SPECIAL EDITION

Transportation & Mobility: Accelerating innovation for a brighter future

Renault Version 6 in practice Jaguar Land Rover Business transformation with Version 6 Alstom Transport Sustainable mobility in the rail industry In this issue Editorial NEWS 4 | Local Motors 4 | McLaren Racing 5 | eCar Design Challenge 5 | BMW For more than 25 years, Dassault Systèmes has OVERVIEW been instrumental in helping companies worldwide 8 | DS Transportation & Mobility offerings Contact mag master their information to drive innovation. Transportation & VERSION 6 10 | Renault Mobility 14 | Jaguar Land Rover The PLM Magazine 18 | Tesla Motors published by 20 | Great Wall Motors Dassault Systèmes The Transportation & Mobility Industry is at a crossroads. Times are challenging: 10, rue Marcel Dassault 22 | Hella 78140 Vélizy-Villacoublay globalization, stringent regulations, ecological concerns, increasing vehicle France 24 | EDAG Light Car complexity and reduced cycle times in which to meet consumer desires have Publication Executive: combined to create tremendous pressure. Emmanuelle Saby OEMs Chief Editor: 26 | Honda But with great challenges come great opportunities – for those nimble enough to seize them. Michael Marshall 28 | Peugeot Virtual Reality Center Transportation & Mobility Editor: 30 | Toyota Faced with a major transformation, leading actors around the globe – including Jaguar Bernadette Hearne 32 | Ford Land Rover, Renault, Great Wall Motors, McLaren Mercedes, and Tesla Motors – are Contributing Editors: 34 | Bentley Motors fundamentally changing their PLM strategy to gain agility, speed, cost reduction, regulatory Sabrina Khouchane Gregory Fournier control and, perhaps most importantly, the insights that lead to innovation. Each of these

Editorial Board: education companies, and hundreds more across a dozen industries, have adopted the open Version Olivier Sappin 37 | Georgia Tech/University of Detroit Mercy 6 platform for its unique value in helping them transform their operations to meet the Paul Silver industry’s demanding new reality. Photo credits: Dassault Systèmes’ SUPPLIERS Olivier Sappin customers and partners 38 | Plasan VP Transportation & For more than 25 years, Dassault Systèmes has been instrumental in helping companies worldwide master their information to drive innovation. DS has consistently supported the Design and Production: Mobility Industry The Ramey Agency OTHER trANSPORTATION Transportation & Mobility Industry through every step of its technological and business Printed in France Dassault Systèmes 40 | Motorcycles: Orange County Choppers evolution, from 2D to 3D design and digital mock-up, then moving to lifecycle management, 42 | Trains: Alstom and now to realistic experience of the vehicle in action. We recognize that you count on our solutions to help run your business, and we are committed to your success. Earning your 44 | Trains: Amtrak trust is our greatest achievement, and we strive to always be worthy of it. 46 | Buses: Viseon

Yes, the Transportation & Mobility Industry is under tremendous pressure. But pressure turns coal into diamonds. Together we can achieve the same transformation for the Transportation Industry, polishing a difficult today into a sparkling future.

The pages that follow demonstrate how DS is supporting vehicle makers and suppliers Get videos (and more) on your smartphone! worldwide as they transform their tomorrows. We look forward to doing the same for yours. The colorful square you see here is called a “tag”. It enables you to play videos and other With our technology and your ingenuity, the potential is limitless. bonus content throughout Contact mag. Here is how it works: 1. Open the browser on your smartphone and go to http://gettag.mobi 2. Follow the simple, free download process to get the mobile app appropriate for your type of smartphone 3. Open the app, focus your phone on a tag, and snap or scan it. Your browser will take you to the related content. This new technology allows Contact mag to offer you the same bonus features already available to the Contact mag Interactive readers. Enjoy!

3 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 3 From concept to road in 6 months eCar Design Challenge news Local Motors, which specializes in crowd-based design and manufacturing, took a new military vehicle from concept to working prototype in less than six months using the stimulates creativity Dassault Systèmes Version 6 platform.

Local Motors asked its community of more than 12,000 designers and enthusiasts to Dassault Systèmes (DS) – in collaboration with Show in September, help create a military vehicle as part of the U.S. DARPA (Defense Advanced Riversimple and the 40 Fires Foundation – presenting his winning Research Projects Agency) design challenge for a crowd-derived combat- recently launched an online eCar Design “Otto” design (right) to support vehicle. Using the DS Version 6 platform, individuals designed Challenge. The competition was created to industry professionals independently and then collaborated online, providing feedback on encourage global collaboration among design and the public. more than 150 entries. students by developing ideas on an open- source platform – the DS Version 6 platform. Anne Asensio, vice president of Dassault The winner, Victor Garcia’s FLYPMode design, was built into an Systèmes’ Design Experience, believes the operational prototype that incorporated concepts proposed by the Christopher Reitz, head designer at contest generated some exciting concepts. In addition to Baruchin, eCar peer community in the open-source process. Riversimple, says the competition “We wanted to formalize in a new context a competition finalists were: Clément motivated young designers to match their place where people feel secure and visible in Hoffner’s “Flower,” Ernö Péter’s “Definitive,” “Dassault Systèmes is a natural partner choice for us on this project,” Local capabilities against a wide range of their creativity,” she says. This contrasts with Raj Shekhar’s “Hydro-Hub” and Acatrinei Motors CEO Jay Rogers said. “We both see the future of product creation competitors, helping to further hone their the traditional approach of protecting designs Lucian Nicholae’s “Libertis.” based upon an open process where we gain wisdom from the masses in order to skills. The competition’s winning designer, for as long as possible, which can hinder the For more information: deliver truly relevant products. We could not have achieved the same outcome without Ido Baruchin, accompanied Dassault design and development process by creating http://perspectives.3ds.com/design/ecar their intuitive design and collaboration tools and support.” Systèmes to the Frankfurt (Germany) Auto what she calls a ‘black hole effect.’ McLaren Racing to deploy Version 6 Premium automaker implements Version 6

Dassault Systèmes’ Version 6 collaborative PLM solutions will play design, purchasing and manufacturing BMW chooses Version 6 PLM solutions to develop the electrical, be connected to the current BMW enterprise constituents,” said Jonathan Neale, environment, demonstrating the openness a vital role in helping streamline McLaren Racing’s processes. McLaren Racing’s managing director. “At electronics, and embedded software (E/E) architecture of its cars. of the Version 6 platform. This successful McLaren Racing, we are looking at every deployment, already in operation today, is McLaren Racing, the operating arm of the innovative design and concurrent opportunity to cut our time to market – BMW will leverage the Version 6 platform to platform. With the Architecture, Integration the first step in a ten-year partnership Vodafone McLaren Mercedes Formula 1 engineering, enhancing McLaren’s whether that’s through clever design, the manage the future complexity of embedded and Design for Automotive Project (AIDA), between BMW and Dassault Systèmes to team, is turbo-charging its development development efficiency. introduction of improved processes or, in systems in its cars, providing a master BMW will implement a seamless build the best infra­structure and applications efficiency with Dassault Systèmes’ open the case of Version 6 PLM, by introducing a architecture for all car derivations and collaborative process to connect the various for the E/E domain. Version 6 PLM solutions. “While it may look straightforward to guide a sophisticated product lifecycle management enabling continuous modernization of car constituents and actors of the E/E process, racing car from a 3D digital model to the system to improve efficiency throughout the functions. The re-use of functions and the putting BMW’s customers’ values at the “We at Dassault Systèmes are thrilled to ENOVIA Version 6 powers collaborative racetrack, it’s a process that involves an production cycle.” separation of hardware and software center of its innovation initiatives. The see that BMW is using our Version 6 platform innovation at McLaren, with a single extraordinarily complex and components in the development process Version 6 PLM systems design solution will and receives all the benefits of a unified, reference for managing engineering, disparate series of interlocking will help BMW gain significant cost savings collaborative PLM environment,” said Dominic intellectual property and business in the E/E domain. BMW and Dassault Systèmes Florack, senior executive vice president, processes. CATIA Version 6 will drive have signed a ten-year Products - R&D, Dassault Systèmes. “By Because of the flexible PLM backbone and strengthening Version 6 with new search the large degree of out-of-the-box, partnership to build the best technology, Dassault Systèmes provides a specialized functionality for systems infrastructure and applications new class of PLM Systems Engineering engineering, thousands of BMW engineers for the E/E domain. Solutions, which give a strong competitive will be using Dassault Systèmes’ Version 6 advantage to our customers.” zoom in… High-octane supplier Strategic systems Global competitive Turbocharge product innovation engineering advantage development Ford Motor Co. collaborates with DS, Leverage insights from DS experts Gain distance on the competition Master operational excellence ensuring strategic solutions to and fortify your global competitive by developing lighter, stronger by improving communication and Use your smartphone accelerate innovation in its global Use your smartphone advantage. Use your smartphone components while ensuring optimal Use your smartphone standardizing processes throughout the to read about to read about to read about to read about supplier innovation supplier community. systems engineering global advantage product performance. operational excellence enterprise and across the product lifecycle.

4 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 5 Focus on Transportation & Mobility

May you live in interesting times, the old saying goes. For Transportation & Mobility companies, these are not just interesting times, but challenging ones. Design cycles are shorter. Time to market is compressed. Demands to do more with less only keep growing. Clearly, old ways of working can no longer keep pace.

But interesting times can also be times of tremendous opportunity, when innovative approaches can convert difficulty into success. In this special edition, Contact mag looks at the transportation OEMs and suppliers that are changing the way the industry works and the Dassault Systemes solutions that are helping them thrive in interesting times.

6 Contact mag | Dassault Systèmes

V6 Innovation Body Accelerating vehicle innovation Styling OVERVIEW Virtual Simulation in White with Version 6 Knowledge-Based Global By Olivier Sappin Collaboration Vice President Transportation & Mobility Industry] Compliance Design/Engineer DS is the leading PLM solution provider to more than 70% of Program Management global automotive OEMs and Powertrain Engineering their suppliers. and Manufacturing Vehicle Architecture Production & Assembly suppliers, DS experts support strategic initiatives focused on the transformation of automotive Global Product Program Management product development, manufacturing and Engineering Motorcycle enterprise collaboration processes to: Eco-Car Body-in-White • Develop zero-default vehicle geometry, fit Engineering and Manufacturing Train and fabrication. Vehicle Systems • Produce the safest, high-performance Architecture vehicles with comprehensive requirements Automakers are under intense or more than 20 years, manufacturers and Version 6 also provides a single platform that performance and effectively manage traceability. suppliers of automobiles, motorcycles, trains, consolidates product-related information, strategic activities, all while collaborating with • Design energy-efficient vehicles with pressure to improve the efficiency Fbuses and more have relied on the power of making it visible and actionable by participants global teams and key decision makers. permanent weight control and systems and effectiveness of how they design Dassault Systèmes PLM to help achieve concurrent from all areas of the extended enterprise. With • Powertrain Engineering & Manufacturing: optimization. and build vehicles. OEMs must deliver development, seamless integration, simultaneous Version 6, “PLM online for all” comes to life, Develop and optimize engine and • Accelerate new product innovation and engineering, and real-time visibility. allowing users everywhere to work concurrently transmission design; simulation and improve quality in a “3D online for all” what the consumer wants, when and where in real-time on the same data via a simple web environment that optimizes the in-car they want it, at an acceptable price. Only a Today, however, automotive manufacturers and their connection to a single server. experience with consumer feedback suppliers need more from their PLM solutions. gained through social innovation. profound evolution of the industry’s infrastructure, To meet requirements for global product development With 3DVIA for lifelike experience, CATIA • Simulate product performance in the processes and core technologies can meet this and increasingly complex vehicles, they must expand for virtual product design, ENOVIA for digital stage, when changes are least PLM beyond engineering and manufacturing. collaborative innovation, DELMIA for digital expensive to make. demand for new vehicle innovation. By including everyone with a role in a vehicle’s life – manufacturing, SIMULIA for realistic • Manage a single PLM platform/repository from internal functions to end consumers – simulation, 3DSwYm to create dynamic online for IP management. manufacturers can slash development times and communities, Exalead for information Regulatory • Reuse design/production data and delight retail car buyers. intelligence and 3DSwYm for social innovation, Compliance Management preserve methods and processes across automotive manufacturers and suppliers can: programs. Accelerating innovation validation; structural dynamics, noise and • Enhance global collaboration at multiple with Version 6 PLM • Vehicle Design/Styling and Surfacing: vibration; manufacturing casting and forging, sites and throughout supply chain. To achieve these goals and innovate efficiently, Master the entire vehicle design/styling machining, and assembly planning. • Ensure delivery of projects within Transportation & Mobility companies must master workflow, including concept design, • Body-in-White Engineering & Manu- performance and timing guidelines. disparate sources of globally distributed intellectual mechanical design, surfacing, refinement, facturing: Accelerate BIW design, • Provide accurate, real-time 3D review and assets and facilitate open, frequent, ad-hoc and reverse engineering. development and production, simulation, reporting of program status. collaboration across the enterprise and into the • Vehicle Systems Architecture: Manage and validation. Optimize occupant safety, • Leverage proven, “ready-to-use” PLM marketplace. end-to-end vehicle software architecture strength and durability. business processes. and systems engineering processes, • Regulatory Compliance Management: Dassault Systèmes’ online, collaborative Version 6 including functional analysis; logical Deliver innovative yet environmentally From vehicle design concept to embedded PLM solutions enable OEMs and their suppliers to systems design; multi-physics behavior compliant products that meet global systems engineering and powertrain production, accelerate the development of innovative products with modeling and simulation; and market demands. DS provides world-class capabilities that ensure higher rates of market success. The integrated DS configuration and change management. success. PLM portfolio enhances business processes and • Global Product Program Management: Innovation beyond software Vehicle Design/Styling and Surfacing facilitates global collaboration, transforming information Leverage intellectual capital, navigate As the leading PLM solutions provider to more For more information: www.3ds.com/automotive into actionable knowledge in a lifelike 3D environment. program content, assess project than 70% of global automotive OEMs and their

8 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 9 At Renault, bringing high quality, affordable vehicles that meet the market’s expectations for advances in customer experience and environmental VERSION 6 responsibility are not just lofty goals, but the key tenets of doing business. Renault drives the customer To successfully deliver on these challenges and set itself clearly apart from its competitors, Renault chose Dassault Systemes’ Version 6 PLM platform By Lisa Roner experience with Version 6 ] as the cornerstone of its global automotive engineering processes.

enault wanted an enterprise-wide PLM Renault chose Dassault Systemes’ management across product, process, Colmard. “Version 6 met these requirements, impacts of travel,” Colmard says. “And we also solution that would effectively address issues simulation and performance,” says Olivier while offering a strong dose of ergonomics over have the ability to understand each other better Version 6 PLM platform as the Rof standardization for its processes and Colmard, vice president, Information Systems older systems. It was important for us to and interact more easily with colleagues in design tools. With more than 40% of its engineers cornerstone of its global automotive for Engineering & Quality, at Renault. “This new simplify 3D navigation through a vehicle or foreign languages through the common located outside of France in “technocentres” in engineering processes to support an tool, in addition to being modern and efficient, engine that allowed access to all of our language of 3D drawings or scans. I think there Romania, India, Korea, South America and Spain, the must facilitate collaborative design between our engineering documents or deliverables.” are real benefits to working around a screen Use your smartphone company needed a global engineering tool that would internal program called NewPDM corporate technocentre and Renault’s other together, even if it’s remotely with 3DLive.” to learn more about how Renault uses allow its designers to effectively and efficiently technocentres around the world. In addition, we Collaboration with 3DLive Version 6 Olivier Colmard, vice president, Information collaborate around the globe. Systems for Engineering & Quality, Renault sought a solution that would support openness Colmard says through Renault’s Quick Win Data access and to outside collaborators, suppliers, our Alliance deployment approach the company has been management with Version 6 “To achieve our strategic growth plans, we need to Renault also sought a solution that would allow it to partner Nissan and other partners such as able to implement 3D collaboration with 3DLive A single database prevents problems with data ensure our performance in R&D and investments. And easily access and manage all of the company’s data Avtovaz and Daimler as part of Renault’s among its sites. The immediate and future reconciliation, says Jean Pierre Chatenet, that performance depends on reducing development – from product design and process to simulation, extended enterprise.” benefits are clear, he explains. NewPDM Architect & Functional Infrastructure cycle times and standardizing the components we testing and resources information – while ensuring manager at Renault. The appeal of one repository develop,” says Odile Desforges, EVP, Engineering and its traceability. “Renault chose Dassault Systemes’ Version 6 “First, we can measure savings in travel time. with fast response times for users regardless of Quality, Renault. “It became immediately obvious to us PLM platform as the cornerstone of its global We no longer have to send our Romanian and geographical location, he says, was a key reason that Dassault Systèmes, with its programs, software, and “We wanted a single PDM that could be deployed automotive engineering processes to support Korean designers to France and vice versa. for choosing Version 6. “We needed a system that tools was the company best suited to address our needs.” worldwide to cover all of Renault’s needs for data an internal program called NewPDM,” says This saves the time, cost and the environmental was quite independent of latency,” he stresses.»

10 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 11 First, we can measure savings in travel time. We no longer have to send our Romanian and Korean designers to France Document management also is vastly Systèmes to enhance and implement Version 6 Being able to and vice versa. This saves the time, cost improved with Version 6, Colmard says. in a variety of pilot and production projects that display the “Through our Doc Eng Project, we’re able to are beginning to prove its integral value to complete digital and the environmental impacts of travel. manage our engineering deliverables,” he Renault’s future and help keep it a step ahead mock-up of a explains. “Before, to be honest, our documents of its competitors. car or engine in Olivier Colmard, vice president, Information were scattered and poorly managed. With real time is another Systems for Engineering & Quality, Renault Version 6, we’ll have full traceability of all of With PDM Test, Renault will be managing all key advantage, our deliverables. The documents are easily the results of its physical or bench testing Chatenet says. “This was engine project. NewPDM program will enable us to better accessible and, in some cases, even rework centers. And Colmard says PDM Calculation a dream when I started with Chatenet says all of manage different configurations and optimize is avoided, since at any moment you can refer allows the company to store and manage PLM 20 year ago, but we saw three the parts for the motor will be the maximum weight, aerodynamics, etc., while to past studies and transmit know-how and both the input data for simulations and years ago that with Version 6 it was quite designed and managed using Version 6. And effectively reducing our time to market and results to downstream teams.” calculations, including aerodynamic and possible,” he says. “You can view parts, explode graphs are in another system,” he explains. plans are underway for a new vehicle project to meeting our customers’ expectations. other tests required by regulators, and the sections, get drawings – all in real time.” “With Version 6, it will be managed in the same begin using Version 6 at the beginning of 2012. In the two years since its selection of Version 6, results of each of these calculations for the system with relationships between process Partnering with DS Renault has worked closely with Dassault different versions and configurations of the Chatenet says because Version 6 enables even information, function and part instance through Driver experience Renault is proud of its partnership with DS to digital models its engineers use. Eventually, those not skilled in the use of CATIA to access strong relationships between BOM and DMU.” Renault’s end goal is always to provide its develop next generation solutions that meet the he says, these solutions will be deployed and view digital mock-ups, an advantage customers with the best vehicle possible at an unique needs of the automotive industry. The throughout the company. Renault calls democratization, DMUs can be “As you know, the car has become a complex affordable price. For drivers, Colmard says, company praises DS R&D as a strong force for used to navigate, review and retrieve system,” Colmard explains. “With more there is a clear quality issue. “Through the innovation and believes its PDM solutions are a A single platform yields information. “You can quickly assess the level electronics, computers and on-board telematics, kinds of tools Version 6 provides, there is an tipping point for the industry. one version of the truth of maturity of a design and even casual users we need a tool to manage all this complexity and efficiency of design that allows us to ensure Renault also sought a single, integrated can see where there are problems or where systems engineering using NewPDM allows us that we do many good things with maximum “Together, we are not doing another platform for all of its PDM/PLM tools. “In the validation is still required,” he says. to do that. Also we can manage and test return of experience and knowledge optimization of an existing generation of PDM, past, we had CATIA V5 with a variety of PDM/ physical simulation data and results to optimize embedded into our products,” he says. “The but a new generation of PLM 2.0 based on the PLM solutions,” Chatenet says. “We saw with Once Version 6 is fully implemented and our systems and processes. And the level of quality axis is very important.” processes and needs we have at Renault,” functional design, for instance, it was difficult to all engineering information is inside the same digital continuity Version 6 provides will allow us Colmard says. He believes Renault’s use CAD from one vendor and PLM from system, Chatenet says, Renault will be able to to leverage engineering data in marketing and Colmard believes Version 6 can help Renault partnership with DS to develop new solutions another. Because we had CATIA and did not manage the associativity or digital continuity even after-sales activities such as repair and meet its responsibilities and commitments to its gives his company a leg up on its competitors want to change, Version 6 with CATIA V6 among different domains or clusters of diagnostics. There is a digital continuity from customers. “Our goal is to design vehicles that on implementation of Version 6. completely integrated was an obvious choice. information that today are split between different start to finish, from design to the customer.” are both effective and as efficient as possible, It guarantees relationships between objects are systems. “For example, today inside DMU, we while being affordable and offering maximum For more information: managed and we know we’ll be able to better manage parts, but not welding points and Since September 2011, Renault engineers use benefits to the passenger,” he explains. “It is www.renault.com manage functional design.” process information like body-in-white assembly CATIA V6 and ENOVIA V6 for PDM on a new clear that with a tool like Version 6, our www.3ds.com/automotive

12 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 13 VERSION 6

Use your smartphone to learn more about how Jaguar Land Rover uses Version 6

aguar Land Rover’s heritage comprises some of compatible. To flourish in business, all our data must the world’s most iconic vehicles, including the be interoperably integrated and intuitively available to JJaguar Mark II, the E-Type, and the Land Rover every JLR stakeholder.” Defender. Having passed through the corporate hands of Ford, Jaguar Land Rover (JLR) has emerged within To enhance innovation and reduce development time, Tata Motors as an exciting, dynamic global enterprise. JLR has partnered with Dassault Systèmes (DS) to deploy Version 6 in a business transformation A glance at the Jaguar C-X16, C-X75 and Land Rover program called i-PLM. “Many business users, and DC100 shows the shape of things to come, while press even suppliers of PLM strategies, fail to understand its Jaguar Land Rover: Transforming acclaim greeted Range Rover’s recent launch of the end-to-end power,” Davies says. “They see PLM as a lighter, greener Evoque. Turning heads from Chicago data management system rather than a business to the foothills of Kanchenjunga, Nepal, Evoque is a true transformation (BT) tool, as IT rather than BT. Version its business with Version 6 inheritor of its parent brand’s hard-won esteem. 6 provides a powerful yet simple out-of-the-box PLM solution with ENOVIA as its backbone and CATIA, Complex history DELMIA, SIMULIA, and 3DVIA to deliver business and Due to its varied ownership history, JLR inherited a engineering value across Jaguar Land Rover, in partnership with Dassault Systèmes, is deploying complex and mixture of auto industry software from the JLR organizations.” Immediate benefit of creating, seeing, By Nick Lerner ] Version 6 PLM across its extended enterprise. This bold move delivers its previous owners, not scaled or supportive of JLR’s experiencing and sharing data in a aggressive business plan. JLR i-PLM covers the important engineering, technical and commercial benefits for sustainability, entire vehicle definition Version 6 environment, translating into business and vehicle development. Paul Davies, JLR’s director of Product Development and features across 14 time savings of up to 40% for some Operations, leads the teams that define JLR’s vehicle domains. These include specific roles in product development development processes, tooling technology, and bills of material, parts and project and Product Lifecycle Management (PLM) assembly, requirements technologies for the worldwide engineering community and verification, plus in- Paul Davies Director of Product Development of 8,000 JLR people. “The challenge of expanding vehicle embedded Operations, Jaguar Land Rover JLR’s vehicle portfolio into segment-defining products software, which accounts requires strong technical foundations,” Davies says. for 60% of new car development. Electrical design, “Our IT history has generated more than 600 islands styling, and computer-aided engineering, including and silos of JLR legacy data. The majority is not inter- multi-physics and FEA, are also included. »

14 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 15 assets. This allows people to more fully engage with JLR and its spirit of innovation. Sharing designs synchronizes teams at JLR and its suppliers. Engineers, manufacturers, marketing and sales, feasibility, sourcing, and finance can collaborate earlier with the joint vision Version 6 delivers.”

3DVIA extends digital enfranchisement even further, Program Central, for example, manages collaboration providing accurate, live, current and fully validated 3D and helps to deliver business acceleration through data within and beyond JLR. It reduces errors, losses concurrent development. “When information is open and waste by providing accurate, timely information. and shared, skills can be deployed more effectively,” These factors raise morale as people work with PLM Davies says. “This data availability means people can 60% solutions matched to their needs. work up to 20% more efficiently.” JLR i-PLM covers the entire Team challenge Knight-Gregson adds: “i-PLM makes better use of vehicle definition As design progresses, DELMIA Version 6 simulates resources, including time. It also introduces multiple and features and validates JLR production environments virtually, efficiencies.” For example, SIMULIA Version 6 enables across 14 including buildings, production cells and even JLR to perform virtual tests of vehicle and material domains. These technicians, who are represented by lifelike digital performance in a virtual 3D environment. Errors are include bills of manikins. “Simulated digital representations in detected and corrected earlier to produce significant material, parts DELMIA enable optimization of our production savings. “In addition, virtual build improves physical and assembly, environments,” Knight Gregson explains. “3D digital build quality and productivity through enhanced requirements factory overviews, coupled with highly detailed training and cognition for production engineers,” and verification, plus in-vehicle machining operations, allow us to more fully Knight Gregson says. “It also values fitted parts in embedded understand and further optimize operations. This also real-time, providing an accurate business cost of software, which enhances processes and their interactions at JLR. each vehicle made.,” accounts for These measures augment sustainable development 60% of new car through efficiencies leading to reduced energy and i-PLM with Version 6 also extends beyond the JLR development. resource usage. enterprise, supporting access by JLR dealers, service engineers, and customers. “This allows vehicle “Version 6 empowers data users and managers with live John Knight Gregson is i-PLM program lead at JLR. ENOVIA Version 6, meanwhile, gives JLR a single purchasers and drivers to more fully understand » 3D visualizations of all product data and manufacturing “JLR deploys DS Version 6 from vehicle design source for regulatory and materials compliance data ranges and option choices for better driving, owning operations,” Davies says. “Assembly and disassembly concept, through engineering and manufacturing, to that is available to all stakeholders. This helps JLR and servicing experiences,” Davies says. routines with legislative parts and vehicle governance marketing and sales,” Knight-Gregson says. “It’s a increase scale and volume of products with data are readily available in manageable formats. The robust, seamless and integrated solution that delivers confidence of compliance. ENOVIA Version 6 Version 6 and i-PLM are being jointly developed by immediate benefit of creating, seeing, experiencing and data consistency across suppliers, financial control Jaguar Land Rover and Dassault Systèmes to sharing data in a Version 6 environment is translating and supply chains. An ERP interface provides further become the automotive industry’s most advanced into time savings of up to 40% for some specific roles in systems and process synchronization and PLM system. product development.” management. Working with Version 6 generates a single version of the truth at JLR and brings high- “We chose Dassault Systèmes as a partner, not just Smooth is fast percentage efficiency returns. Data that is entered on technical or commercial merit, but because they Version 6 deployment also delivers improvements in once is shared and reused many times. display the same level of passion and pride in their vehicle volumes and quality at JLR. For example, i-PLM Concurrent engineering between teams across business as Jaguar Land Rover does,” Davies says. produces precise cost-benefit criteria for more the world generates collaboration with a “Together we are building a lifelike product experience informed decision making. “Version 6 delivers extra guarantee of accuracy that cuts waste while system that connects us to our products and time for innovation so that JLR can build more and improving productivity.” communicates throughout the enterprise using the better vehicles,” Davies remarks. “Version 6 provides a universal language of 3D. Harnessing the power of seamless operating world, with extensive Tier-One i-PLM facilitates bringing 3D digital models and our partnership with Dassault Systèmes, i-PLM helps supplier involvement. These factors, and the product definitions into context and further use Jaguar Land Rover confidently and successfully build considerable financial and business benefits that i-PLM by JLR and its suppliers, Knight Gregson on its heritage through Version 6 business delivers, mean that JLR can add vehicle programs and comments. “Version 6 provides enterprise wide transformation.” smoothly accelerate global product development.” availability of CATIA 3D product simulation For more information: www.jaguarlandrover.com www.3ds.com/automotive

16 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 17 Tesla Motors: Changing the By Greg Rice] VERSION 6 automotive paradigm with Version 6

“Tesla has been using DS products almost since its Scaling up for the Model S inception,” notes Paul Lomangino, Tesla’s engineering In developing Model S, Tesla is leveraging much of the tools director. “SolidWorks and ENOVIA SmarTeam engineering work that went into developing the Roadster. helped us start this company and were critical to the success we’ve had to date. ENOVIA Version 6 is ENOVIA Version 6 will allow Tesla to open up the helping us build on that success by managing all of collaborative process even further, making it possible our existing data as well as the increased complexity to involve partner-suppliers and even customers in of our collaborative environment and our product the development process. Meanwhile, the offerings.” collaborative and interactive communication We’re not customizing Version 6 capabilities enabled by two other DS per se, so we have something Version 6 plays central role solutions, 3DLive and 3DVIA, become even that’s easily upgradable but is in Tesla’s processes more critical to delivering a detailed view of ”V6 PLM is intrinsic to the way Tesla works today,” new product development. still tailored to our needs.” Lomangino says. “It provides the common language we use in collaborative product development and “We’re already working to get supplier Jack Brown production every day.” access into the system so there will be one PLM Support Specialist source of design truth in a secure environment,” Brown Tesla Motors Going forward, Lomangino says Version 6 will touch says. “3DLIVE and 3DVIA will help to open up the design nearly all aspects of Tesla’s operation, from concept process even further because you don’t need to be a development to engineering, manufacturing, quality CAD expert to work with them.” assurance, sales and marketing, so that everyone in the company can participate and contribute more Lomangino adds: “At Tesla Motors, we depend on effectively. everybody to be as creative and productive as possible. Part of the power of Version 6 is its ability to allow “Quality is absolutely critical to Tesla,” Lomangino everybody involved in the product development process notes. “The ability of ENOVIA Version 6 to handle to focus on being creative and productive rather than the complexity, both in our product and our process, focusing on the process and tools.” as we move forward is very important. Its ability to Version 6 PLM is intrinsic to the way Tesla works unify multiple organizations under one banner and To read an expanded version of this article visit bring them all together within a common tool will today. It provides the common language we use in www.3ds.com/contactmag-extra collaborative product development and production. help us immeasurably going forward.” By standardizing on an integrated DS solution, including For more information: Use your smartphone Paul Lomangino ENOVIA Version 6 for collaborative data www.teslamotors.com to learn more about www.3ds.com/automotive Tesla Motors. Engineering Tools Director, Tesla Motors management, CATIA for integrated product design, and DELMIA for digital manufacturing and production, Tesla also will no longer face the need The Tesla Model S is a family-sized As an automotive start-up, Tesla Motors needed esla Motors, based in Palo Alto, California, to translate data. sedan designed from the ground up was founded in 2003 by engineers who set as an electric vehicle. to efficiently engineer a vehicle from the ground up Tout to prove that electric vehicles did not have Jack Brown, PLM support specialist at Tesla, says with an electric powertrain. Collaborative design to be unattractive, slow econoboxes with limited that because Version 6 eliminates data translations range. Instead, they could be awesome. and other barriers to collaboration, functions is a critical element as Tesla paves the way for throughout Tesla are realizing the benefit. “To get all market acceptance of electric vehicles. The Tesla Roadster, introduced in 2008, is arguably departments involved early and get their feedback one of the most attractive sports cars on the road on the initial releases is a lot better than getting that and boasts performance that few expected from feedback at the end, when it becomes much more an electric car: 288 horsepower, a top speed of expensive to incorporate those changes,” Brown 125 miles per hour, and 0-to-60 acceleration in less says. than four seconds.

18 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 19 VERSION 6

first of its kind In China. “ENOVIA ensured that Great Wall Motor masters materials compliance our RRR certification program functioned smoothly,” said Yuchuan Wang, deputy director of International Market Promotion Department, GWM. “Without it, we wouldn’t have been able with ENOVIA Version 6 and CATIA to fulfill our goal in such a short time. With ENOVIA, we can collaborate across many To diversify into international markets, GWM needed to establish an enterprise-wide compliance materials selected during product development departments, including product design, supply meet relevant regional and global regulations, and chain management, manufacturing, material platform capable of ensuring adherence to eco-design standards and enhanced product quality. enable enterprises to collect, sort and generate testing, materials data system development, and Using DS PLM solutions, GWM was granted the EU accreditation certificate for materials compliance part-level material verification reports and material laws and regulations management.” for four of its models in 2009, becoming the first Chinese brand officially accredited by the EU. composition data more easily. Zhang says. “In the past, it would have taken Improved design quality around 20 people working together to simply GWM product compliance engineers can view with CATIA design a new product. Now, less than ten reat Wall Motor Company Limited into the international market. A cornerstone of We are focused on creating material content information in the context of the As GWM’s business continued to expand, the people are required to complete a product (GWM) is a privately owned automaker its strategy was a PLM solution that would world-class vehicles and product bill of materials and cross-reference this company chose CATIA to deliver products on design, which has helped to dramatically Gwith headquarters in Baoding, China. enable GWM to enhance its eco-design to data against multiple regulations. “ENOVIA MCC time and on budget. GWM uses CATIA to shorten the time to market.” With revenues of $1.2 billion and products sold meet the environmental standards and expanding our reach...DS has enables us to proactively manage all of the perform virtual design and testing, digital mock in more than 120 countries, GWM was China’s regulations of the European Union (EU). To help been a great strategic partner reporting and analysis requirements for up and digital assembly, and to reduce R&D In September 2009, GWM became the first first private automobile enterprise listed on the achieve this objective, GWM selected Dassault who understands our vision thousands of parts and the multitude of suppliers development cycles. Chinese automaker to receive the EU WVTA Hong Kong Stock Exchange. Systèmes’ (DS) Product Lifecycle Management involved in the development of our products,” accreditation certificate. Four models received (PLM) solutions. and is now playing a crucial says Shuli Li, deputy president, GWM. “With CATIA, we can insert the driver virtually the accreditation: Florid, Coolbear, Hover 5, As the largest commercial pickup and SUV role in helping us realize it. into the digital mock-up of the car,” said Yong and Wingle 4. “Thanks to Dassault Systèmes’ manufacturer in China, GWM wanted to Using ENOVIA to achieve Rising to the challenge Zhang, chief of information management, assistance in helping us improve the eco- improve its competitive advantage and expand eco-design compliance Particularly challenging among all the EU GWM. “We can then optimize the simulation design and shorten the certification process, Shuli Li To gain unrestricted access to the European testing items is the Reuse, Recycle, Recovery design to ensure that the driver will fit perfectly we finally made it,” Li says. “We are focused on Deputy President, GWM market, GWM had to meet the EU’s Whole (RRR) certification, which governs and monitors and be able to operate the car with maximum creating world-class vehicles and expanding Vehicle Type Approval (WVTA) certification. The GWM chose ENOVIA Materials Compliance the environmental impact of an automobile. It safety and comfort.” As the deployment of 3D our reach to take advantage of new global EU certification consists of 48 testing items, Central (MCC), part of the ENOVIA Version 6 bans the use of materials that contain heavy virtual design expanded to more departments, markets. DS has been a great strategic partner which set high standards for vehicles in platform. ENOVIA MCC is a business process metals, mandates recycling design, and GWM improved the quality of its designs, who understands our vision and is now playing areas that include emission levels, application that empowers companies to adopt requires a data collection and monitoring avoiding mistakes in the earlier phases and a crucial role in helping us realize it.” safety, and environmental proactive environmental compliance strategies system for all the materials in the supply chain. reducing costs caused by mistakes. impact. throughout a product’s lifecycle, from design to For more information: disposal. Its strong search mechanisms and To obtain the RRR certificate, GWM established “DS PLM solutions play a key strategic role in www.gwm.com.cn/en analytical capabilities allow users to verify whether an End of Life Vehicles (ELV) project team, the helping us bring the innovation process to life,” www.3ds.com/automotive

20 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 21 VERSION 6

Version 6 provides a Overview of the themes The integrated visualization features of Version 6 and modules complete PLM environment also may lead to a reduction of data transfer rates Working with Dassault Systèmes and its partner with significantly more and could significantly reduce network peak Transcat PLM, Hella decided to carry out a process information available loads. This is extremely important for Hella as it “Version 6 Starter Kit” pre-project. The starter kit wants to improve international collaboration. involved a test installation with several Version 6 than we had before. test licenses of CATIA, DELMIA and ENOVIA, Next Steps plus the implementation of 13 workshops lasting Dr. Ulrich Kertscher Hella believes that the Starter Kit provides one to two days each. Version 6 key topics and Design Methods & Tools excellent support for the introduction of Version 6. solution modules were presented to a total of ten Hella “We wanted to evaluate Version 6 capabilities IT, software development, design, production as well as identify what effort we would have to and shop floor planning representatives and expect to customize the solution according to complemented with hands-on demonstrations to our needs,” Dr. Kertscher says. “The Starter Kit reinforce each topic. allowed us to get a feel for this, and now we The validation phase lasted two months. know which modules of the Version 6 PLM Automobile supplier Hella Workshops focused on installation, Improvements were recorded in the CATIA environment will be useful for us.” Hella has configuration and user interface as well as environment, including advantages in how design also expressed its appreciation for the concepts such as change management, bill of data can be delivered and accessed, in simplified contribution made by the Dassault Systèmes optimizes its processes materials management, requirements processing of large assemblies, as well as better and Transcat PLM employees: “Everybody management and the SAP interface. Specialists support for multi-site development. The potential involved was highly motivated in helping us By Heike Blödorn examined, for example, whether the use of Version 6 for requirements management is learn more about Version 6.” Hella therefore ] with Version 6 Version 6 functionalities available in CATIA for facilitated by its comprehensive set of functions believes that the validation process was well integrated product design, DELMIA for digital as well as ability to trace and manage worth the investment. Two more projects Hella KGaA Hueck & Co., ella KGaA Hueck & Co. is an Always one step ahead manufacturing and production, and ENOVIA for requirements across the different functional, are planned. a CATIA user since the mid- automotive supplier that develops and To help it meet a temporary surge in workload, global collaborative innovation, met Hella’s logical and physical views. Hella could therefore Hmanufactures automotive lighting designers working at Hella’s headquarters in requirements and whether the company’s use it to avoid having to resort to a separate In the near future, the deployment roadmap 1980s, investigated systems, including headlamps and rear lamps, Lippstadt, Germany, are assisted by teams existing processes could be optimized. The aim solution for mechanical development. will be defined, including an assessment of adopting Dassault Systèmes as well as electrical systems, including sensors working in India, China, the US and across the cost involved for a startup. In the first and actuators or driver-assistance systems. The Europe. In this way projects can be rolled out in phase, a detailed project evaluation will Version 6 solutions early in company employs more than 23,000 people a continuous manner, 24 hours a day. be carried out. Additionally, the overall 2010. Through a series of worldwide, distributed across 70 production benefits for Hella in the field of requirements workshops, together with sites, fully owned subsidiaries and joint-ventures “Our vision of responding to market demands management will be evaluated. in 30 countries. More than 3,500 engineers and faster than our competition and anticipating Dassault Systèmes and technicians are dedicated to research and future requirements are what motivates us,” The automotive supplier is already a step ahead Transcat PLM GmbH, Hella development throughout the group. explains Dr. Ulrich Kertscher, who is responsible of the first evaluation was to be able to ask Thanks to the new database concept in Version 6, of the competition: “We want to introduce for the Design Methods & Tools used at Hella. pertinent questions regarding the the product models are filed using metadata and Version 6 because we are convinced it will evaluated Version 6 Hella has an installed base of 1,300 CATIA seats implementation procedure. “We wanted to are up to date; link management is significantly enable process improvements,” Kertscher both from a strategic and worldwide, dedicated to the development “Version 6 provides a complete PLM know what to expect in terms of customization, improved; and distributed engineering is says. “We also want to be prepared as the first of products that include headlights, lighting and environment with significantly more process which interfaces we should implement, and optimized. In addition, Hella now benefits from an OEMs and partners adopt V6.” methodological point of view. front-end modules as well as body electronics, information available than we had before,” Dr. how we will need to manage structures in the easier management of large assemblies, as driver-assistance and climate-control systems. Kertscher says. “Even though this is new future,” Dr. Kertscher explains. “It was also different users can now load, edit and store them For more information: With CATIA, designers often manage assemblies territory for us, we are excited to apply its many necessary to clarify how we exchange SAP simultaneously. Users no longer risk accidentally www.hella.com that contain thousands of parts and benefits to our work and to demonstrate these objects with Version 6 through migration, overwriting sections, and concurrent changes www.3ds.com/automotive subassemblies. benefits to our management.” conversion or infrastructure.” can now be easily merged.

22 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 23 EDAG Light Car: VERSION 6

Electric car of the future Detailed engineering in three phases understand intuitively, because they correspond to real life. Karina Schäfer, a project manager and expert responsible “Version 6 is reflected in the simple and intuitive for digital factory production solutions, explains the decision representation of assembly sequences from the EBOM by for DELMIA Version 6 with the positive experience in using drag and drop,” Möller said. DELMIA software for other EDAG projects. “The detailed engineering with EDAG basically occurs in a three-stage After completion of the pilot phase, the advantages of model,” Schäfer said. The first stage covers pre- DELMIA Version 6 could be applied to day-to-day tasks. engineering, including the definition of product standards Since processes are assigned with the predefined and and the investigation of influential factors. “Pre-engineering planned resources in influences the product with regard to production 3D, this significantly Version 6 is reflected in the simple requirements.” In the second stage of the digital factory, the simplifies project and intuitive representation of concept engineering and 3D detailed engineering are processing. “Thanks to depicted. Finally, the third step describes the virtual the 3D element, assembly sequences from the commissioning and implementation of the system. “After application is simplified, EBOM by drag and drop. all, our customers are also able to inspect the system more comprehensible using the virtual model,” Schäfer pointed out. and efficient for the Torben Möller planner,” Möller said. In Planner, EDAG This method using DELMIA Version 6 particular, data acquisition can be carried out more provides clear advantages by easily. “If in fact all information is available when using accessing an integrated data Version 6, the real work of the planner — that is the model that does not require creative part of his job — can be significantly expanded, problematic interfaces. “With since with DELMIA Version 6 the process of information EDAG Light car - The new generation EDAG Light Car, we’ve acquisition is considerably more transparent for of electric vehicles with O-LED Technology as a communication element outdoors implemented DELMIA Version 6 planning.” for the first time in a pilot project,” said Torben Möller, a planner from EDAG. “The product developer generally determines the structure of how the individual parts are assembled. With Version 6, operation is simpler because The EDAG Light Car has a body through an intuitive drag and drop concept developed specifically function, the necessary compo­nents and EDAG Group is a partner of the international mobility elements can be used and integrated, for for the new generation of electric industry. Its main activities include the complete example, into the assembly or process vehicles using the latest lightweight development of vehicles and production facilities. sequence.” DELMIA Version 6 is conceived Additionally, the company is positioned as a turnkey partner in such a way that it permits database- materials, semi-finished parts and in plant construction and small-series production. To supported planning in conjunction with assembly sequences. With its develop and implement this unusual, future-oriented ENOVIA. For the EDAG Light Car, the approach for design, traffic control systems and vehicle simple and intuitive operation of the innovative lighting concept, it is one technology, the teams at EDAG take advantage of the planning software has been employed and Isometric view of the manufacturing cell designed with DELMIA Version 6 of the first vehicles to use O-LED Product Lifecycle Management (PLM) solutions from tested with the database. technology as an individually Dassault Systèmes (DS). The successful, constructive and close cooperation New horizons with Version 6 between EDAG and DS continues. “We are engaged in adaptable design and Starting with the design all the way to the finished product, The successful pilot project highlighted additional a close dialogue with DS in order to improve DELMIA communication element outdoors. the process includes the entire scope of manufacturing improvements for the day-to-day work of users. The “lifelike Version 6 even further for productive project lifecycle management and PLM. The EDAG Light Car was experience” provides users with a better overview of implementation by drawing on experience from the developed using CATIA Version 5. The production concept intermediate products and greater transparency throughout EDAG Light Car project,” Schäfer added. was realized with DELMIA Version 6 — from planning the the manufacturing process. Version 6 solutions offer assembly and process sequence to the setup of the powerful, user-friendly search and navigation capabilities in For more information: manufacturing cell, robot simulation and line balancing of order to access desired information from anywhere online www.EDAG.com the EDAG Light Car manufacturing cell. and depict it in realistic 3D environments that people www.3ds.com/automotive

24 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 25 OEMs

The automotive market is in a period of great change, so model- CM: So calibration and evaluation are definitely based design that leverages 3D digital simulation (CAE) is increasingly required to achieve greater accuracy? important in helping automakers keep pace. Kazuo Sakurahara, KS: That’s right. What is important is to note formerly head of engine development for the Honda F1 team, is that calibration and evalutation are seen as “tests to increase the accuracy of simulations.” leading creation of a new development process at the Honda R&D Feeding the statistical model obtained from the Co., Ltd. Automobile R&D Center that relies heavily on CAE for results of experiments back into the physical model allows the simulations to come closer to © Shutterstock/Yaro mass-produced vehicles. the real world. This allows greater precision at the start of development. At the moment, the CM: Why is Honda focusing so heavily on the to cut a perfectly fitting mesh is vital when it process often goes back and forth between use of simulations with Computer-Aided comes to using CAE. Furthermore, using basic design and detailed design. We want to Engineering (CAE)? optimization tools like Isight can greatly reduce reduce the need to go backward by increasing the amount of work and time CAE takes, and the accuracy of the physical model. KS: We want to avoid building anything in the that’s another way in which we are seeking to way of prototypes. It takes a lot of time to build increase the range of design CAE. CM: How is this different from the comparison something and then test it. We want to take it between CAE and experimental results? to the level that you only have to build CM: Isight is an optimization tool. When do you something as the final check, so we desire use it? KS: No matter how accurate the results for a greater accuracy from our CAE. Until now, certain specific engine, there is no way of there have been many very simple simulations, KS: Take, for example, the engine. There are all knowing whether the results are accurate for a just at the level of “it breaks/it does not break.” sorts of conflicting requirements. It needs to be new, totally different engine. For us to use But in future we need to be able to test as light as possible but strong; to be quiet model-based development in the future we Honda leverages functions, capabilities, and everything using without too much vibration yet sufficiently need to feed the experimental results for all the simulation. powerful. Somewhere you have to find a vehicles we develop back into the physical tradeoff. The existing manual process involves model. In the initial phase, this will increase the simulation to meet CM: In the development process, how are you adjusting the model, carrying out CAE, making number of experiments performed. But as making use of CAE? a judgment, and then repeating this process accuracy continues to increase, the number of over and over. In the new workflow Isight experiments required will decrease. Organizing changing market needs KS: In the process from selection of processes patches, while the shape of the this process and building it into the development specifications through basic design, the parametric model is changed automatically flow is vital. designer carries out CAE using CATIA Analysis during CAE, finding the best © Shutterstock/Thor Jorden Udvang Contact mag: What effects have issues such as environmental regulations, plus to check and optimize the specifications. In the possible shape. rapid market growth in developing countries, had on the development workplace? detailed design process, the quality of prerelease designs is evaluated using CAE. CM: With the expansion of Kazuo Sakurahara: Speed is everything. Automobile manufacturers need to Areas that are highly integrated and require a applications for CAE, what is increase the rate of their development to the point that they can handle whatever lot of time, like nonlinearity and vibration noise, your opinion about analytical changes arrive next, or they are not going to survive. are performed by specialists using SIMULIA precision? Abaqus. CM: What steps are you taking to increase the pace of development at Honda? KS: In the case of Honda, if CM: What has enabled designers to apply CAE you include every degree to KS: We strive for a process that makes full use of CAE, aiming to allow for more widely? which evaluation can be optimization of functions and measurement parameters at an early stage of advance performed, from complete development. We want to ensure that the development of the hardware skeleton is KS: The evolution of CATIA is largely to thank evaluation to evaluation of a already complete as the vehicle goes into preparation for mass production. This for that. In particular, the fact that the mesh in compatibility to determine a For more information: model-based development (MBD) will heighten competitive power in comparison CATIA can now be cut so much more easily general policy, we are capable of using CAE to www.honda.com with the traditional experiment-and-experience process. than before is a major factor. The time it takes evaluate around 70%.

26 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 27 Immerse yourself in the OEMs By Dora Lainé ] automotive world of tomorrow

Key figures • 3,188,000 cars sold worldwide • 196,000 global employees • Europe’s second largest carmaker with 14.5% of the market • Environmental leadership: the only employees can work comfortably with fewer Tell your story in 3D. European carmaker in 2009 to have physical constraints. Immersive virtuality can be used to study the best task sequence, for Tell your story with 3DVIA! sold almost 1 million vehicles example, when welding or when installing car 3DVIA offers an innovative approach to the emitting less than 130g/km of CO2 seats and whether the operator has proper creation and delivery of information that • European leader in light commercial visibility when performing these tasks. Different enables anyone at any skill level to Courtesy of PSA Peugeot Citroën - Stéphane Meyer possibilities can be virtually tested while communicate their ideas in 3D. Breaking vehicles, with market share away from traditional 2D environments, ergonomics specialists analyze the best task increased to 22.4% 3DVIA solutions immerse users into lifelike 3DVIA Virtools is an integral part of PSA Peugeot Citroën’s CRV (Centre de Réalité Virtuelle sequence for the operation. 3DVIA Virtools can experiences that allow a more natural also be used to train technicians on how to interaction for the most vivid perceptual or Virtual Reality Center) at the Automotive Design Network, located in Velizy, France. This operator tasks on the assembly line. The first is perform certain tasks safely and efficiently such experiences and understanding. virtual reality center enables designers and engineers of the group’s future products to related to the driver’s perception of the car while as welding. in the driver’s seat, including ergonomics and the The active community of more than 190,000 immerse themselves in the virtual 3D projection of a future car and its surroundings and to feeling of comfort; overall impressions such as “Using virtual reality to explain optimum task 3DVIA enthusiasts includes enterprise Use your smartphone professionals, graphic artists, and interactively test design alternatives before building any physical prototypes. and touch the future roominess, windshield visibility, reachability of sequences helps save time and provides with the CRV programmers alike – each with access to a controls and buttons; and whether drivers can operators with the means to practice these dynamic suite of applications to rapidly see details that they should not see, such as sequences before doing the actual welding,” create and deploy interactive 3D applications. he Automotive Design Network (ADN) peripheral equipment such as glasses, which enable cables. “Most details that can diminish the Masfrand says. Finally, using a peripheral such This includes cutting-edge technologies such resides in a 70,000 square-meter, three- them to see in 3D, and positioning sensors located on perceived quality of the product are analyzed as a HAPTIC arm, PSA can even simulate the as virtual reality, augmented reality, gaming Tfloor building. It can accommodate up to their bodies. They can see how the car and its here,” Masfrand says. “The immersive experience force felt by a person when lifting equipment. technologies, motion capture, and more. 1,100 people from all of PSA Peugeot Citroën’s styling surround-ings react via 3D simulation, providing our enables designers to verify these aspects very Offering continuous innovation in areas of studios and innovation teams and is entirely dedicated designers with a lifelike experience in the first person.” early in the design process.” Using 3DVIA Virtools’ virtual reality technology simulation, documentation, gaming, and to automobile design. The CRV houses three systems: to conceive its designs helps PSA Peugeot immersive virtuality, 3DVIA software TM the immersion room or CAVE (Cave Automatic Experience the virtual automobile Another scenario aims to improve the ergonomics Citroën shorten vehicle development cycle solutions realize Dassault Systèmes’ vision Virtual Environment), a stereoscopic screen, and a 3DVIA Virtools is used to develop and deploy a wide of operator work areas so that assembly line time by reducing the number of physical to provide the ultimate lifelike experiences. holobench. Thanks to stereoscopic projection, designers variety of industry-specific immersive applications prototypes, which are expensive and With applications supporting technical can perceive reality in 3D and on a scale of 1:1. “The at PSA Peugeot Citroën, including design reviews, take time to build. “Virtual documentation, product configuration, designers can put assembly/­disassembly applications, and prototyping accelerates the training, marketing, simulation, visualization, themselves in a physical collaborative project reviews. Thanks to the decision-making process social media development, and more, 3DVIA is making an impact on how users communicate driver’s seat or in an versatility, accessibility and performance of 3DVIA and enables us to explore and experience products in life. operator’s post in the Virtools for virtual reality (VR), PSA Peugeot Citroën more design possibilities, factory as they would in the has developed its own powerful VR applications, to make the right The benefits are extensive. Businesses produce real world,” says which have helped better manage the production choices, and to virtually content faster and deliver it with greater Stéphane Masfrand, Virtual process and enhanced reactiveness. touch the car of impact. Developers prototype, develop and Reality Center Manager at tomorrow,” Masfrand publish their 3D applications more rapidly. PSA. “By physically turning Virtual reality helps improve driver concluded. Customers better explore products for a richer understanding and purchasing experience. the steering wheel, for and operator experience example, they can interact Two of the scenarios addressed using 3DVIA Virtools www.3dvia.com with the virtual car using are review of the digital mock-up and management of

28 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 29 Toyota Motor Corporation’s OEMs Body Engineering division replaced its in-house CAD system with CATIA and fully implemented Computer- Aided Engineering (CAE). The division succeeded in shortening the development cycle time to one-fourth of © Shutterstock/Darren Brode what was previously required using templates in conjunction with the Design CAE solution embedded in CATIA.

Linear static analysis with CATIA allows Toyota engineers to predict deformation and stresses from various loads, such as a child hanging his full weight on the Toyota cuts analysis time locked position of a door frame.

by three-quarters with CATIA displacement fields of the door for both cases Analysis time has The CATIA template based on this theoretical are calculated and evaluated using CAE. significantly decreased with formula is called the “Stiffness Visibility Tool”. oyota Motor Corporation (TMC) applies and follows geometry replacement once This tool shows possible buckling areas in red CAE (digital simulation and analysis) constraints or issues are known and defined. Visible Tool Facilitates Use of the implementation of the during simulation. As this area matches the Tin its design and manufacturing Design CAE Design CAE tool embedded in results of experiments (sensory tests with processes. For body design, the Body The Body CAD department gathered both CAE Static linear analysis does not take into account CATIA. For instance, time to multiple panels), one narrows down areas Engineering division performs CAE independent and test results and built a database to conduct geometric nonlinearity, however. An example of where the CAE stiffness test is necessary. Test from the CAE Expert team, which is tasked absolute evaluation or side-by-side comparative a nonlinear analysis with large deformation is an perform side door stiffness teams select where to perform stiffness with crash, vibration, driving stability, and evaluation. Test data from mass-production out-of-plane analysis of the outer panel of a analysis was cut in half with computation based on results of the Stiffness stiffness analysis. cars, plus the CAE computation results stored door. For instance, when a car is being waxed, CATIA, and then further Visibility tool and request the Body CAD in the database, allow engineers to easily the outer body panel might buckle due to department to provide this information as CAE Engineers in the Body CAD department carry predict physical test results from CAE results insufficient rigidity. The displacement field is reduced to about one-fourth computation input. With this tool, stiffness of out static stiffness analyses using Design CAE on new car development, making CAE absolute checked as well as the occurrence of buckling. with macros. styling design increases and ribs required in low tools embedded in CATIA. They evaluation easier. This performance forecast is This type of analysis is applicable to all of the stiffness places are put at optimal locations. Macros and templates, which were also perform simulation jobs that reflected in the modeling for quality “outer panels” that form the car body. half with CATIA, and then further reduced to not available with the in-house are relatively easy to do and improvement, a major advantage of using CAE about one-fourth with macros, compared to Analysis that was passive in the past became directly related to experiments, inside a CAD modeler organization. TMC developed CATIA templates for designers to TMC’s in-house CAD. This led to shortening the active thanks to the evolution of the Visible Out- CAD, have improved efficiency, then quickly incorporate the easily check out-of-plane rigidity. To create cycle time between CAE analysis and actions. of-plane Rigidity tool. So far, CAE has been especially in reducing analysis results to improve design quality. Full Use of CAE Improves Quality templates, TMC first determined the reason used to prevent defects, a passive application. time. Incorporating macros also Linear static analysis assumes linear material buckling occurs. Buckling analyses using CAE Macros and templates, which were not available However, as CAE is now deeply incorporated in Databases enable test properties and minimal deformation. For were done repeatedly with different model panels. with the in-house CAD, have improved efficiency, design, CAE can be used more proactively. has eliminated errors possible with prediction by CAE example, door analysis with a child as a load especially in reducing analysis time. Incorporating manual work methods. The Body Engineering division assumes a case where a child hangs on a door. Most analysis times reduced to macros also has eliminated errors possible with uses CATIA Analysis for linear If the door is not sufficiently stiff, plastic or one-fourth manual work methods. Macro analyses also analysis, and Abaqus for CATIA, together with permanent deformation might occur, which will Analysis time has significantly decreased with always return the same results regardless of a For more information: SIMULIA Abaqus, for nonlinear analysis. CAE prevent the door from opening and closing the implementation of the Design CAE tool user’s skill. As a result, TMC enjoys the benefits www.toyota.com embedded in CATIA greatly reduces workload properly. So a door analysis is done with two embedded in CATIA. For instance, time to of reduced analysis effort, quality improvement, www.3ds.com/automotive if used with customized tools such as macros, cases in mind: open and closed. The perform side door stiffness analysis was cut in and proper utilization of human resources. 30 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 31 As part of a global development partnership OEMs with Ford, Dassault Systèmes worked with the cast model short time we were able to program the cutting paths in the department to expand and new application just as fast as in the old optimize the NC module. software,” Hoffstadt says.

vehicles, and a process that could integrate “The goal right from the start, however, was to design and machining had obvious advantages. reduce programming time even further, which “The various departments, from product was also successful. Depending on the size CATIA NC. development to stamping engineering to and complexity of the casting pattern to be The program- toolmaking, would be linked to each other more produced, production times were reduced by mers can use it efficiently,” Hoffstadt says. “Data would no up to 20%. This is a tremendous step toward to check in advance longer have to be manually transferred from greater efficiency, and gives us a competitive whether the raw stock one application to the next. The fewer interfaces advantage, especially in a market where time can be milled cleanly, or we have, the less information loss we would constraints are constantly getting tighter.” whether residual material will experience. The result is less rework. If every be left. Until now, the NC department uses the same software, the costs AUTOMATED NC PROGRAMMING programmers had no way to for hardware and training also drop, and the Speed matters. Together with Dassault analyze whether all the areas to be complexity level for IT as a whole is reduced.” Systèmes, Ford achieved it by standardizing machined could actually be and automating repetitious programming tasks accessed. Today, this verification step But Ford had put great emphasis on using its and storing them in templates. The team is replaced by a complete simulation on previous CAD/CAM tool, and on developing it included DS employees from the Service and the PC. Another advantage of the in the area of casting pattern production. “Our Product Development departments, in addition simulation is that the risk of a crash, where casting pattern programmers worked very to Ford’s experts. the milling head collides with the machine Ford optimizes NC productively with the existing application,” tool table, can essentially be eliminated. Hoffstadt says. “The bar was thus set very high For example, preset parameters, such as feed for a new tool.” In addition, CATIA NC was rates and speeds, can be used to program The tooling shop manager in Cologne, Paul R. programming with CATIA optimized for machining metal, but not for clamping slots more quickly. The NC module can Weissenberg, says the conversion has been Styrofoam. “Styrofoam has completely different also automatically calculate fillet curves, which the completely worthwhile. “CATIA NC is so easy properties. This meant we had to test the new system thoroughly to identify its advantages hen the new Ford Focus 2011 NC PROGRAMMING USING A 3D MODEL and disadvantages. We also provided a good Depending on the size and The casting pattern shop at models went on display in dealer To produce the Styrofoam pattern, Solberg and deal of feedback.” complexity of the casting pattern to be produced, production times Ford in Cologne, Germany, showrooms, Andreas Solberg and his colleagues now work with a completely W were reduced by up to 20%. Arnd Lauer had long since moved on to new virtual 3D model of the tool design to be CLOSE PARTNERSHIP FOR 20% has optimized its processes, projects. The two numeric control (NC) produced. Using this virtual model, they create DEVELOPMENT implementing CATIA numeric specialists at Ford are responsible for the NC programs offline, which are then sent to As part of a global development partnership programmer previously had to manually insert in to use that we had almost no problems with the control (NC) with support from programming casting patterns used in tool the milling machines that ultimately cut the real with Ford, Dassault Systèmes worked with the the virtual model. These predefined templates changeover, also thanks to the excellent manufacturing – a job with very tight timelines. patterns out of Styrofoam. casting pattern department to successfully enable the programmers to progress more method-based training from DS. The same Dassault Systèmes (DS). The expand and optimize the CATIA NC module for quickly and without errors, because all of the goes for implementation, which was completed result has been a reduction in “Our production is set up for making the tools as Until recently, the department used the NC machining Styrofoam. The department, which parameters have been pre-checked, and also in a short time. I have been pleasantly surprised the time required to quickly as possible, which can then be used for module of the company-wide C3P program is set up as a profit center and produces allow all programmers to use a standardized in every aspect.” deep drawing, trimming, and forming of the (CAD-CAM-CAE-PIM) for NC programming of the casting patterns for the entire Ford group as approach for orientation. One employee can thus manufacture casting patterns, doors, side walls, or hoods,” Solberg says. Lauer parts. This program was introduced by Ford in well as external customers, reached the seamlessly take over another’s task, such as at a Weissenberg, who was responsible for with a solution that will carry adds, “Every day that the start of production is the mid-1990s to make development and breakeven point after just 18 months. “Within a shift change, because they both use the same converting the process to the new system, says delayed causes incredible cost increases.” production more efficient. This requirement still programming methods. the potential he sees in the software is at least Ford well into the future. exists today, of course, but with the C3P program as important as the success that has already The tooling – which can be up to five meters reaching the end of its life, Ford now uses CATIA NO MORE CRASHES WITH been achieved. “With CATIA, we are now on a long for the sidewall of the Ford Galaxy – is cast for C3PNG (Next Generation) design. VIDEO SIMULATION technology platform that will carry us forward in a dead-mold process. For this casting In the course of standardization, the team of into the future.” process, a Styrofoam model of the tool design INTEGRATED PROCESS MEANS FEWER Ford and Dassault Systèmes also improved is produced at a scale of 1:1.02. This pattern is CORRECTIONS production strategies by shortening the paths embedded in sand, which is solidified using a Ralph Hoffstadt, manager of the casting pattern that the milling heads need to travel through the For more information: binding agent. This produces a mold that the department, had to decide which software air, a wasted motion. www.ford.de tool manufacturers fill with molten steel; the applications his employees would use www.3ds.com/automotive Styrofoam evaporates, and the cast metal part to create machining programs in the C3PNG Another factor for increasing speed is photo is created in its place. program. Ford uses CATIA to design its and video simulation, which was launched with 32 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 33 OEMs

Bentley Motors: When By Nick Lerner]

For Bentley Mulsanne, we have been able to heritage meets technology integrate production functions much earlier than previous projects, reducing risk, retaining knowledge and enjoying the considerable retaining knowledge and enjoying the considerable Bentley Motors benefits from Dassault Systèmes (DS) 3D manufacturing benefits of concurrent collaborative working. benefits of concurrent collaborative working.

simulation tools to communicate and optimize designs for production John Unsworth “3D provides greater stakeholder cognition, allowing CAD Strategy Manager, Bentley of the new Mulsanne. extended input to design-and-production scenarios at the right point in time to make a difference,” Unsworth continued. “We are now able to integrate Mulsanne: straight to success wider business departments in our quest to exploit he recently launched Bentley Mulsanne is with luxury features that include sustainable Ian Swann, Bentley’s senior virtual assurance digital data. Aftersales and Service teams, for Bentley’s all-new flagship grand tourer. DS hardwood veneers and specially treated leather engineer, described how Dassault Systèmes (DS) example, now have concurrent access to our T PLM solutions, including CATIA, ENOVIA, upholstery and trim. It takes nine weeks to build a 3D technology is used to develop the Mulsanne: evolving 3D data. This allows teams to construct DELMIA and 3DVIA, have been deployed to allow Mulsanne, bringing together and assembling “We use DS manufacturing simulation tools to technical illustrations in parallel with the design Bentley to exploit 3D visualization and simulation approximately 10,500 separate parts to create a develop seamless introduction of new products. By evolution process using 3DVIA Composer. This techniques across the core product lifecycle unique combination of luxury and performance. modeling a total of 831 build operations across 30 integration has saved considerable time and processes. stations, the complete build process was simulated valuable resource and has improved cross- In 1919, Bentley’s founder, W.O. Bentley, had a vision in 3D. Using this simulation, a detailed assessment functional working and overall communication.” The Mulsanne sets new standards for comfort, of building “a good car, a fast car, the best in its of the build process was then carried out, and any effortless performance and hand-crafted refinement class.” More than 90 years later, Mulsanne’s position potential build concerns were identified and then Unsworth says the foundation for exploiting these – the very qualities for which Bentley is renowned. It at the pinnacle of the premium segment is a sign of resolved much earlier in the design process.” technologies revolve around Bentley’s ability to combines a completely re-engineered V8 engine Bentley’s commitment to its founding principles. 9 manage all of its data in one database. “All data is weeks This methodology, facilitated with DELMIA, includes managed in ENOVIA, and all departments access 3D reviews at regular ‘virtual build’ meetings. The this data concurrently. The same data is presented It takes power of 3D visualization allows production build in DELMIA, where Manufacturing associates can nine weeks associates to make valuable contributions to the plan and simulate manufacturing build processes to build a design process and influence the design based on in parallel with design evolution. We have one set Mulsanne, their experience and specialist knowledge. of data accessed by all departments from during which Styling, Concepts, Digital Design, Engineering and time around “Part load feasibility, clearance and tool access Manufacturing. No longer do we manage separate 10,500 are crucial factors for optimized production, and data silos across departments. All have the ability separate parts these are readily reviewed and assessed using to access and author data from the ENOVIA are brought DELMIA during these cross-functional meetings,” database, making informed decisions without the together and Swann says. “Using 3D visualization, any design need for a data preparation exercise.” assembled. or process changes can also be validated and optimized accordingly. Any potential problems Action plan can then be planned for and other complexities “The methodology at Bentley is an example of accurately assessed.” PLM in action,” Unsworth continues. “Our unique blend of PLM exploitation now encompasses a Tooled up complete virtual build. With its technical complexity, “DS PLM tools allow us to exploit improved working use of both traditional and new composite practices throughout the Bentley Product materials and our exacting quality standards Lifecycle,” says John Unsworth, CAD strategy means that the Mulsanne is like no other car. Our manager at Bentley. “For Bentley Mulsanne, we digital validation has helped us rectify many issues have been able to integrate production functions and concerns much earlier than would previously much earlier than previous projects, reducing risk, have been possible.” » 34 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 35

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Dassault Systèmes Dassault

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ION DUCAT E Plasan Carbon Composites SUPPLIERS advances design and production with composites solutions

Plasan Carbon Composites needed to give its automotive customers fast, accurate quotes and deliver high-quality composites parts quickly, with less physical waste and improved material We’re now able to virtually estimates. Plasan chose a Dassault Systèmes test the strength of our solutions suite that includes CATIA Composites Design, composites in a matter of SIMULIA Abaqus Finite Element Analysis (FEA), and minutes instead of hours, Simulayt fiber modeling. days or weeks.

Gary Lownsdale lasan Carbon Composites USA, a matrix that must be cut into precise shapes and Earlier visibility renders comes from the ability to work in a single CATIA Director of R&D, Plasan wholly owned subsidiary of Plasan of then layered and treated with high pressure more accurate estimates platform that is fully integrated with tools from Carbon Composites USA PIsrael, is a supplier of carbon composites and heat is a complex process that has long With its previous software tools, Plasan could Simulayt, Salerno says. parts to leading automotive OEMs worldwide. been defined by trial and error. Craftsmen have not design the carbon fiber ply kits for its The company, which has made body traditionally used the “paper doll” method, composite parts until an OEM’s tool molds Advanced flattening and producibility simulation components such as hoods, roofs and fenders trimming and splicing the fiber plies to fit them arrived at its facilities. But with CATIA algorithms in Simulayt allow engineers to “We used CATIA and Abaqus throughout the for high-end sports cars including the Chevy to the underlying shaping tools, a slow and Composites Design and the Simulayt Advanced understand how fibers in composite materials are process to make sure our computational tools Corvette and Dodge Viper, also is leading the expensive process. Fiber Modeler, Plasan can quickly provide conforming or deforming around the complex were conforming to what we were actually charge to bring composites to automotive frame accurate quotes to its customers based purely geometries typical in automotive components. measuring,” says Gary Lownsdale, Plasan’s and sub-structural components, a Sustainable To better serve its customers, Plasan wanted on the OEM’s part data, which is available long “Our customers are very concerned with director of Research & Development. “We Innovation designed to increase strength and to eliminate the trial-and-error processes that before the lay-up tools themselves. inconsistencies in the surface,” Salerno says. “For would not have been able to have the press passenger safety while reducing weight to contributed to wasted composite material. To an automotive component going on an expensive equipment in place today if not for those improve fuel efficiency. achieve its goal, Plasan replaced its three-CAD “This first level now takes only about 30 minutes sports car, it has to look like glass. Simulayt lets two solutions.” system with an advanced composite design, to complete rather than half a day,” says us see how far we can push our materials before But while its sights are firmly set on the manufacturing and simulation solution suite James Salerno, CAD and FEA (finite element they start wrinkling and causing a problem.” DS PLM solutions also help Plasan to reduce future of automotive composites, Plasan from Dassault Systèmes’ (DS), which combines analysis) engineer at Plasan. The result: the number of plies used to produce parts, is also focused on the design and CATIA Composites Design, Simulayt solutions faster, more accurate quotes that help Plasan Improved manufacturing another Sustainable Innovation that saves production of state-of-the-art surface for fiber modeling and linking, and Abaqus FEA respond more quickly and competitively to processes lay-up time, improves the strength and durability parts for today’s vehicles. from SIMULIA for virtual testing of a design’s customer requests. Plasan also is using its new solution to develop of the finished part, and reduces the amount of structural integrity. Because CATIA, Simulayt next-generation processes that create parts waste fiber – an improvement that is good for Streamlining a highly and SIMULIA Abaqus are fully integrated to Using technology to faster by replacing autoclave treatments of the the environment and the bottom line. manual process work within a single user interface, Plasan improve processes composites materials with pressure-based Creating carbon composite saves time, eliminates translation errors, and On its most recent pre-production program, approaches; an innovation the company calls parts with an epoxy resin streamlines training. Salerno says, he was able to arrive at a 100% Out-of-Autoclave. The savings to date from For more information: manufacturable kit for two required parts in just Plasan’s Out-of-Autoclave innovation include a www.plasanusa.com two iterations using CATIA Composites Design, 75% reduction in curing times, which translates www.inceptra.com With its advanced CATIA and SIMULIA ply design and analysis solutions, a 50% improvement. Much of the speed at into significantly decreased energy demand www.3ds.com/automotive Plasan Carbon Composites’ lay-up technicians know they can achieve smooth, which Plasan can do preliminary analysis and faster delivery to customers. 38 Contact mag | Dassault Systèmes clean applications of plies on the first try, eliminating waste and cutting costs. Contact mag | Transportation & Mobility Special Edition 39 motorcycles Orange County Choppers throttles up with SolidWorks Premium

When the reality television show “American Choppers” debuted on the Discovery Channel, orders for Orange County Choppers’ custom motorcycles skyrocketed. standpoint. He recruited me to join OCC in a Visualizing cool ideas “Whether we’re working with an outside vendor SolidWorks Premium has helped OCC benefit from this concept artist and 3D modeling capacity.” accelerates design or in our own machine shop, SolidWorks makes windfall with a 75% reduction in cycle times that cut the Instead of trying out different concepts in the it easier to efficiently create usable parts,” Pohl With a background in art and computer shop using actual prototypes, the company says. “In my experience, 2D techniques hide company’s time-to-market in half and eliminated several graphics, Pohl knew OCC would need a now iterates on designs in the SolidWorks flaws; 3D design reveals flaws. When it’s time to rounds of expensive physical prototyping. design application that could blend the design environment, which is more efficient manufacture a part, SolidWorks enables us to artistry of chopper design with and cost-effective. Since implementing have confidence that the model is right. That actual manufacturing SolidWorks, OCC has accelerated its time- makes our lives a whole lot easier.” techniques and to-market by 100 percent, cut design cycles engineering data. by 75 percent, and eliminated several rounds Communicating more “Basically, we had of prototyping. effectively with customers any kind of software SolidWorks software has also helped OCC available to us but “When you’re modeling a bike, you can try a lot interact more effectively with customers, who needed to choose of different things to make it look really cool,” often want to see how the motorcycle will look the right package, Pohl explains. “The curve ball is that in addition before placing an order, especially for the not only to capture our ideas but also support advanced manufacturing processes in our new factory. A friend at a tool and die shop recommended SolidWorks software, so we gave it a whirl and discovered it was exactly what we needed.” Orange County Choppers relies on SolidWorks Premium software to efficiently respond to the onslaught of orders that accompany the popularity OCC chose SolidWorks Premium software as its of its “American Chopper” television show. standard design platform because it is easy to use, includes design visualization and surfacing lthough many people associate Orange challenges that the custom shop could no tools, and integrates well with MasterCAM 3D Design 3D Design Analysis 3D Design Communication County Choppers (OCC) with longer address using its original approach. computer-aided manufacturing (CAM) software, A“American Chopper,” the breakthrough Senior Designer Jason Pohl, now a regular on which automates machining on the company’s to looking good, the design has to function, growing number of corporate bikes made at reality television show that debuted on the the television show, was working on the HAAS CNC production systems. which is where SolidWorks comes in. We can OCC. Using SolidWorks design visualization Discovery Channel in 2002, the company prototype for a video pinball game in 2004 thoroughly evaluate a design before parts are and communications tools, including founded by Paul Teutul Sr. began when Teutul contacted him about joining OCC. “Every bike that we build is a 100% custom ordered and quickly eliminate the bad ideas PhotoView 360, OCC can show high-quality With SolidWorks we can refine designing and building custom design,” Pohl says. “With SolidWorks we can that simply won’t work.” renderings of custom motorcycle designs to the design and then control the motorcycles in 1999. Since then, the “I created some virtual chopper models for the refine the design and then control the production clients, which helps to confirm expectations massive and mustachioed founder game that were loosely based on OCC designs,” of parts with a high degree of precision. Better efficiency boosts and finalize orders. production of parts with a high degree has become a celebrity, and the Pohl recalls. “Paul Sr. saw my work and realized SolidWorks has become the backbone of our throughput, controls costs of precision. SolidWorks has become television show’s popularity has how computer modeling could help the development effort because By using SolidWorks software, OCC efficiently “SolidWorks saves countless hours of R&D and the backbone of our development brought worldwide fame – and a company evolve from a design and production everything revolves handles the increased volume of orders it communications back and forth with the client,” dramatic increase in business – to around the SolidWorks now receives, both in development and Pohl says. “SolidWorks is more than a design tool effort because everything revolves the custom motorcycle manufacturer. model.” during production. SolidWorks support for for us. It’s more of a design weapon because it around the SolidWorks model.” automated machining boosts throughput. really enables us to turn and burn.” OCC outgrew two previous shops, in And because manufacturing from a solid Jason Pohl, Senior Designer Rock Tavern and Montgomery, NY, SolidWorks design model is more accurate, OCC is able to keep and now operates a state-of-the-art visualization tools, its costs down. Since implementing For more information: factory in Newburgh. The onslaught of orders including PhotoView SolidWorks software, the custom motorcycle 360, enable OCC to www.orangecountychoppers.com that accompanied the fame of “American manufacturer has cut its development costs communicate more www.solidworks.com Chopper” created development and production effectively with its by 50 percent. customers. 40 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 41 TRAINS

Alstom Transport: Sustainable Alstom Transport controls and reduces the impact its product development cycle, both within the company products have on the environment throughout their as well as with our suppliers and partners,” lifecycles, from design to manufacturing and through Sougoufara says. to recycling. The results are products that are more mobility for the rail industry economical to operate, consume less energy, present The company also will migrate from CATIA lower decommissioning costs, and are less detrimental Version 5 to CATIA Version 6 to leverage 85% to the environment and human health. all 3D mechanical design, resulting in a fully coherent system for all its activities. Metropolis metros “We strive to minimize the use of materials that can be “With Version 6 we will enhance the level of and Citadis tramways Alstom Transport has united its business processes on Dassault Systèmes’ harmful to man and the environment,” Ricaud 3D design collaboration between our are now at least 85% ENOVIA Version 6 platform, replacing its disparate legacy applications with explains. “For example, our Coradia Nordic regional different engineering centers,” Sougoufara recyclable, and this train is 98% recyclable, thus reducing its carbon comments. “It will enable us to streamline can rise to as high as a single PLM solution. The goal is increased collaboration and faster time-to-market, Use your smartphone footprint to a minimum.” our design-to-manufacturing processes 98% for the Coradia to learn more about as well as achieving the company’s ambitious goals for sustainable mobility. sustainable mobility and deliver quality products to market Nordic regional train at Alstom Transport. Phased implementation faster.” in Stockholm. Alstom Transport has deployed ENOVIA Version 6 at its different sites so that all stakeholders, wherever With Version 6, Alstom is moving full speed ahead toward they are, can work together on customer projects and fully sustainable product design and process efficiency, s the world continues to shrink, governments is a major requirement in today’s world,” says Jean- share their expertise. Through the single Version 6 and helping to shape the future of rail transport. are faced with the complex challenge of Louis Ricaud, chief operating officer, Alstom Transport. platform, project teams access the latest and most Atrying to move more people and freight while “Because they run on electricity and do not emit carbon up-to-date product data. “ENOVIA is the backbone For more information: reducing energy consumption, pollution, and traffic. dioxide, trains are one of the most environmentally on which we base engineering and manufacturing www.alstom.com/transport www.3ds.com/automotive Delivering sustainable solutions that address 21st friendly means of transportation today.” collaboration, as well as sourcing throughout the century mobility needs is a major goal for urban developers and transportation companies, including Alstom Transport makes great efforts to ensure the Alstom Transport. flawless integration of its trains into urban and rural Citadis Tramway in use in Rabat, Morocco, July 2011 landscapes, using Dassault Systèmes’ PLM solutions Ecologically to demonstrate digitally during the preliminary phases and economically of a project the way its products will fit into the efficient solutions environment. “Through 3D simulation, our customers Alstom Transport places can experience the way our trains will blend in with environmental preservation at their surroundings,” says Mama Sougoufara, director the core of its development Method and Tools and IS, Alstom Transport. “It is an strategy. Through technological innovative and powerful way to convince them that innovation, Alstom Transport the result will meet their objectives in terms of mobility delivers solutions that satisfy its and at the same time preserve their cities’ architectural customers’ profitability, heritage.” ecological, and sustainability objectives. “Sustainable mobility THE AGE OF REGULATORY COMPLIANCE © Alstom Transport / T.Miles / Transport Alstom © To achieve sustainable mobility, Alstom integrates Pendolina Virgin train undergoing maintenance at Liverpool, UK, in June 2010. environmental parameters early in the design stages of its products – a practice called eco-design. Alstom Transport Environmental and recycling specifications are As a world leader in the rail market, Alstom Transport develops defined and managed in ENOVIA Version 6. and offers the rail industry’s most complete range of systems, equipment and services, always keeping sustainable transport in “All the norms our products have to comply with are mind. Alstom Transport manages all transport systems from rolling managed with ENOVIA, such as ELV (End-of-Life stock to signaling, maintenance and infrastructure, as well as Vehicles), RoHS (Restriction of Hazardous turnkey solutions. During the 2010-2011 fiscal year,A lstom Substances), WEEE (Waste Electrical and Electronic Transport reported sales of 5.6 billion euros. The company is Equipment) and REACH (Registration, Evaluation, present in more than 60 countries and has 26,000 employees. Authorization and Restriction of Chemicals),” Ricaud says.

42 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 43 © Alstom Transport / P.Thebault / Transport Alstom © TRAINS AMTRAK® modernizes U.S. train travel with SolidWorks

MTRAK®, the only U.S. high-speed rail For decades, AMTRAK’s engineers used a Modernizing the include LED lighting and recycling bins. operator, operates more than 300 combination of 2D tools for their design passenger rail fleet SolidWorks also helped AMTRAK’s designers SolidWorks has allowed us to take a railcar that is decades old Atrains a day, providing affordable travel work. But in 1999, engineering management With SolidWorks, AMTRAK has transformed its increase productivity by 60 percent and realize to more than 500 destinations spread across determined that 3D solutions were necessary passenger cars of old into bright, inviting, and time savings of 40 percent. and make it look like it was made within the last two years.” 21,000 route miles in 46 states, the District of to take the rail company’s transportation comfortable coaches. The company Columbia, and three Canadian provinces. offerings into the21st century. added new seats and lighting to “Our goal in creating sleek, comfortable car John Campbell, Industrial Designer, AMTRAK its completely refurbished interiors is to make rail the civilized way to To support ridership growth and maintain its After evaluating available 3D systems, AMTRAK interiors, plus green travel,” notes industrial designer John competitive position, AMTRAK must continually chose SolidWorks software from Dassault elements that Campbell. “SolidWorks has allowed us to take and also reduces the number of prototypes “We have tightened revision control, removing update and modernize its railcars, which now Systèmes because of its ease of use, compatibility a railcar that is decades old and make it look required, plus we can produce prototypes in duplicate documents, and have benefited average 26 years old. “The company that with legacy 2D data, and its integrated analysis like it was made within the last two years.” hours instead of weeks.” from fast-search capabilities, eliminating manufactured the Amfleet passenger cars went and PDM (product data management) downtime,” Hoffman says. “The system, out of business in 1986,” explains Bruce F. applications. After implementing 25 licenses used Simulation saves time and money Integrated PDM which is really simple to use and readily Hoffman, manager of document control for by designers and engineers throughout the AMTRAK uses SolidWorks Simulation to analyze boosts productivity accepted by our users, helps us to improve AMTRAK in the Mechanical Department’s rolling- rolling-stock engineering group, structural performance and ensure safety in The SolidWorks Enterprise PDM system is a quality and cut errors. It also lets us generate stock engineering group. “To beat our AMTRAK later added SolidWorks critical components. Instead of contracting out significant contributor to AMTRAK’s time and cost savings in the versioning and competition—the airlines and intercity bus Simulation and SolidWorks much of its analysis work, as AMTRAK had done productivity improvements. The rail company’s reuse of parts.” companies—we have to do much more than just Enterprise PDM software. in the past, in-house designers can now validate diverse project teams use the system to keep the equipment running. We have to performance during design, saving time, manage more than 500,000 design files, modernize and redesign our interiors so that we SolidWorks integrated reducing costs, and improving quality. including engineering data, drawings, offer a level of comfort and a set of amenities that design, analysis, and technical specifications, and procedures. The not only match, but also exceed our competitors’.” PDM solutions provide “The ability to simulate and show how a part will PDM system enabled AMTRAK to automate the productivity boost For more information: perform is a big plus,” Campbell says. “It allows document approval processes with electronic that AMTRAK needs to www.amtrak.com support a record us to strengthen parts while simultaneously workflows and email notifications to streamline www.solidworks.com number of passengers. removing material. This saves time and money its processes.

44 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 45 VISEON puts buses on BUSES the road with DS PLM

Using CATIA and ENOVIA SmarTeam, VISEON is producing more buses in less time. CATIA makes it easy to mix and match standard components to create a customized bus, while SmarTeam manages all of the versions and variations and feeds critical information to VISEON’s SAP system, helping to keep corporate processes on track.

By Heike Blödorn]

EOPLAN brand buses have been produced in plan was to connect applications progressively for says. “We can use our various building blocks to 100 Buses in the First Year of Production Pilsting, Germany, for more than 35 years. manufacturing, production and quality control, and to develop variations of existing products very quickly or to A certain number of seat types, seat spacing options, NAfter the plant was purchased from its holding provide viewers for all downstream areas,” explains create a new product within a short time by adding a positions and widths of doors, as well as different company, MAN/Neoplan, as part of a management Christian Dittert, who is VISEON’s development supplementary building block.” The coach, the first accessories, are available for each bus type. Sales staff buyout in April 2009, partners Joachim Reinmuth and manager for high-floor vehicles. “ENOVIA SmarTeam result of the modular building set philosophy, is currently members begin by discussing the basic layout, the Ernö Bartha continued the tradition with the new was exactly the right system for this purpose.” available in three different lengths. vehicle color and the interior equipment with the VISEON brand. customer. This determines the building specifications The initial operation of CATIA in combination with This approach enabled the designers to handle the for the vehicle. The customer vehicle is then compiled The plan was to connect applications for ENOVIA SmarTeam was based on the Transcat considerable challenge of developing a complete, from a bill of materials in a database. These module manufacturing, production and quality Standards myV5 and SmarTCbase – a database for proprietary product range of travel buses in three sets in CATIA/ENOVIA SmarTeam include the options assurance, and to provide viewers for all ENOVIA SmarTeam that was developed for instant use. different versions: a double-decker bus, a trolley bus, selected. Combining the various module sets adds the myV5 facilitates the administration of different customer- and a double-decker coach for a third-party customer’s requirements to the basic vehicle, resulting downstream areas. ENOVIA SmarTeam was specific CATIA releases, licenses and add-on products. development contract. Data for an airport bus of the in the final vehicle. exactly the right system for this purpose. An SAP link facilitated integration into the higher-level NEOPLAN brand, which is being produced under corporate process. A “number generator,” structured to license, was entered into CATIA at the same time. The two production lines currently available allow Christian Dittert the vehicle manufacturer’s specifications, allows the VISEON to produce three to five units per week, Development Manager designer of a new component to complete an identity The individual processes, from development and depending on the model mix in the production line. In Viseon BUS GmbH As part of the transfer of operations, VISEON had to card that defines the component and the vehicle type. prototype construction to manufacturing, strongly the first six months of production, VISEON completed introduce a completely new IT landscape. The partners This information is used by the number generator to overlap at VISEON. This helps to speed up the overall 100 vehicles, well on its way to the company’s goal of chose two Dassault Systèmes (DS) solutions – CATIA assign a component number that is then used by all process. Staff members involved in prototype 250 buses per year. V5 for design and ENOVIA SmarTeam for data VISEON departments throughout the development construction and production use viewer interfaces in management – implemented by DS partner Transcat process. CATIA to navigate in a virtual model, which includes PLM GmbH. dimensions that have not yet been specified by the Complete Product Range within Two Years development department. Users can also break down VISEON wanted a data management solution that VISEON’s team of 240 staff members is committed to and view the whole vehicle in all its construction Further information: would be easy to handle and cover the requirements for developing buses in a short time at low cost. “We have segments, from the body shell to the paneling, to get a www.viseon-bus.com www.3ds.com/automotive drawing administration and change processes. “The decided on a strictly modular product range,” Dittert better understanding of the product to be manufactured.

46 Contact mag | Dassault Systèmes Contact mag | Transportation & Mobility Special Edition 47 Stay Ahead of Your Competition Your competitors are closer than you think.

Looked in your rear-view mirror lately? Our industry is recovering faster than predicted and your competition is eager to secure your share of new opportunities.

What’s your automotive advantage? And does it include specifi c, world-class strategies and capabilities that will ensure your success?

Dassault Systèmes is a visionary partner, providing automotive leaders with the powerful tools they need to transform their business and accelerate innovation. Our integrated suite of Product Lifecycle Management (PLM) solutions – including CATIA, SIMULIA, DELMIA, ENOVIA and 3DVIA – enhances business processes, automates knowledge and enables global collaboration.

Explore your options. Fortify your automotive advantage with resources from industry experts. Visit www.plmv5.com/globaladvantage to discuss your challenges with our automotive team, and put some distance between you and your competition. 3DVIA are registered trademarks of Dassault Systèmes or its subsidiaries in the US and/or other countries. © Dassault Systèmes,All© 2011. rights reserved. CATIA, DELMIA, ENOVIA, EXALEAD, SIMULIA, SolidWorks and

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