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Success Factors for Digital Mock-Ups (DMU)

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Technische Universität München Institut für Luft- und Raumfahrt (ILR) Lehrstuhl für Luftfahrttechnik Success Factors for Digital Mock-ups (DMU) in complex Aerospace Product Development Walter Richard Dolezal Vollständiger Abdruck der von der Fakultät für Maschinenwesen der Technischen Universität München zur Erlangung des akademischen Grades eines Doktor-Ingenieurs genehmigten Dissertation. Vorsitzender: Univ.-Prof. Dr.-Ing. Florian Holzapfel Prüfer der Dissertation: 1. Univ.-Prof. Dr.-Ing. Horst Baier 2. Hon.-Prof. Dr.-Ing. Dieter Schmitt 3. Univ.-Prof. Kristina Shea, PhD Die Dissertation wurde am 26.11.2007 bei der Technischen Universität München eingereicht und durch die Fakultät für Maschinenwesen am 29.04.2008 angenommen. II Acknowledgements This work is the result of the research I have done over the last couple of years while working in the Digital Mock-up Integration team of Airbus in Bremen, Germany. I may regard myself as lucky, because even after busy years of intense and challenging professional and research work on the mock-up topic the Digital Mock-up in particular is as exciting as on day one, and the complexity approach has been even more a thrilling and mind- expanding enterprise. I especially want to thank my doctoral advisor, Prof. Dr.-Ing. Dieter Schmitt, Institute of Aeronautical Engineering, for his support and confidence in my work throughout the years. I am very grateful for both the freedom he granted me exploring the field of mock-ups with a rather unusual approach and for his rigour turning a work strongly influenced by an industrial environment into a scientific thesis. I want to thank Prof. Dr.-Ing. Horst Baier, Institute of Lightweight Structures, for being the first reviewer and for his advice in choosing the appropriate title of my thesis. Then I thank Prof. Dr. Kristina Shea, Institute for Product Development, for being the third reviewer and for her detailed feedback and improvement proposals. Also, I want to thank Prof. Dr.-Ing. Florian Holzapfel, Institute of Flight System Dynamics, for accepting the chair of the examination board and for the smooth organizational handling of the dissertation process. I am grateful to numerous colleagues in Bremen who shared their time providing valuable insights from different disciplines’ points of view, who supported me with data, background material – in particular on the Engineering Mock-up campaigns which took place long before I joined the company – and who gave feedback and advice at different stages of my work. It deserves particular mentioning that my superiors during that period – Ralf Garbade, Thomas Stockhinger and Marc-Niels Jaeschke – granted me the freedom to arrange my professional occupation with my research the way I found most convenient. I am particularly grateful to Dieter Weinhauer, a very experienced and now retired aircraft development engineer and manager, who supported me from the very beginning when the thesis began to take shape. I owe special thanks to him for his valuable and detailed feedback and for long-lasting discussions on the various aspects of my work. He greatly enhanced my holistic understanding of the Digital Mock-up, on its place in aircraft development and its potentials. Last but not least I want to thank my family for their continued – moral – support throughout these challenging yet rewarding years. Early on I decided to write this thesis in English. Translations I have made by myself, and even though having put greatest care in correctly expressing my thoughts, I can’t exclude that errors had gone undetected. If so, I apologize for that and hope that the text will nevertheless be readable and understandable. Stuhr, May 2008 Walter Richard Dolezal III IV To my parents and grandparents for their love and support V VI Table of Contents TABLE OF CONTENTS.................................................................................................................................. VII ABBREVIATIONS .............................................................................................................................................IX DEFINITIONS ....................................................................................................................................................XI CHAPTER 1 INTRODUCTION ....................................................................................................................... 1 1.1 ECONOMIC CHALLENGES, TECHNOLOGICAL ADVANCES AND NEW WAYS OF WORKING......................... 1 1.2 AIM AND SCOPE .................................................................................................................................... 2 1.3 MOTIVATION FOR THIS STUDY .............................................................................................................. 2 1.4 INDUSTRIAL AND SCIENTIFIC APPROACH – RESEARCH METHODOLOGY................................................. 3 1.5 CHAPTER OVERVIEW ............................................................................................................................ 4 CHAPTER 2 THE DIGITAL MOCK-UP ........................................................................................................ 5 2.1 DEFINITION........................................................................................................................................... 5 2.2 A HOLISTIC VIEW ON THE DIGITAL MOCK-UP ....................................................................................... 6 2.3 TECHNICAL DIMENSION OF DMU – OVERALL CONTEXT ..................................................................... 7 2.3.1 From Hardware Mock-up to Digital Mock-up................................................................................ 7 2.3.2 Emergence of Digital Mock-ups...................................................................................................... 9 2.3.3 Virtual Product Development........................................................................................................ 10 2.3.4 Challenges and requirements for DMU operations ...................................................................... 11 2.4 TECHNICAL DIMENSION – THE ELEMENTS OF THE DIGITAL MOCK-UP................................................ 13 2.4.1 Geometry - Basic considerations for the 3D representation of digital objects ............................. 13 2.4.2 Metadata I – the Product Structure............................................................................................... 14 2.4.3 Metadata II – the Attributes .......................................................................................................... 17 2.4.4 Digital Information Objects .......................................................................................................... 17 2.4.5 The Configured Digital Mock-up (CDMU)................................................................................... 19 2.5 TECHNICAL DIMENSION – PROCESSES AND ORGANIZATION............................................................... 20 2.5.1 Electronic Data Interchange (EDI)...............................................................................................20 2.5.2 Data and Design Quality............................................................................................................... 20 2.5.3 Check and Review Processes ........................................................................................................ 21 2.5.4 Organizational Adaptations .......................................................................................................... 22 2.6 COMMUNICATION DIMENSION – VISUALIZATION AND DISTRIBUTED COMMON REFERENCE.............. 23 2.7 MANAGEMENT DIMENSION – EARLY WARNING AND RISK MANAGEMENT & MANAGEMENT OF COMPLEXITY ...................................................................................................................................... 24 CHAPTER 3 THE DEVELOPMENT ENVIRONMENT OF COMPLEX PRODUCTS .......................... 26 3.1 CHARACTERISTICS OF COMPLEX PRODUCTS AND THEIR DEVELOPMENTS............................................ 26 3.2 THE PRODUCT IN A HIGHLY DEPENDENT ENVIRONMENT – THE SYSTEMS VIEW ................................... 27 3.3 THE MARKET CHALLENGES ................................................................................................................ 28 3.4 THE MANAGEMENT CHALLENGES....................................................................................................... 29 3.5 THE MEGAPROJECT CHALLENGES ...................................................................................................... 30 CHAPTER 4 COMPLEXITY IN THEORY .................................................................................................. 32 4.1 INTRODUCTION TO COMPLEXITY – WHAT IT IS, WHERE IT COMES FROM.............................................. 32 4.2 THE OBJECTIVE AND SUBJECTIVE SIDES OF COMPLEXITY IN MORE DETAIL.......................................... 34 4.2.1 Structural or objective complexity ................................................................................................ 34 4.2.2 Functional or subjective complexity.............................................................................................. 34 4.3 Mastering complexity .................................................................................................................... 36 4.3.1 Ways to cope with complexity ......................................................................................................
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