that components do not involve to people or the environment. It is possible to evaluate these conditions from standards or internal standards of the company. If a factor is identified, the designer must return to the modeling phase and change the model.

Figure 2. Security analysis representation 590 J. Schmidt et al. / Using Business Process Models for Supporting Early Digital Mockup

3.3. Ergonomic Analysis

The third activity corresponds to ergonomic analysis and is represented in Figure 3. Based on standards, the designer must verify the factors related to ergonomics. These factors involve form, aesthetics, ease during assembly and disassembly, user comfort and safety and other requirements that are directly related to the function of each component or assembly developed. By identifying that an ergonomic requirement was not met, the designer must return to modeling stage and make the necessary changes.

Figure 3. Ergonomic analysis representation.

3.4. Manufacturing Analysis

This activity corresponds to assess whether the modeled components can be manufactured within the company or by suppliers (Figure 4). Product Engineering should request information from Manufacturing Engineering or suppliers to assess whether there is compatibility between the developed components and the tools available. If any restriction or impossibility is detected, it is necessary to return to modeling stage or other manufacturing alternatives must be proposed.

Figure 4. Manufacturing analysis representation. J. Schmidt et al. / Using Business Process Models for Supporting Early Digital Mockup 591

3.5. Operating Conditions Analysis

This activity, shown in Figure 5, should be done so that the designer can identify the factors that influence operations (e.g. noise, vibration, and handling). The presentation of information regarding operations must be indicated appropriately (i.e. ergonomically, with appropriate colors and symbols) to avoid problems in the system itself, neighbors or other systems that generate any operational uncertainty. This check can be performed based on standards. If the representation is not in accordance with the standards the designer must return to the modeling stage to perform the correction of the model.

Figure 5. Operating conditions analysis representation

3.6. Maintenance Analysis

Check the maintenance conditions is the activity that corresponds to evaluating the assembly and disassembly of the component or assembly for simplifying maintenance procedures and inspection (Figure 6). This assessment should be made based on standards and on information provided by Manufacturing Engineering and Product 592 J. Schmidt et al. / Using Business Process Models for Supporting Early Digital Mockup

Support. If the designer identifies potential improvement opportunities or potential problems that may be related to maintenance, he should return to the modeling step.

Figure 6. Maintenance analysis representation.

3.7. DFX Analysis

The last process activity is represented in Figure 7. It corresponds to the analysis of the model with respect to ease of assembly, maintenance and manufacturing and the possibility of cost savings [18]. It is important that design engineers address those analyses at this stage of product development. Thus, alternatives that are often found in later steps (e.g. physical prototyping, manufacturing) can be raised. To guide the designers in the implementation of this activity, a checklist was associated.

Figure 7. DFX analysis representation. J. Schmidt et al. / Using Business Process Models for Supporting Early Digital Mockup 593

4. EDMU Process Results and Evaluation

After performing the sequence of activities presented in the previous section, the has a revised and more consistent model, which can be forward to vehicle architecture analysis. Such analysis corresponds to an important PDP stage of the company. To validate the process some activities were conducted, according to the criteria presented in section 2. Initially, the distribution of questionnaires to stakeholders made it possible to assess the feasibility of the process. The questions presented in the questionnaire were, as follows: 1. Is the process applicable to any project? 2. Is the process clear about the sequence and activities? 3. Is there any inconsistent activity? 4. Is there any activity that could be inserted in the process? 5. Does the use of the process add complexity to the job? Stakeholders who answered to the questionnaire belonged to different teams of Product Engineering and the responses obtained from this questionnaire, in general, converged. They confirmed the applicability of the process, consistency about the sequence of activities and pointed out that there was no activity incoherence. Question number 4 was the one that most returned different answers, not only with suggestions for activities but also possible inputs for the activities already submitted. Great part of the stakeholders stated that the use of the process would not bring greater complexity to the execution of the work, but pointed out the lack of time as an obstacle to a full implementation. Through the responses and an assessment carried out in the laboratory environment, the initial process was revised. The DFX analysis activity was a suggestion accepted and inserted in the process, as can be seen in section 3. Thereafter, the new process was again sent for designers to use in practice. Thus, it was possible to identify that the process was applicable to any project and was easy to use. Furthermore, the use of a formalized process shows improvement in process efficiency, since it allowed the reduction of rework. These results proved that the process met the operability, efficiency, generality and ease of use criteria. Therefore, in addition to rework reduction, other benefits of using the process were evidenced. Among them, the increase in aggregated value associated with project activities, encouragement for integration among stakeholders, increased reliability of digital mockup and therefore the final product, and the standardization of a sequence of activities that helps in project management.

5. Final Considerations

The present study allowed to recognize that even great companies face problems while conducting activities throughout the product development process. Decisions are made according to random criteria, for formalized procedures are nor followed. Thus, the possibility of someone to neglect important activities may generate non-conformity problems. In the scenario presented in this paper, these problems can cause rework and failure to execute important activities, which consequently imply new engineering change orders. 594 J. Schmidt et al. / Using Business Process Models for Supporting Early Digital Mockup

One of the challenges of this study was to fully understand how the flow of activities was conducted at the partner company environment. It was important to know what the difficulties and needs of designers were to thereby, develop a coherent and complete process with activities that actually contribute to reducing rework. One possible sequence for this study may be related to the development of other processes to formalize the flow of activities in relation to subsequent activities. Moreover, associating this process to a support tool would ensure better use of the process. Thus, it would be not only a guide, but also a set of obligatory steps. The EDMU process can also be used or adapted to other companies, as it was developed with the purpose of being used in any project.

References

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