3882-UK/Dassault 7/11/05 9:34 Page 28

Contact
1

mag

11 2005
The V5 PLM Magazine

INTERNATIONAL

Monaco Yacht Show

Solutions for the luxury
yacht market

UK AND IRELAND

SECURISTYLE
Window producer benefits
feature from CATIA and SMARTEAM

Accelerating Transformation
in the Automotive Supply Chain

MECHTOOL
Enclosure maker streamlines
design process with PLM
DASSAULT SYSTEMES LTD
Suite 9 -10 Riley Court
Milburn Hill Road
Coventry CV4 7HP
United-Kingdom
Switchboard +44 (0) 2476 857400
Fax: + 44 (0) 2476 857403
e-mail: info-solutions@ds-fr.com
www.3ds.com
3882-UK/Dassault 7/11/05 9:34 Page 2

Editorial International
ver the last couple of years, PLM

O has come out of the design office

community and is increasingly
raised at the top level of companies which
4 news
• Dora Lainé reports live from ECF 2005
operate in various market segments.
We used to discuss with our customers how
they could increase by 10-15% some speci- 7 Solution spotlight
fic process, how they could produce drawings more quickly, how • Solutions for the luxury yacht market
CATIA data should be managed by some other PDM etc. • Powerful CATIA data exchange
IT used to lead the discussion and dictate some rules; Engineering based on SMARTEAM
and Manufacturing people were asked to comply with those
IT rules (whatever they could be) but still get strong enhancements
(whatever IT decided). 8 feature
Only a minority understood that PLM had to be taken the reverse way: • Accelerating transformation
select the end-to-end processes to optimize or change, select new in the automotive supply chain
methods, select PLM tools with IT then ask IT to drive integration.
This minority has clearly won today! More and more PLM is owned
by the Business and by the Management as PLM is fully understood 12 success story
as the main leverage for strategic initiatives which will drive the • Meissner: CATIA, SMARTEAM and CADBAS-
companies in their next market position (… or out of the market if PartExplorer to model tooling and molds
they are unable to lead change). • Toyota Motorsport: doubling design
There is a strong logic behind this ownership change: PLM serves productivity with V5 PLM
to improve top line by enabling more innovative products launched
earlier and PLM also serves to improve bottom line by enabling
cost reduction and managing diversity. No other initiative will have
15 Product overview
• Interview: Nordine Marouf, ENOVIA market
a larger footprint in the coming years!
development manager
“V5 PLM Transformation” has become our motto to help you our
customers and business partners. We have also decided to
change to be better positioned with you. We have reshaped our
long-time partnership with IBM so that the various teams of
Dassault Systèmes are closer to you in your various countries,
while retaining the recognized added value of IBM in the large
UK and Ireland
accounts. Since this summer, many of you have already appre-
ciated this change and we will continue to accelerate in this 18 in practice
direction. • Generative Mechanical Design
• Lawton stays ahead in the medical instrument market
You have in your hands this new magazine that we will use 3 • Mechtool cuts time to market
times a year to report how customers, business partners, • Securistyle increases its edge
IBM and Dassault Systèmes work together to implement V5 • Blackflag Composite customises yachts
PLM… and share success ! Enjoy reading…

Contact mag
DENIS SENPÉRÉ
Vice-President PLM Europe
Dassault Systèmes ] The V5 PLM Magazine published by Dassault Systèmes - 9 quai Marcel
Dassault - 92150 Suresnes - France • Publication Executive: Denis Senpéré
• Chief Editor: Gilles Kircher • Editorial Board: Céline Pérès, Carole Genolhac,
Philippe Bonnard, Achim Loehr, Mike Crow, Frédéric Lefebvre, Jean-Marc Galea,
Steffi Dondit, David Treacher, Maria Ivanova • Photo credits: Dassault Systèmes’
customers and partners • Design and Production: Images et Formes • Printed in
France - “ISSN applied for”

Contact mag | n°1 3

3882-UK/Dassault 7/11/05 9:34 Page 4
Live from ECF 2005
Main Session
Transformation was the keyword of this plenary
session, describing the evolution of our
‘Channel Management’ partnership with IBM,
as well as the evolution of PLM to assist
companies in their pursuit of the coveted title
of market leader.
For transformation to occur, companies need
to constantly innovate to meet their customers’
expectations. “Innovation, said Bernard Charlès,
President and CEO, Dassault Systèmes, will
drive the future of the manufacturing business.
PLM enables engineers to play a role from
initial product requirements all the way to cus-
tomer experiences.” Companies that integrate
in their product’s life cycle how this product will
be used in real life situations will have a clear
lead over their competitors.
Nick Donofrio, Executive Vice President,
Innovation & Technology, IBM, explained, “The
value of PLM technology is to enable innovation
by capturing the complete lifespan of a product.”
He emphasized that in today’s global market,
an innovative company is one that is open by
building on what already exists and that has
understood that they cannot do it alone but
in a collaborative fashion by taking advantage
of the talents and resources of the world
wherever they may be.
Nick Donofrio Bernard Charlès
ECF 2005 Facts and Figures
• 45 exhibitors
• 1400 visitors
4 Contact mag | Dassault Systèmes
news
By Dora Lainé
]
Customer Corner New Comers CAA V5 Corner
major happening at this year’s ECF in the DS Group
A were the more than 70 conferences
and workshops that took place giving
customers and partners a forum where they Dassault Systèmes held a press conference on CAA V5 Gold Software Partner
shared their PLM experiences. All industries October 5th to announce the acquisition IGE+XAO, software editor dedicated
were represented and the topics that were
covered in the customer presentations high-
completion of two major to electrical engineering and systems
lighted the transformation process in motion market players in the area design, unveiled their development
and the breadth of PLM solutions used. of product simulation.
plan for six new products fully based
Here is the personal selection of Contact Mag:
on CAA V5 technology for electrical
• Sennheiser, one of the world’s leading “The addition of ABAQUS Inc.,
electroacoustics companies, implemented leader in advanced finite element modeling and diagram generation.
CATIA V5 and SMARTEAM to meet the analysis software, to the Dassault
rapidly growing pressure for shorter deve- Systèmes family will bring real life simulation to
lopment cycles, quicker responses to late our customers and make the virtual world real”, The rollout plan is
design changes and the need for increased said Bernard Charlès, President and CEO, Dassault Systèmes. in two phases,
collaboration with external partners. Mr. Charlès announced the addition of a new brand to the existing the first involves
• Fissler, market leader in cookware, decided portfolio called SIMULIA, an open scientific platform for multi-physics applications for
to redesign their PLM processes by imple- that will enable the integration of all types of simulation applications the development
menting CATIA V5 and SMARTEAM and • Volvo’s truck business area successfully thereby providing an accurate simulation of the product behaviour of topology and
recorded a 20 - 25% global productivity implemented CATIA V5, ENOVIA V5 and under operational or extreme conditions. generative systems
increase as a result. DELMIA V5 for the development of their new schematics for time”, said Alain forces to bring their
• Volvo Construction Equipment’s “One truck generation which will hit the market electrical and the Di Crescenzo, customers a
Company Vision” required them to increase under the Volvo, Renault and Mack brands second phase will Chairman & CEO, complete end-to-end
collaboration within the group. They migrated • DaimlerChrysler explained in great details Another major announcement was the acqui- be an electrical IGE+XAO. comprehensive
to CATIA V5 from other CAD systems, imple- how CATIA V5 is now massively used in all sition of VIRTOOLS creator of software solu- diagrams offering “Our customers have solution in electrical
mented SMARTEAM and as a result their business areas for cars, trucks, bus and tions that enable companies to bring 3D to life, and generative reacted positively to engineering, the
Images courtesy of PSA Peugeot Citroën
created a full multi-site environment where powertrain under the Mercedes, Chrysler, a major driving force in Dassault Systèmes views for publishing. our partnership with added value is
they could “design anywhere, produce Freightliner or Mitsubishi Fuso brands and strategy to democratize 3D. Virtools’ applica- “Our partnership Dassault Systèmes immediately
anywhere”. how they are accelerating the integration of tions allow users to quickly and easily add life with Dassault where our solutions perceived”.
• Bobst Group, leading supplier of complex their suppliers into this new environment experience to any 3D object. For example, Systèmes will offer will complement the
equipment and services for the folding carton, • BMW gave a very similar message to their imagine being able to visualize what a driver seamless integration Dassault Systèmes
corrugated board and flexible materials suppliers, reinforcing the direction that feels, in terms of ergonomics, while virtually with the V5 portfolio V5 electrical PLM
industries, reduced total development costs the German automotive industry is taking driving his/her car. This is the future of product thereby helping our offering. When two
by 15% with ENOVIA V5 and CATIA V5. with CATIA V5. development. This is what PLM can do for you. customers save market leaders join
“
Virtuous cycle of innovation
If you change the way you look
Pr
at things, things change
”
n
od
tio
va
uc
New this year The Customer forum, representatives. Moderated by Alex Taylor,
no
tiv
ity
In
an opportunity for customers to exchange more than 160 customers participated, Growth
views with Dassault Systèmes and IBM making this first edition a success. Cycle WALTER H. DONALDSON JR.
[General Manager, WW Product Lifecycle Management, IBM.]
Contact mag | n°1 5
Collaboration
3882-UK/Dassault 7/11/05 9:34 Page 6
Solutions for the
Luxury Yacht Market
]
By Céline Pérès
DASSAULT SYSTÈMES LEADER
IN THE YACHT INDUSTRY
The luxury yacht business is riding on the crest
of a wave at the moment. Yachts are bigger,
clients more confident and service providers
more professional than ever. The naval archi-
tects and the yards compete fiercely and
today have a strong demand for efficient
integrated shipbuilding system to replace
the suite of non-integrated niche tools that
have been used until now for design and
manufacture. Capabilities, cycle time, costs and
quality are no longer good enough to support
the requirements on the Megayachts market.
After a great success in the small and medium
yachts segments with references such as
Beneteau, Jeanneau, Hallberg-Rassy, Poncin
Yachts, Seaway, Cranchi, Berret-Racoupeau,
H2O Yachts, Dassault Systèmes now addres-
ses the Megayachts industry with a complete
V5 PLM solution based on CATIA V5,
DELMIA and SMARTEAM which supports
design in context with modern shipbuilding
modeling and manufacturing features. High
end functionalities coming from aircraft and
cruising ships industries have been made
available for the yachting industry, such as full
support of composite materials, now widely
used for yachts.
F
or the first time Dassault Systèmes was
present among the exhibitors on the
September Monaco Yacht Show with
the CAA V5 Partner OPTIS and four IBM/DS
Business Partners – Cenit, DSF, Spaziosystem
and Transcat PLM.
The Monaco Yacht Show is the only show in the
world devoted exclusively to luxury yachting.
With 530 exhibitors over 14000 m2 and 93
handpicked 70-to-200-foot yachts in the water,
this is the yacht show for professional yachts-
men, owners and the industry as a whole.
As usual, in addition to the marine exhibitors,
there was a considerable presence of luxury
goods companies such as Baccarat crystal,
Jaguar cars, Blancpain watches etc, that are of
interest to the typical well-heeled show attendee.
Among the celebrities, HSH Prince Rainier III,
who died earlier this year, was an enthusiastic
yachtsman and patron of the show, a passion
shared by his son, HSH Prince Albert II who offi-
)
cially joined the show this year •
A new customer : Vaton Design
Right after the Monaco Yacht Show,
Vaton Design selected Dassault Systèmes’
V5 PLM solution and immediately started
the general design of a large high speed
vessel with new CATIA V5 yacht packages
including structures and systems design,
with the support of IBM/DS French
business partner DSF.
Powerful CATIA Data Exchange
INTERIOR DESIGN
WITH OPTIS
OPTIS is the first company to pro-
By Diane Benjuya
vide light simulation solution fully based on a
physical model inside CAD/CAM software
to answer industrial needs for interior design.
Its unique colorimetry, ergonomy and lighting
solutions answer the needs of the yacht industry,
architecture and design. SPEOS integrates
photometry, colorimetry, lighting and photo-
realism capabilities to build highly realistic virtual
prototypes. LIGHT computes the illumination
level inside any 3D architecture scene and
brings it exact light levels, aspects and colors.
Both modules are CAA V5-based and smoothly
integrated within CATIA V5.
The YONtech S36 made
by Yonca Onuk.
A great reference :
Yonca Onuk
Yonca Onuk design and manufacture their
high speed and patrol boats in Turkey.
They have been using CATIA V5 since
2001 and have just introduced
their latest model in the
YONtech S line of luxury high
speed motor boats. Intended to be
the symbol of excellence and perfection,
the “YONtech S36” (for 36m long)
is a radical machine capable of speeds
in excess of 65 knots, accommodating
8 guests in extreme luxury and styling.
It features advanced composite DNV
classified structures.
] Based on SMARTEAM
Packaged for Delivery:
SMARTEAM’s capabilities for
reconciling 3D CATIA data
across design environments.
A collaborative design facilitator, SEE enables
visualized comparison and selective
reconciliation of CATIA V5 3D models.
solution spotlight
GET READY TO RECONCILE !
The supply chain faces daily obstacles in
getting its work done, burdened by complex
data exchange methodologies, threats to
design integrity, manual entry of OEM data
and other interaction pains. SMARTEAM’s
powerful new engineering package exchange
tool (SMARTEAM – CATIA Supply Chain
Engineering Exchange - SEE) provides a swift,
cost-effective collaborative solution to these
challenges and more.
SEE enables suppliers to interactively compare
and reconcile a set of CATIA assemblies and
parts coming from an OEM or other supplier
with those stored in a targeted SMARTEAM
installation, while preserving all relational links
and data integrity.
Any CATIA-SMARTEAM site can use SEE to col-
laborate with any other CATIA site, including OEMs
using ENOVIA or SMARTEAM, suppliers using
SMARTEAM, and another with alternative PDM.
Seamlessly accessed through the SMARTEAM
menu, SEE lets CATIA users import packages
of 3D engineering data – assemblies, drawings,
parts and/or analysis documents. After loading
the source in CATIA V5, users identify and com-
pare documents common to both source and
target. Advanced queries, application of busi-
ness rules, such as to file naming, and other
knowledge management features optimize
reconciliation and related decision-making.
SEE helps suppliers improve productivity and
quality, while adding muscle to their competitive
edge: a supplier of windows for car doors can
Engineering data package before reconciliation
Collaborative design facilitator: Visualized comparison
and selective reconciliation of CATIA V5 3D models.
ensure that the glazing is a tight and accurate
fit with the OEM’s latest model for the door.
A Frankfurt-based supplier can collaborate with
a small team of engineers at its Seoul-based
sales office, capturing product configuration
input closest to the customer. A backlogged
engineering unit can rapidly parcel out work
off-site to meet delivery targets. End users can
enjoy productivity gains through offline work on
extracted files, relying on SEE to import them
smoothly back into SMARTEAM.
SEE joins multi-site, Web, and community por-
tals in providing robust SMARTEAM enterprise
and supply chain collaboration. “SEE powerfully
expresses SMARTEAM’s overall value proposi-
tion: giving the mid-market competitive edge
through fast, flexible, low cost of ownership
collaboration,” comments Stéphane Deleville,
SMARTEAM European competency center
manager at DS.
More information on SEE will be available upon
V5R16 release • )
Contact mag | n°1 7
3882-UK/Dassault 7/11/05 9:34 Page 8

feature

Dassault Systèmes’ Solutions

to accelerate Transformation
in the Automotive Supply Chain
By Olivier Sappin, Manager, Automotive Solutions, Dassault Systèmes
]
The industrial automotive

environment is transforming
into a comprehensive network
of specialized suppliers and
integrators to manage nearly all
aspects of a vehicle’s
development plan. The growth
opportunities for these
equipment manufacturers and
suppliers will thus tend to
increase and companies who
know how to innovate will be
taking the lead.
« • The use of standardized business processes
An offer specifically
adapted to manufac-
turers and their
suppliers in order
to provide them with
the means to better
collaborate, in an
efficient and
consistent manner.
S
uppliers in automotive product deve- • The complete control of solutions for the Today, the percentage of value creation out- projects generates large quantities of motive industry. This offer - “S4” – is specifically
lopment and manufacturing are exchange of engineering data in order to save sourced by OEM to suppliers is around 65% information, of which the sharing and the adapted to automotive suppliers in order to pro-
subject to strong market demands in time and money and protect intellectual and shows a trend to increase to a level of 80% reuse become a critical success factor vide them with the means to better collaborate,
terms of technological innovation. Companies property in the near future. Companies able to offer the for future projects. in an efficient and consistent way. “S4” has
in this industry must deal with fierce internatio- n Communication between OEM and sup- most innovative solutions will necessarily be already been adopted by several manufacturers
nal competition and they must offer manufac- plier in order to extract, compare and recon- best positioned to win contracts. In order to allow companies to meet these for their supply chains.
turers a rapid and accurate response to their cile engineering data. challenges, Dassault Systèmes and IBM have
❯❯
requirements. DASSAULT SYSTÈMES’ SOLUTIONS implemented the “Automotive Synchronous
• The optimization of the collaboration environ- For a supplier, working with several OEMs Supplier Solution Set (S4)” offer on a world-
The initiatives allowing suppliers to deal with ments around product data, in order to while managing concurrently various wide scale and in collaboration with the auto-
these major challenges are various in nature: maximize knowledge re-use and reduce time
to market
• The implementation of design and manu- n Multi-site collaboration across extended
facturing processes which allow a rapid enterprise.
response to RFQ (Request For Quotation)
n Capitalization and reutilization of know-how. • The capability to introduce innovation, even
very late in the process, in order to generate
to ensure compliance with the quality standards
incremental business, reduce costs and
minimize the risks of reduced profit margin
of OEMs n Generative design.
TIER n Concurrent
n Management of projects and workflows. APQP Design
Body in TIER 1 Chassis
White
OEMs Engineering
Today Package
RFQ Response Exchange
Customers Customers Customers Interior and
Exterior Powertrain
Car resellers Multiple-Brand
Distribution
Equipment
OEMs
Generative
Tooling
Electrical
Wiring
OEMs OEMs
>

R&D Production 80%

65%
>

Assemblers Integrators
>
> >
>
>
>
>
> >
>
>
>

>
>
>
>
>

> > > >

>

>

>

>
>

>

>

>

Supply Chain Supply Chain Specialized

Supply Chain
8 Contact mag | Dassault Systèmes Contact mag | n°1 9
3882-UK/Dassault 7/11/05 9:34 Page 10

Accelerating Transformation in the Automotive Supply Chain

feature

« ❯❯
« Shared strategies
for product
The CATIA V5 The “S4” offer from Dassault Systèmes includes: available for each of the automotive domains
and allow optimal re-use of product development life-cycle
products, the ƒ Design solutions based on CATIA V5: processes. They provide a working environ-
management.
“S4” solutions and ‘Generative Car’, adapted to the vehicle ment that facilitates innovation and 3D
processes, allowing innovation even very late in communication for products, processes and
their associated the design stages, for the following domains: knowledge.
methodologies are • Body-in-white,
• Powertrain, ƒ Collaborative solutions based on
available for each of • Chassis, SMARTEAM:
the automotive • Interior and exterior equipment,
• Electrical wiring.
• RFQ Response,
• Advanced Product Quality Planning (APQP),
domains. • Concurrent Design,
• Engineering Package Exchange (EPE). ILLUSTRATION OF SOME OF Need: Answer to RFQ (Request for • Capability of tooling simulation in the context
THE CHALLENGES ADDRESSED Quotation) quicker and more accurately of an assembly line
BY DASSAULT SYSTEMES’ • Rapid response to RFQ with predefined • Standardization of tools thanks to catalogs
“S4” SOLUTIONS: generic models and re-use of existing product of generic models from car makers
information n Solution: Generative Tooling Design.
Need: Reduce the time between project • More precise analysis of product configuration
kick-off and start of production (SOP) prerequisites thanks to standard processes CONCLUSION
• Real-time concurrent engineering with the OEM n Solution: Management of RFQ. Dassault Systèmes’ V5 PLM solutions meet
• Real-time access to updated information for suppliers needs to provide automotive manu-
suppliers participating in the project thanks to Need: Ensure the satisfaction of OEMs facturers with parts, modules and systems.
a single bill of materials while remaining compliant with their These suppliers support an important part of
‘Generative Tooling’, adapted to the tooling • Reduction of costly iterations between the quality standards (ISO/TS16949) the R&D activity, while working closely with
business, with the aims of standardization and various partners in the project • Quality control through process optimization OEMs from the early stages of product design
know-how re-use: n Solution: Concurrent Design. • Development costs lowered by providing to maintenance and recycling.
• Injection molding, quality information on time and to all project
• Forging, The functionalities of SMARTEAM that are a Need: Collaborate with various OEMs partners CATIA V5 and SMARTEAM represent an
• Tooling. part of the “S4” offer, allow the sharing and working with multiple CAD and PDM n Solution: Advanced Product Quality integrated solution for the management of
the data management within the company tools, while protecting intellectual Planning - APQP. products data and business processes. It
extended entreprise – between the engineering property helps suppliers to answer manufacturers
units, manufacturing, the suppliers and the • Engineering change facilitated by a relational Need: Reduce the significant costs of expectations: the best possible combination
OEMs. The supplier thus becomes the “hub” design approach non-standardized tooling and avoid )
of innovation, reactivity, quality and cost •
of the project and controls all data and • Management of product data from heteroge- starting design from scratch for each
resources that will allow delivering the right neous solutions new project
product as quickly as possible and with • Protection of intellectual property • Reuse of generic tooling models from one
the best profit margins. n Solution: Engineering Package Exchange. project to the next one

Whatever domain the suppliers are dealing

The CATIA V5 products and the “S4” solutions
with their associated methodologies are
with, these dedicated “S4” solutions are
available through packages built with CATIA To learn more about the “S4”
and SMARTEAM products and with metho- configurations that fit your projects:
dologies adapted to the company’s size, info-solutions@ds-fr.com
processes and IT architecture.

10 Contact mag | Dassault Systèmes Contact mag | n°1 11

3882-UK/Dassault 7/11/05 9:35 Page 12
Doubling Design
Productivity
with V5 PLM
Toyota Motorsport, Toyota’s Formula 1 racing team, has obtained
significant benefits from its V5 PLM implementation – and that
across the whole development process.
P
anasonic Toyota Racing is the official
name for Toyota’s Formula 1 Team.
Established in 2001, the team is run on
behalf of Japan’s Toyota Motor Corporation by
Toyota Motorsport GmbH. 2005 is Toyota’s
fourth season in Formula 1, making it one of the
youngest teams on the grid.
With more than 600 staff from 32 different
nations, Toyota Motorsport has developed its
complete Formula 1 car — chassis and engine—
from scratch under one roof at its factory in
Cologne, Germany. Toyota’s long-term goal is to
beat the more established teams in Formula 1
and become a world championship constructor.
A TIGHT TWO-WEEK RACE SCHEDULE
To win races, Toyota Motorsport (TMG) must
provide its two drivers with the fastest car
possible, respecting the tight, two-week race
schedule. This means that, for every single
race, TMG must quickly adapt car design to
upcoming racing conditions, such as circuit
configurations, driver racing style, and weather
conditions.
“Ultimately, when you win races, you win them
in the design area,” says Mike Gascoyne,
Technical Director Chassis, Toyota Motorsport.
“Getting new ideas into the car is key when
12 Contact mag | Dassault Systèmes
you’re working on a two-week timeframe.
That’s where Dassault Systèmes V5 PLM
solutions are absolutely crucial to our core
functions.”
V5 PLM TO COVER THE ENTIRE
DEVELOPMENT PROCESS
To accelerate F1 car development, TMG chose
Dassault Systèmes’ V5 PLM solutions based
on CATIA V5, ENOVIA, DELMIA and DS
Generative Car Solution. Specialized applica-
tions from Dassault Systèmes’ software
partners CAA V5 are also used. They include
ABAQUS for CATIA V5 for nonlinear simulation,
LMS Virtual.lab Motion for dynamic motion
simulation, CENIT’s CAA V5-based FasTRIM
product for automatically programming laser-
cutting robots and Transcat PLM’s Q-checker
for data exchange quality insurance.
“We needed a long term PLM solution
that covers our entire development process,
as well as a partner capable of under-
standing our job,” says Thomas Schiller,
General Manager, IT department, Toyota
Motorsport. TMG has achieved clear and
tangible benefits from its V5 PLM imple-
mentation throughout its entire development
process.
Chassis process: time gains
The V5 PLM Digital Mock-Up (DMU) tools are
crucial to achieving the harmony between the
chassis and the engine. “By using V5 PLM
DMU solutions, we can check the car’s assem-
bly while we’re still in the design stage, because
the designers are not designing in isolation,”
says Mike Gascoyne. “We quite simply no lon-
ger see the problems we used to have in terms
of car’s first physical assembly. Before, it could
take two or three weeks. Now we do it in two or
three days. The time gain gives us a tremen-
dous advantage.”
Aerodynamics process: productivity gains
“Moving from CATIA V4 to CATIA V5 has
enabled us to almost double the number of
prototypes we can make in a given time,” Mike
Gascoyne adds. “This in turn enables us to
double the number of tests in the wind tunnel
and double the car aerodynamic performance.
That’s absolutely essential to high performance
on the track!”
Another benefit measured by TMG’s aerody-
namics team comes from implementing the
Generative Car solution. “Using the Generative
Car solution in the aerodynamics department has
increased design productivity by 30%, and by up
to 80% if we look at parts such as the front wing,”
notes Stéphane Chosse, Wind tunnel Model
Design Manager, Aerodynamic department,
Toyota Motorsport.
Engine process: design quality improvement
The powertrain challenge lies in producing the
most powerful engine while keeping it as light-
weight and reliable as possible. “Design quality
is the key issue to a successful Formula 1 car
engine,” says Luca Marmorini, Technical Director
Engine, Toyota Motorsport. “In particular, CATIA
V5 analysis tools enable us to simulate the
constraints endured by extremely complex mo-
dels, such as blocks or crankshafts. This definitely
helps us increase the engine’s design quality.”
Car transmission process: time savings
TMG has obtained very significant time gains in
the development of its car transmission since
upgrading from CATIA V4 to CATIA V5. “CATIA
V5 implementation in the transmission area was
very impressive,” Thomas Schiller points out.
“It took us the same amount of time to imple-
ment, train people, and design the car transmis-
sion in CATIA V5 as it took us just to design
it in CATIA V4. Plus, we were able to double
design and analysis iterations!”
Cockpit ergonomics: innovation for the
F1 driver
V5 PLM enables engineers to design the car in a
way that optimizes its interactions with the driver.
“With V5 PLM Human Modelling ergonomics
tools, we insert the driver virtually into the digi-
tal mock-up of the car,” says Mike Gascoyne.
“We can then optimize the ergonomic design
of the monocoque to ensure that the driver will
fit perfectly and be able to operate the car while
driving it at the limit.”
success story
EXTENDED COLLABORATION
AROUND THE DIGITAL MOCK-UP
With CATIA V5 and ENOVIA, TMG has a virtual
Formula 1 development hub, where any team
member can access the car’s digital mock-up. Key V5 PLM benefits
for Toyota Motorsport
For instance, the car’s digital mock-up can be
accessed by the purchasing or marketing
departments to perform specific tasks in CATIA
V5. “In our marketing department, we use
Time reduction
• up to 80% in the aerodynamics design
process (Generative Car solution)
• 90% for first physical assembly – down
CATIA V5 Real Time Rendering to get an idea
from 3 weeks to 2 days (DMU V5)
of what the car will look like before we build it,”
says Markus Schwarze, Manager, Technical Improved car performance
Applications, Toyota Motorsport. “It is absolu- • +100% wind tunnel prototype production
tely essential for our sponsors to see what mil-
lions of people will see on TV screens before the
car is on the track.”
and test (knowledge-based designs)
• One of the most reliable F1 engines
(the department has moved to CATIA V5)
Cost reduction*
Furthermore, V5 PLM solutions are actually
• 60% cost and time savings searching for
present on the track, too. “By using CATIA V5 information during the design processes
and ENOVIA, the track mechanics are able • 40% cost savings fixing BOM errors
to see, in 3D, how they have to fit all the car • 48% cost savings for administering
)
components,” adds Mike Gascoyne • Engineering Change Requests (adminis-
tration, tracking, distribution, etc.) and
57% savings in labor costs to complete
ECRs
*findings based on an independent study performed
by CIMdata, PLM consultant.
“
We view all partnerships as a win-win opportunity. Dassault Systèmes
offers us car development solutions that give us the cutting-edge
performance that is required in Formula 1. At the same time, we like
to think we’re pushing their technology to new limits because
of the ultimate challenge of material and performance that
Formula 1 demands.
JOHN HOWETT
”
President, Toyota Motorsport GmbH
Contact mag | n°1 13
3882-UK/Dassault 7/11/05 9:35 Page 14
World-class
Tool Modeling
Meissner AG is under pressure
from global competition.
Its response has been to
leverage the unique benefits
of CATIA V5, SMARTEAM, and
CADBAS-PartExplorer for
modeling its tooling and molds.
CATIA V5
CATIA V5 handles all modeling methods,
the modeling of parts and assemblies as
well as the production of technical drawings.
CATIA knowledgeware modules are exten-
sively used.
SMARTEAM
Management of CAD documents coming
from a multi-CAD environment is crucial for
Meissner. This will be progressively extended
to management of other documents (Office,
archives, etc.). SMARTEAM also manages all
data exchange processes and security.
CADBAS-PartExplorer
The PartExplorer solution ensures clas-
sification of repetitive parts in order to
improve reuse and carry-over. The libraries
of standardized parts and supplies as well
as the expanded intelligence of the TG1
and MDT CATIA modules allow automatic
generation of CAD geometry.
14 Contact mag | Dassault Systèmes
F
or over 80 years, Meissner of
Biedenkopf-Wallau in Germany has
been a hallmark of foundry tools, blow
molds, and tooling for vehicle bodies.
Investing in CATIA V5, SMARTEAM, and
CADBAS-PartExplorer will underpin its
worldwide leadership and enhance its com-
petitive edge.
The combination of these solutions helps
Meissner achieve several objectives. It
enhances development and modeling
productivity, but also increases flexibility and
creativity in general. It helps standardize
their CAD/CAM environment, better share
knowledge, tighten data exchange security
and reduce IT spendings.
Short term focus areas have been
selected by Meissner in order to quickly
collect benefits:
• Document management (of CAD and non-
CAD objects);
• Bills of materials and performance data;
• Certifications of parts utilization;
• Classification of repetitive parts (assemblies,
proprietary drawings, standardized parts
and supplies);
• Use of libraries of standardized parts and
supplies;
• Elimination of isolated solutions and redun-
dant data entry;
• Optimization of the modeling methodology
through knowledge management.
WORKING TOGETHER
CUTit! Systeme is the IBM/DS PLM Business
Partner selected by Meissner to implement
CATIA V5 and SMARTEAM with the right
design methods. CADBAS advises Meissner
on classification methods and processes
supported by CADBAS-PartExplorer.
Dassault Systèmes AG provides additional
guidance to make sure the latest technical
enhancements are made available to the
)
users •
ENOVIA V5 - Meeting the
Challenges for the High-end
The ENOVIA V5 suite is available on the market, helping large and
mid-sized enterprises alike. Contact Mag asked Nordine Marouf,
ENOVIA Market Development Manager, to give a run-down on the
ENOVIA V5 benefits and the challenges it helps solve.
Contact: What are the main benefits
of ENOVIA V5?
Nordine Marouf: ENOVIA V5 is designed for
the high-end of manufacturing industries, those
which have complex products to develop and
a high degree of diversity to manage. These
are large enterprises such as aerospace and
automotive OEMs but are also medium-sized
companies such as in the machinery industries.
The unique strength of ENOVIA V5 is the ability
to manage innovation processes in an
increasingly complex environment for design
collaboration, manufacturing and after-sales.
With a complete implementation of ENOVIA V5
together with CATIA V5 and DELMIA V5, our
high-end customers get the full power of V5
PLM and maximum ROI. They can replace their
costly legacy PDMs and multi-CADs by a
single PLM system where every aspect is
optimized from end-to-end until linkage to the
production systems. And this can occur in
many different ways and steps to cope with
each customer’s priorities.
Contact: How does ENOVIA V5 affect the
key milestones in the development process?
NM: ENOVIA V5 contributes to reducing the
product development cycle time with improved
CATIA V5 feature management, rapid access to
structured data, upfront manufacturing and
improved collaboration across the extended
enterprise. It also allows customers to readjust
their relative design and manufacturing
times to optimize cycle time and cost.
Contact: Who is using ENOVIA V5
today and how?
NM: From the growing number of customers
in production, it is easy to notice that ENOVIA
V5 customers have all made a clear decision
to deeply transform their end-to-end proces-
ses. Such a decision may result from merging
environment as Volvo AB is having in their
truck division with Volvo, Renault and Mack
brands: here the primary goal is to enable a
common way to develop trucks across multiple
engineering and manufacturing sites and at
the lowest cost. It can also be driven by a huge
transformation as the one that Boeing decided
to implement for their 787 program which is
co-developed with 40+ risk-sharing partners.
For medium-sized companies, the most
frequent decision factor is the globalization
which requires to re-think the value chain
inside the enterprise. Strategic aspects
around management of product structure,
in-house components, sourcing and intellectual
property are coupled with enhancement of
configured DMU processes or know-how
capture and re-use. This is the case at Bobst,
product overview
a Switzerland-based group which produces
large machines for the packaging industry or
at Homag, a German group which is very
similar but for the wood industry.
Contact: What about your existing
customers with VPM?
NM: We also have customers who implement
part of ENOVIA V5 in order to first enhance
their design environment thanks to the tight
integration with DMU processes based on
CATIA V5. This is typical of Tier 1 suppliers
such as Bertrandt Engineering in Automotive
or Latécoère in Aerospace. Our VPM V4
customers often start with this step as it
appears quite logic when they want to get
maximum benefit from CATIA V5.
Contact: Then tell us what does ENOVIA V5
consist of?
NM: The ENOVIA V5 portfolio is basically made
up of three lines of applications:
VPM V5 enables relational product develop-
ment so that manufacturers can rapidly opti-
mize product definition early in the life cycle.
Inside CATIA V5, this is called VPM Navigator.
LCA V5 is a set of Web-based applications that
manage lifecycle. It provides access to both 3D
and non-3D data and manages the proces-
ses between engineering and manufacturing.
DMU V5 is a collaborative decision support
platform for real-time virtual product visualization,
navigation, analysis and simulation. It reduces
the number of physical prototypes required and
increases the visibility of design changes on
product variants • )
Contact mag | n°1 15
3882-UK/Dassault 7/11/05 9:35 Page 16
Advertorial
Dassault Systèmes and Intel
join forces in PLM
A Product Lifecycle Management solution
for small and medium manufacturing businesses.
The challenge: increase innovation and
profitability for SMEs by reducing development
cycle time and cutting costs without having
to invest in expensive mainframe computer
technology.
The solution: CATIA V5 and SMARTEAM.
CATIA V5 is the product design component,
allowing manufacturers to simulate all the
industrial design processes. SMARTEAM
provides knowledge and process manage-
ment, enabling users to optimize business
processes through product knowledge mana-
gement and collaboration.
The technology:
The following technologies are used to deliver
real-time visual collaboration for distributed
project teams in the manufacturing industry:
Intel ® processor-based server platforms
Powered by the Intel Xeon™ processor family
Client devices based on powerful mobile tech-
nologies developed by Intel. (LDAP) server 7
• High performance client desktop systems
based on the Intel Pentium 4 processor can
contribute significantly to the overall proces-
sing power available to the end user.
• Mobile laptops based on Intel Centrino
mobile technology were designed, tested
and tuned specifically for mobility and enable
secure wireless connectivity that protects the
network from misuse.
Today’s typical manufacturer is faced with
an overwhelming array of issues – devising
customized products, getting to market fast,
eliminating inefficiencies, communicating
effectively with partners and suppliers,
meeting performance and quality objectives,
designing for manufacturability and servi-
ceability.
CATIA V5 and SMARTEAM, in combination
with Intel technology enable SMEs to acquire
an entry-level PLM solution and then grow it
as the business thrives.
THE CASE OF MASCHIO
Italy's Maschio Group is a world leader in the
manufacture of agricultural machinery. Its
challenge is to bring to market innovative and
market-specific machines, but also to dramati-
cally shorten the product development cycle
to meet seasonal deadlines.
Maschio implemented Dassault Systèmes’ PLM
solution in 1999, integrating the 3D product
development capabilities of CATIA V5 with
the data and lifecycle management features
of SMARTEAM.
The benefits: since then, Maschio designers
have been able to explore 50% more design
options for each project, which improves quality
and fosters innovation. In some areas, the
development cycle of new machines has been
reduced by 55%.
“By slashing the cycle time, we are now
much more able to adapt to market demand.
The benefits to us are priceless”
Massimo Crozzoli, Maschio IT Director.
Viewpoint UK and Ireland
am delighted to introduce the
I first UK section of the all new
European Contact Mag. This year
is an exciting one for Dassault 18 in practice
Systèmes in the UK, not least
because our new subsidiary Dassault
Systèmes Ltd has been up and
running since July 1st. We have established a strong team of
40 specialists, half of whom are dedicated to our channel
development activity. Our office, located in the Midlands, in GENERATIVE
MECHANICAL DESIGN
the City of Coventry, means we are centrally situated for our Discover the benefits of GMD and see
business partners, and we are also close to Birmingham how it can be used as a differentiator
airport. I have extended an open invitation to all BPs and their
customers to use our new facilities as if these were their own,
since I really want to create an atmosphere of an extended
Dassault Systèmes family amongst us all.
20
Our Channel Development team comprises Sales,
Technical, Marketing and Business Administration people
with many years of PLM experience between them. They
come from diverse backgrounds and have a variety of
LAWTON
skills, but today they have one common goal, which is to
Understand how this
help our Business Partners to be even more successful leader can stay ahead
with their customers. in the Medical
Instruments market
Having worked for a BP myself, and through speaking to
numerous BPs and customers at length, I know how
important it is to have good local technical support,
22
both accessible and well qualified. Consequently, SECURISTYLE
See how the combination of
our organization includes a Technical PLM
CATIA V5 and SMARTEAM
Competency Centre to address this need. Our techni-
cal team is closely linked with the European PLM
24 give a window manufacturer
a clear competitive edge
Competency Centre in Paris and ultimately, of course,
to the Dassault Systèmes software development
organisation.
MECH-TOOL
In this issue you will find the latest information on
Learn how Mech-Tool are
new solutions that are now available, together
on track to achieve a 25-fold
with some interesting articles about how custo- reduction in time within
mers are reaping the benefits of our PLM solu- their design process
tions, not only in the UK but also overseas.
26
PHILIPPE BOULAY
Director Channel Development
United Kingdom
Dassault Systèmes Ltd
] BLACKFLAG COMPOSITE
Read how this young company
exploited tailored functionality for a
successful yacht project
If you would like to receive future issues of this magazine
please contact David Treacher via dtp@ds-fr.com Contact mag | n°1 17
3882-UK/Dassault 7/11/05
Generative
Mechanical
Design
a ‘Must Have’ for SMEs
]
By Fabrice Dreneau and Olivier Boces
Reducing time and cost while improving quality are key priorities
for most industries.
« The design of a product
must take into account
its total lifecycle.
18 Contact mag | Dassault Systèmes
9:35 Page 18
T
here are various ways to improve the
use of in-house knowledge, the forma-
lization and standardization of business
rules, plus the automation of repetitive tasks
and the management of a design’s evolution.
These are all factors which enable a company
to get a head start, at the concept design stage
of a product, so freeing up more resources to
invest in innovation.
A rapid return on investment is only possible
if the right tools and the right methodologies
are applied. In particular, significant gains can
be made through:
Design process optimization. Customization
should be minimized, to avoid having to
re-invent entire designs. The re-use of
standard parts reduces risk.
Enhanced flexibility. Companies are
obliged to design increasingly complex
products that meet standards which
are constantly evolving, while delive-
ring innovation and quality.
Collaborative work. Coordination is
crucial. The various partners must
speak the same language, exchange consistent
data, and be able to access the right informa-
tion at the right time.
Lifecycle management. The design of a product
must take into account its total lifecycle. The
associated documents must evolve with the va-
rious versions of the product. The more its con-
tent and processes are standardized, the easier
and cheaper the product will be to maintain.
If companies are to achieve these improve-
ments, they must set up an environment that
promotes innovation. But that means that low
value-added tasks need to be automated.
Leveraging know-how
• Use previous projects to develop quotations
for new ones.
• Analyze which part in a new project is
unique and which part is repetition.
• Use the best methodology to design and
manufacture the product.
• Guide the sales people toward standardized
solutions with automated technology to
reduce costs and risks and increase margins.
The ultimate objective is to sell products
made of standard modules.
Implementation of Publication of trade design rules.
a technological element taking
constraints into account.
Standardizing functions and components
This can represent sets of data describing
sub-sets (3D geometry, 2D drawings, cabling
diagrams, functional architecture, component
catalogues, etc.), standard component bills of
material, or any other recurrent information.
Standardization imposed by business rules
incorporated in the system ensures that two dif-
ferent designers work towards the same solution.
Deploying company rules
This will ensure product traceability and
standards compliance. Spreading the business
rules to all the partners of a project and integra-
ting them into the working tool is a key benefit.
These factors, integrated into the traditional
CAD working tool, ensure that the company
designers are really focused on innovation and
added value. In turn, this enables a company
to get a competitive edge, rapidly launch new
products, and secure its margins.
INTRODUCING GMD
Based on CATIA V5, Dassault Systèmes’
Generative Mechanical Design (GMD) integrates
a logical layer above the parametric setting of the
design data. This is a true differentiator compa-
red to tools currently on the market. It allows you
to define the design rules, standardize the com-
ponents, and capitalize on the business rules.
Some of the benefits of CATIA V5 Generative
Mechanical Design:
Rule management controlling dimensional
parameter setting
• If a designer has to define the length of a given
component, he does not do so manually; he
specifies the required length and the system
updates the component.
• In the example of the conveyor belts illus-
trated above, the user’s only role is to specify
the height of the conveyor belt. CATIA V5 auto-
matically selects the required type of support.
Maintenance constraints taken into account
• A maximum number of components of a
certain type can be imposed in a sub-set
to make maintenance easier.
in practice
Definition of the
parameters for a flange.
• The rules for choosing components can
take into account maintenance department
requirements to select the best components.
IMPLEMENTING GMD
Dassault Systèmes and its partners offer user
training and the methodology for implementing
The Benefits of
and optimizing use of Generative Mechanical
Design for companies of all sizes.
the Generative
Method
Implementation stages:
• Identify the repetitive modules. Each module
must always be adapted to client needs,
• Integrate ‘design rules’ into design
activities; this avoids task repetition
and the duplication of errors.
and this can be entirely using the generative • Re-apply know-how within new
approach. contexts (client projects).
• Define the design rules for these modules. • Focus on innovation.
• Improve communications among
• Build the generic module and integrate the
design rules into CATIA V5.
• Implement on site.
project partners.
• Give reliable and accurate
quotations.
Two modes of implementation:
• The company defines its design rules in the collaborative data management tool providing
specifications and does not need to modify workflow management, a Web interface, mana-
them in the short term. In this case, the gement of bills of material, and the automatic
company only acquires the ‘Run’ modules. production of quotations. SMARTEAM also
• The company defines its own rules and wants allows for rule sharing and process compliance
them to evolve. In this case the ‘Build’ modules by the different teams.
are required to integrate the rules in its proces-
ses and modify them later, plus the ‘Run’ modu- CONCLUSION
les to use them. SMEs implementing Generative Mechanical
Design can promote innovation, reduce errors,
The initial investment will be rapidly amortized. increase margins, and gain market share.
Gains of over 50% have been measured in the Whatever the business processes or the com-
design stages. pany standards, Generative Mechanical Design
To promote collaborative work and optimize is a differentiator for those wishing to explore
the business processes in SMEs, Dassault the limits of PLM and offer their clients the best
Systèmes recommends SMARTEAM. This is a products at a competitive price • )
Preparation Design Modification
3D Design
Software
Basic
CATIA-V5
Usage
CATIA-V5
Generative
Design
Approach
Contact mag | n°1 19
3882-UK/Dassault 7/11/05 9:35 Page 20
New Challenges for Leader
in Medical Instruments
By Reiner Haag,
General Manager,
Lawton, Fridingen ] that is really obvious and tangible. The surfaces
F
or a company of our size the experience
of our workforce is our most valuable
asset. While our standard products can
be produced overseas, our premium products
can only be produced in-house. Therefore a
primary objective is the long-term security
of Lawton’s facility in Germany together with
our profitability.
Reiner Haag-General Manager
Harald Müller-EVP Product In recent years, we have faced growing com-
Development and Production. petition for our standard products, particularly
from the Far-East. Consequently, new strate-
gies were developed and implemented
to overcome this trend:
• New materials, new technology and new
processes were introduced. Quite clearly,
that calls for new procedures with more
engineering. CATIA V5 provides the basis
to describe complicated products and their
20 Contact mag | Dassault Systèmes
Lawton is a medium-sized
company located on the
river Danube in Fridingen,
Southern Germany.
Established in 1947, Lawton
designs and manufactures
surgical devices and medical
equipment. The product range
includes most types of
medical instruments, and
comprises around 14,000
individual products, available
in 80 countries around
the world.
variants, while taking into account the effects
of manufacturing. For example, the CATIA
Realistic Surface Optimiser automatically
compensates for any shape deformations
that result from our production processes.
• To react quickly to market demands, efficient
communication is essential. For example,
when the sales and development people
work together, new ideas and opportunities
are generated. Representatives from our
dealerships are in the loop also, which
means we need fast communication tools
and media such as the internet, images, film,
presentations and even rapid prototype
models. In addition to the traditional data for-
mats, we are now exploiting the new 3DXML
viewer. This enables us to communicate
about new ideas and concepts instantly with
any customer.
« The new 3DXML
viewer enables us
to communicate
about new ideas and
concepts instantly
with any customer.
• By reusing our successful designs and embra-
cing the latest technology, we are able to
manage the innovation which is becoming the
norm. Without innovation, even our premium
products will quickly become obsolete. We
are able to not only accelerate our design
time, but also to improve and optimise at the
same time. For example, we can now investi-
gate the mechanism of an instrument much
earlier and more extensively than before.
• Our future products will be even more attrac-
tive, better styled and more user-friendly. This
further differentiates us from competitors who
offer cheaper products. Achieving this is more
expensive, but the result is a superior quality
of our new products all blend smoothly toge-
ther and match the quality commonly seen in
the Automotive and Consumer Products
industries. At the same time, the amount of
basic CAD modelling effort is being reduced.
3DXML
One outcome - our ergonomic handles -
will revolutionize medical instruments, and
prevent operator’s hands from slipping.
• Even though we have introduced changes,
any new way of working together necessitates
the need for clearly defined processes.
Therefore, our future PLM vision includes a role
for Product Data Management in addition to
a long-discussed ERP system. The exchange
of data with our customers and our suppliers,
all operating within a network, will bring cost
savings and a competitive advantage.
• Market leading products are ‘lean products’
and our offerings must be available at the
price the customer is willing to pay, but also
include some product differentiation. However,
they must also be cost effective for us to produce
and we have found that premium products do
not necessarily have to include every latest
gimmick. With the help of CATIA V5 we are
able to develop a sophisticated product for a
particular price and this does not always
mean the lowest price on the market.
• Time to Market can always be improved. Since
customers like to shop around for the best
contract, it inevitably means that a very short
time is available to develop a product from the
initial idea though to market readiness. We have
a strong reputation for our fast turn-around time
from concept to production. Many Doctors,
with whom we have developed instruments,
are delighted by our responsiveness.
We installed CATIA V5 in January 2005. Initially
we thought about using a mid-range system,
but soon realized that with such a system our
requirements were not achievable. After the
initial basic training course in CATIA Solid
Modelling and GSD Surfacing, we completed
our first project. During this learning phase we
continued to work as before while using the
new tool. But we soon had an ideal opportunity
to change when one of our sales people sug-
gested a new type of instrument handle. We
in practice
modelled his idea and sent him back a 3DXML
file to visualise the result. In this way we were
able to discuss the first design within a week.
After 2 more iterations and an STL represen-
tation, the optimum design was found.
Meanwhile, as a parallel exercise, we investiga-
ted new production methods. Our suppliers
were able to provide accurate cost estimates at
an early stage and hence we were well placed to
decide upon the best manufacturing procedure.
The parts and assemblies we have previously
developed have been split into basic building
blocks and further developed into so called
‘Powercopies’. This has been a real boost for
our development team because these elements
are now used as templates which enable us to
develop new offerings from these individual
components. For example, to design a new pair
of scissors we bring together tips, blades and
handles based on previous projects. We do not
waste much time in modelling, but immediately
start to optimize the product.
Our sales people take advantage of the innovative
power of our development tool and present our
products in a totally new way ( 3DXML ). We can
already attribute our first commercial successes
to this approach, and we have shortened our
development time by two weeks • )
Contact mag | n°1 21
3882-UK/Dassault 7/11/05 9:35
Mech-Tool Engineering
Proves the Value of CATIA V5
UK enclosure manufacturer, Mech-Tool Engineering,
opted for CATIA V5 and GMD Solution to radically
transform its design process and recapture
margins in a highly competitive market.
« shing for the industry’s suppliers. “Not long ago
A serious mistake in a BOM
can result in dire commercial
consequences. Now BOMs
are generated instantly
and error-free.
22 Contact mag | Dassault Systèmes
Page 22
T
he North Sea is one of the world’s
harshest environments for offshore oil
production. But Ron Davison, Technical
Director of Mech-Tool Engineering, knows the
competitive environment can be just as puni-
there were companies all across the UK servi-
cing the offshore industry and
making a reasonable living,”
Davison recalls. “Today, 80%
of our products are sold into
the world market and only
a third of our business is
offshore.” Margins, meanwhile,
continued to shrink.
Mech-Tool responded by diversifying from its
core business of explosion and fire-proof enclo-
sures for offshore oil rigs. It added industrial
noise-control enclosures and packaged equip-
ment modules for pumps and engines. But
everywhere it turned, it ran into foreign compe-
titors with labor costs as much as 65% lower
than in the UK.
“We knew that making a small tweak here and
there wasn’t going to work any more,” Davison
said. “Our biggest cost centers are engineering
and manufacturing. We had to make a radical
change if we were to recapture our margins.”
CATIA V5 AND TRANSCAT PLM:
THE RIGHT SOLUTION
Just moving Mech-Tool’s design process from
2D to 3D could fundamentally improve Mech-
Tool’s economics. But finding a system that
could deliver was difficult. “Our manufacturing
process relies totally on drawings of a certain
quality,” Davison said. “The first system we tried
was fine for modeling, but on the drawing side
it was totally inadequate.”
Mech-Tool next turned to IBM/DS Business
Partner Transcat PLM. Sales engineer Andy
Simkins introduced a novel approach to
creating new designs. Transcat PLM helped
Mech-Tool create reusable knowledgeware
templates in CATIA V5, to capture its processes
and standards, leverage its existing know-how,
and avoid having to create new designs from
scratch.
These reusable knowledge templates were
integrated with the Generative Mechanical
Design (GMD) solution in CATIA V5. So GMD
has enabled Mech-Tool to slash new design
development time, reduce engineering and
manufacturing costs, and boost accuracy.
“We knew instinctively that Transcat PLM was
right,” Davison said. “But when the name CATIA
V5 was first mentioned, I thought I’d never
convince my board. We thought CATIA was
something that Ford and Boeing use – a solution
that costs lots of money and is way above what
Mech-Tool needed. Now we know better.
in practice
“ It’s early days,
but progress is
very promising and
we expect to make
substantial savings
We no longer look at the cost of the software design variations for a 45-ton pump enclosure
only. We look at the value of the return. Transcat in real-time using CATIA V5. “Because they in the time it takes
PLM’s know-how was invaluable in getting the could see it and watch as we played with
return on our investment. Although all of this various options, the client was able to do things
to produce manu-
was new to us, it wasn’t new to them.” in a more efficient way,” Davison said. “They facturing drawings
were very appreciative and impressed. We think
ON TRACK FOR A 25-FOLD that kind of extra value will help differentiate
for components
IMPROVEMENT Mech-Tool in the marketplace”• ) modeled in CATIA V5.
”
Mech-Tool is implementing CATIA V5 in stages,
beginning with the intake modules for its acous-
tic enclosures. Although that is just 25% of one
product line, the company is on track to achieve
what it believes can be up to a 25-fold reduction
RON DAVISON
[Technical Director,
in the time taken to produce manufacturing Mech-Tool Engineering]
drawings for components modeled in CATIA V5.
Creating Bills Of Material (BOM) from conven-
tional drawings once consumed 30% of the
company’s design hours. Now BOMs are gene-
rated instantly and error-free. “A serious mistake
in a BOM can result in dire commercial conse-
quences,” Davison said. “We can substantially
mitigate that risk.”
Seeing the finished product in 3D helps the
company’s metalworkers better interpret their
2D drawings, saving time and eliminating guess-
work. “In the past we generally had to go to the
factory floor and sort problems,” said Martin
Harris, Mech-Tool’s CAD Team Leader, who
recently used CATIA V5 to engineer a complex
3D box. “With this one, it was a first-time fit.”
3D visualization is also valuable in client-facing
situations. Harris recently showed a client
Contact mag | n°1 23
3882-UK/Dassault 7/11/05 9:35 Page 24
A Window of
Competitive Opportunity
CATIA V5 and SMARTEAM join up to give UK window
hardware manufacturer Securistyle a competitive edge.
S
ecuristyle of the UK is a global leader in
the manufacture of window hardware.
Until recently, it had worked mainly
with a 2D system. As a result, it faced major
design challenges when tackling 3D products
such as handles, gears and the increasingly
complex components used in hinges. At the
same time, specialized architects’ require-
ments combined with rapid legislative
changes within the industry instigated the
need to change towards an alternative system.
Moreover, Securistyle had built a vision and
defined objectives to expand its worldwide
market position.
To meet all these challenges, Securistyle’s
management decided to modify the company’s
design processes to produce new products
more rapidly. Their aim was to manage data
communication between Securistyle and its
customers to provide prompt, professional
responses to customer requests. Extensive
benchmarking was carried out to determine
Dual Action Lock the best system for Securistyle to adopt.
Mechanism with Sprung Hook.
“We were looking for a unified PLM (Product
Lifecycle Management) solution that combined
user-friendly and powerful capabilities such as
24 Contact mag | Dassault Systèmes
clash detection, finite element analysis, and
3D visualization, seamlessly integrated with
a Product Data Management system,” says
Stephen Hall, Senior Project Engineer at
Securistyle.
CATIA V5 AND SMARTEAM:
THE RIGHT CHOICE
In the end, Securistyle opted for a V5 PLM
solution supplied through the IBM/DS
Business Partner Applied PLM Solutions. The
solution combines the 3D product develop-
ment capabilities of CATIA V5 with the data and
lifecycle collaboration features of SMARTEAM.
“We chose CATIA V5 and SMARTEAM not
only because of their unique capabilities but
also because we have an excellent relationship
with Applied PLM, our local IBM/DS business
partner, which implemented the project and
always provides us with good support,” says
Richard Gurmin, Senior Engineer, Securistyle.
High Security Lock Housing.
Fire Escape Hinge. Latest 'Vision' Handles.
CATIA V5 and SMARTEAM provided
Securistyle with the competitive edge it required
to meet and surpass its business challenges.
With a sharp reduction in its design phase and
a better response to the market by designing right
the first time, Securistyle increased innovation
for greater reactivity and competitiveness.
Today, Securistyle has achieved clear and
tangible benefits from V5 PLM solutions:
• increased innovation, allowing the company
to penetrate new markets, while respecting
international safety standards
• reduced product development time and costs
in response to customer demands and
worldwide competitive pressures
• a streamlined bidding process to develop high-
quality proposals for customers more rapidly.
MULTIPLE BENEFITS
Securistyle has achieved a whole range of
tangible benefits from its CATIA V5 and
SMARTEAM implementation.
Increased innovation
“With CATIA V5’s advanced styling and visuali-
zation features, we can now design, validate
and easily demonstrate to architects and
specifiers all of the ideas and innovations we
have in mind,” says Stephen Hall. CATIA V5
enables Securistyle to develop more innovative
window hardware to meet perpetually-changing
legislation and very specific requirements from
architects. “Our capability to offer more inno-
vative products helps us to position ourselves
as a window-hardware solution provider and
even to influence the legislation. This distingui-
shes us from Far-East competitors, who gene-
rally design low-cost commodity products,”
adds Grant Stratford, Technical Manager.
Reduced development costs and time*
“For new products, we have reduced design
time by up to 44% and overall development
in practice
High Security Ancillary
Security Device.
costs by up to 60%, which gives our company
the flexibility it needs to meet customer requi-
rements right first time,” Stratford continues.
«
Thanks to the assembly and tolerance analysis
capabilities of CATIA V5, and SMARTEAM’s Securistyle has cut
ability to control and revise document mana-
gement, Securistyle has cut the number of the number of design
design errors by 50%. This generates time errors by 50%.
savings of 65% for design change manage-
ment and 80% cost reduction at the manu-
facturing stage to correct errors. It also
reduces the number of prototypes. In the
past, Securistyle needed three successive
prototypes per project to validate their design.
Now they generally only need one. This can
save up to three months per project.
In addition, the flexibility of CATIA V5 paramete-
rization enables designers to more thoroughly
integrate new design options and to adapt
existing, validated designs for a new project.
The costs of designing a new part from an
existing one have been halved.
Increased business revenues Market Leading 'Defender' Friction Hinge.
With CATIA V5, Securistyle has streamlined
the bidding process as it provides more
accurate cost calculation using weight
estimates of parts. “With SMARTEAM, we
About Securistyle
have deployed a collaborative participation
Securistyle is based in Cheltenham,
of Sales, Production, Testing, and Quality. Gloucestershire, in the United Kingdom.
All departments can visualize the latest, upda- It is one of the world’s most advanced
ted information. As a result, we provide our manufacturers of window hardware with
customers with more accurate answers to more than 45 million pairs of friction hinges
their enquiries,” says John Mayes, Technical used worldwide. Securistyle designs
Customer Services. “In the coming years, we and manufactures market-leading friction
plan a 50% increase in the number of projects hinges, handles, and lock mechanisms for
we can launch using the same number of all types of window frames and exports to
more than 50 countries across the globe.
designers,” says Paul Cook, Managing
Securistyle’s full product range is designed
Director • ) for worldwide use in commercial, residen-
tial, and public-sector applications.
Contact mag | n°1 25
3882-UK/Dassault 7/11/05 9:35 Page 26

Dassault Systèmes
Supporting Business Partners in the UK

ABERD
ABERDEEN

SCOTLAND
Cadtek
Cadtek House
Station Road

By Anne-Catherine Delecroix
] BlackFlag Composite STIRL
STIRLING
DUNDEEE
DUNDEE
Furness Vale
High Peak
SK23 7QA
01663 741 405

Launches CATIA V5 Project Transcat PLM

GLASG
GLASGOW
GL GOW
EDINBURGH

Applied

for Yacht Customisation Unit 3, Interchange 25

Bostocks Lane
Sandiacre NEEWCASTLE UPON TYPE
NEW
William Lee Buildings
Notts. Sci & Tech. Park
Nottingham
NG7 2RQ

B
lackFlag Composite was recently able to create a virtual model to validate the Nottingham
NG10 5QG DURHAM
URHAM
0115 9259990
involved in an extension for the stern shape of the hull. “The digital model is an asset
of a sailing yacht. This project meant for our clients as it allows them to see their 0115 9210000
that the lines of the hull had to be lengthened product in 3D”. NORTHALLERTON
N

and also raised at the back above the waterline Intrinsys

to create a platform. Only 5 weeks were avai- Digital tooling - Digital mockup representa- Design Rule York Denbigh Road
The company BlackFlag 24 Charter Gate Bletchley
lable for manufacture and during that time the tions of the tools were made, i.e. the templates Leeds
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Composite was established boat could not be immobilized. Consequently for the mold, then those shapes were developed
Moulton Park Kingston
g n Milton Keynes
upon
pon Hull
in 2004 and specialized in the Northampton MK1 1DB
this customised part had to be designed and for the mold surfaces. LIVERPOO
OOL
NN3 6QB 01908 278606
design and manufacture of produced remotely and then installed on the 01604 491661 MANCHESTER
CHESTER Sheffield
customised composite parts boat in just a few hours. Manufacture and final assembly - The new
Stoke-
for the yacht industry. The company invested in a CATIA V5 to gain section was laminated in the mold, then coated on-Trent
nt
NOTTINGHAM INCAT
This industry is gradually access to all the necessary tools for innovation in the workshop prior to assembly on the client’s Solid WALES
STAFFORD
INCAT House
evolving from one using and to ensure the best quality and cost of its pro- boat. During final assembly, extra laminations Applications BIRMINGHAM
BIR
BIRM
RMIN
Leicester NORWICH
Prospect way
ducts. The use of digital mockup was a major were made followed by a finishing coat to The Old Marketplace Coventry
ENG AN
ENGL
ENGLAND
traditional processes to those Luton Airport
factor contributing to the success of the project. ensure a perfect join. Market Street WARWICK CAMBRIDGE Bedfordshire
found in other industries such Oldbury LLAND
ANDBRIDOD
BRIDOD WELLS W H
WORCHESTER
WOR NORTHAMPTON
ORT A IPSWICH
BEDFORD LU2 9QH
as automotive and aerospace. “We needed to create a 3D model in order to “We were able to fix this section on the boat in West Midlands 01582 878750
GLOUCESTER
GLO
OUCEESTER
Meanwhile, the market has been B69 4DH
rapidly simulate the different design variations,” four days thanks to CATIA V5. I learned the
0121 544 1400 OXFORD Southend
uthend
nd on Sea
growing significantly, and explains Charles Pourreau, Design Manager, product functionalities during the project, SWANSEA
ANSEA
NSE BRISTOL
LONDON

shipyards are now offering BlackFlag Composite. without having taken any formal training, and by CAR
CARDIFF
ARDIFF RE
READING
in2grate
a larger selection of models asking advice from Dassault Systèmes. I really
Waterslade House
The project itself was made up of following stages: appreciated how easy it is to learn CATIA. Dassault Systèmes WINCHESTER
INCCH
of a higher quality and with Suite 9-10 Riley Court Southampton Thame Road
The benefit of this software is the direct exploi- Haddenham
more innovation. Milburn Hill Road EXERTER Brighton
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Accurate representation - A digital represen- tation of the design data for manufacturing, Coventry INCAT CenitDesktop
Portsmouth
Portsmo
rtsmou
Bucks
tation of the hull was captured using a laser scan- which thereby reduced our overall project time CV4 7HP 6 Monarch Court Evenlode Court HP17 8NT
Emerald Park Main Road 01844 295 245
ning device which generated a cloud of points. considerably” •) 0247 685 7400 Plymouth
Emersons Green Long Hanborough
Point data was taken every 100 mm along the
Bristol Oxford
hull and at 10 mm intervals for detailed sections.
Dassault Systèmes’ strategy is to help BS16 7FH OX29 8SZ
the boat industry to modernize its tools and 0117 970 9715 01993 883555
Surface reconstruction - “From the cloud
processes by offering solutions specifically
of points, the CATIA V5 reverse engineering
tailored to this industry. This project, made
modules enabled us to rapidly recreate the actual
use of software packages which enabled all
surfaces of the boat hull,” says Charles Pourreau.
the participants to have immediate access
to the best technologies, while supporting
Digital mockup and validation - Thanks to
validated boat-building methodologies.
Extension for the stern of a sailing yacht. the digital mockup, BlackFlag Composite was

26 Contact mag | Dassault Systèmes