Innovative use of Creo for Digital Product Development
Chandrashekhar V Joshi Asst General Manager – KBE and DPD Systems - TATA MOTORS Tushar C Gadhave Sr. Team Leader – KBE and DPD Systems - TATA MOTORS
09/06/2015 TATA Group
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 2 TATA Motors
Tata Motors Limited is India's largest automobile company, with consolidated revenues of USD 38.9 billion in 2013 -14.
Leader in commercial vehicles in each segment and the top in passenger vehicles with products in the compact, midsize car and utility vehicle segments
Global world's fourth largest truck and bus manufacturer.
Subsidiaries/associates: Jaguar Land Rover, Tata Marcopolo, Tata Hispano, Tata Motors Thailand, Tata Motors South Africa
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 3 Product Family
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 4 Innovative use of Creo at Tata Motors
Okay, We are leveraging functionality and deriving the values of Creo, are you ?
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 5 Key Drivers for Innovation
First time Managing right complexity quality Quality
Time to Resource market Cost Time
Technology Productivity
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 6 Key Drivers for Innovation
First time right quality
Managing complexity Time to & Reduce market cost
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 7 Innovative use of Creo for Digital Product Development
KBE–Creo Application
Adding 3D for All Behavior in DMU TML Creo
First time right quality Productivity Improvement Design Point Managing in Piping solutions complexity Time to Design & Reduce market cost
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 8 KBE – CREO Integration
Knowledge Based Engineering (KBE) • In-house developed framework
• Merging of knowledge rules with CAD
• This framework is used to – Capture Best Practice – Reduce Cost / Weight – Improve Quality – Shorten Design Cycle – Integrate Engineering Processes • Helps the organization in – Conceptualization – Detail Design – Manufacturing Planning – Trouble shooting in prove-out
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 9 KBE - Leaf Spring Application
To provide a standard process for leaf spring design Process
Reduce designer’s time and effort. Minimize
Single Point Solution Applicable to all leaf spring Objective types with 3D and 2D model and Scope Editable Geometry creation with Geometry feature history
Leaf Spring Design
Reuse Reuse standard parts from PLM system
Quality To get first time right quality and Model Standardization Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 10 KBE Application for Leaf spring Design:
PLM Single UI Creo Application to Connectivity Automatic generate Leaf Spring Assembly and Reuse of 2D Drawing existing STD Creation with Drawing Automatic Parts through Leaf Spring Creo Application Application Assembly updates All creation Pro/Toolkit STD KBE App for Feature parameters Leaf Spring Library for Automatically Design Leaf Creation Drawing Creation Assembly of STD Assembly parts from of Leaf PLM Apply TML Spring Design Leaf STD Design Design calculation KBE - Leaf Spring Design Process
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 11 Benefits of Leaf Spring Design Application
Creates 2D . Single User drafting with full interface to Design views, section leaf spring views and assembly required notes . Automatically Single Point Creates 3D Solution to Design Process assembly model Leaf Spring and 2D drafting Application UI Single Click 2D PLM Drafting Connectivity
Creates model Creates the model with editable Benefits in PLM Creo features and environment keep references and history Editable Geometry Reuse Design Creation with Data Feature History PLM - Creo
Model Standardization as per TML Standards . Reuse the Creates model as required standard per TML parts from PLM standards with system to avoid necessary Part duplication Parameters PLM Database
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 12 Innovative use of Creo for Digital Product Development
Adding Behavior in DMU TML Creo
First time right quality
Managing complexity Time to & Reduce market cost
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 13 Adding Behaviour in DMU
• Creo Mechanism – Improve verification and validation process and maximize design confidence without the expensive burden of building prototypes.
– virtually simulate the forces and accelerations in systems with moving components. Process Flow Define mechanism in Creo PLM – To visualize the kinematic motion
Motion File in enterprise visualization tool. Designer (Creo ) Server Side Creo/Toolkit programs CAD to generate viewable. Data
Motion Visualized in DMU Viewable
DMU Reviewer
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 14 Adding Behaviour in DMU
• Complete behavior in Light weight format. • Easy for handling motion results in visualization tool. • Helps in vehicle packaging process and DMU checks. • Seamless integration of Pro/Toolkit and Other Toolkit programs to generate motion file. • Automated process and one step towards complete DMU.
Creo Mechanism Definition Reflect in Visualization DMU
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 15 Innovative use of Creo for Digital Product Development
KBE–Creo Application
Adding 3D for All Behavior in DMU TML Creo
First time right quality
Productivity Improvement Design Point Managing in Piping solutions complexity Time to & Reduce market Design cost
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 16 TML UDF Feature Library
TS Standard database Advantages: • Readymade TML Feature Library • Standard Design Process TATA MOTORS STANDARD • Quick and error free
Start the Application Features Created and select Type
TML Features Library
User Selection
Pipe Ends create automatic as per TML STD
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 17 Innovative use of Creo for Digital Product Development
KBE–Creo Application
Adding 3D for All Behavior in DMU TML Creo
First time right quality
Productivity Improvement Design Point Managing in Piping solutions complexity Time to & Reduce market Design cost
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 18 Piping Design Process Automation
Develop the modular Piping DMU which will be Modular Design used for multiple variants Drastic time reduction on piping DMU creation
Time Objective Eliminate
To Eliminate the rework piping DMU for late stage design changes. Deliver the First time right Quality quality piping DMU
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 19 Piping DMU Process Improvement
• Advance Pipe Methodology by • Modular Piping Template Piping follow axis, follow pipe process DMU creation improvement • Multiple variants can be • Customized Single click Bunch developed from one template Drawing and individual Drawing • Easy for modification and creation reusability of Existing parts
Modular Piping Design Process Piping Design and Drawing Drawing Automation and As Automation procured piping process
• Pipe Routing by Advanced • Piping DMU by Dynamic Piping technology like Reference Creation and Follow Axis , Follow Pipe. Modular Design Approach
• Light weight data for • Piping Template for vehicle Reference Creation configuration which be • used for multiple variants • Automation in Bunch Drawing and Individual • Automation in IFD Drawing Drawing creation
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 20 Modular Piping DMU Creation
Aggregate Assembly Pipe Bunch Assembly (All Vehicle Configuration) For I variant (42 WB)
Clamp & Bracket Assembly Pipe Bunch Assembly Modular For II variant (48 WB) Piping Template Bunch Pipe Assembly Model Pipe Bunch Assembly By Advance Methodology For III variant (52 WB)
4 All Aggregate & Follow Axis/ Follow pipe Piping clamps reference Methodology Piping Drawing to VCS & Creo customization for modularity 3 Creation • DPDS Tools used for Piping DMU Bunch and Individual 2 Creation Drawing Creation • Bunch Pipe Assembly Piping skeleton Creation using advance • DPDS Tool for automatic IFD Creation 1 Model and fitting Piping methodology. Assembly Creation Piping Aggregate • Modular Piping Template • Clamp and cable tie design Assembly Creation positioning wrt VCS • All Aggregate reference Creation wrt VCS • Chassis skeleton model independent. Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 21 Piping Drawing Automation
Effort and Time required to create piping drawing should be reduced. Reduce
Unique Standard process should Individual pipe be available for piping drawing. drawing Objective Generate Eliminate scope
Bunch To eliminate manual errors Pipe drawing and rework.
Enhance the data quality and should Quality give First time right quality
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 22 Piping Drawing Automation
Developed Length with Mfg Tolerance Automation
Bunch Bunch Drawing BOM Table Automation Automation
Piping Drawing Automation
Bunch Piping Connector Balloon Table Automation Automation
Piping Notes and Deviation table Automation
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 23 Bunch Drawing & IFD Creation through application
Drawing View with BOM Bunch Notes ballooning
Deviation table, product Bunch BOM table performance table, Tightening Connector table torque table, weight table etc. Created Individual pipe drawing with Bend table and BOM table.
Automatic created IFD
Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 24 Summary
Usability of Creo can be further enhanced by means of mapkeys, custom menus and Pro/Toolkit applications.
Using design rules and material database & Pro/Toolkit we can create parametric feature based geometry which can be leveraged for various downstream applications.
Digital mockup with proper behavior helps to reduce overall product development time.
Productivity enhancement with process improvement using Modular Piping design methodology and Toolkit based Automation.
This innovations reduced more than 40% design cycle time and helps organization to make decision faster.
It helps to achieve company's objective of first time right quality also helps in late stage design modifications.
Ability to make standardize your design data as per the industry standard and flexibility in exchanging information across system.
Apps developed using Pro/Toolkit API reduced the work drastically.
25 Mr. Tushar Gadhave June 9, 2015 Thank You
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Copyright@2015, Tata Motors Limited Not to be copied, printed or replicated in any form without written consent of CTO, Tata Motors Limited 26