Archiv 080905 BMW Tmo Cad Cv5 Ptguide Invalidsince090217

BMW Group BMW specific supplement to the
Body-in-white technology „Basic guideline for the design of

Process technology /
Assembly technology devices and jigs with CATIA V5“
Guideline for the design

of jigs using CATIA V5
-
BMW specific supplement to the
OEM-overlapping
„Basic guideline for the design of
devices and jigs with CATIA V5“
Created by : Working group „jig design“
Version: 2.3
Status: June 2008
Version 2.3; date of creation 06/2008 page 1 of 47

Table of contents
1 Generalities......................................................................................................6
1.1 Application area and other valid documents............................................................................6

1.2 Harmonization of methods ...........................................................................................................6
1.3 Contact persons..............................................................................................................................6
1.4 Qualification external engineering partners in the Body-in-White technology ...............7
2 Conventions and defaults ...........................................................................8
2.1 CATIA V5 Settings .........................................................................................................................8

2.2 Naming convention ........................................................................................................................8
2.3 Colors .................................................................................................................................................8
2.4 Drawing derivation ..........................................................................................................................8
2.5 Data format .......................................................................................................................................8
2.6 Data quality, model preparation and archival ...........................................................................9
2.6.1 Creating an “ALL.CATPart”................................................................................................9
2.6.2 Supply to the DZA (= Digitales Zeichnungsarchiv = digital drawing archive) ..... 10
2.7 BMW Start- and basic models ................................................................................................. 10
2.7.1 Start models for CATPart and CATProduct ............................................................... 10
2.7.2 Basic model for CATDrawing.......................................................................................... 11
2.8 BMW-specific naming convention .......................................................................................... 12
2.9 Position number systematics ................................................................................................... 16
2.9.1 Bill of materials position numbers .................................................................................. 16
2.9.2 Listing components in the bill of materials .................................................................. 16
2.10 Software requirements............................................................................................................... 17
2.10.1 CATIA V5.............................................................................................................................. 17
2.10.2 CARISMA Software ........................................................................................................... 17
2.10.3 PRISMA bill of materials ................................................................................................... 18
2.11 Making data available by BMW ................................................................................................ 18

3 Structuring CATIA V5 assemblies......................................................... 20
3.1 General information ..................................................................................................................... 20

3.2 Input data and preparation of data........................................................................................... 21
3.3 Control by adapters ..................................................................................................................... 21
3.3.1 Body-in-White technology............................................................................................... 21
3.3.2 Assembly technology........................................................................................................ 21
3.4 Link flow with control by adapters ........................................................................................... 23
3.4.1 Direct link flow in the Body-in-White technology ...................................................... 25
3.5 Integration of NUW (NuW = standard- and repetition parts) ............................................ 26
3.5.1 Integration from BMW libraries ....................................................................................... 27
3.5.2 Integration from other sources ....................................................................................... 28
3.5.3 Assembly-overlapping re-use of in-house production parts .................................. 29
3.5.4 Integrating a NuW-CATPart with constraints into an assembly ............................ 29
3.6 Working Products ........................................................................................................................ 30
3.7 Mirroring Parts and Products.................................................................................................... 31
4 Structuring CATIA-V5 in-house production parts ............................ 32
4.1 Basics.............................................................................................................................................. 32
4.2 Body structure .............................................................................................................................. 32
4.3 Output elements .......................................................................................................................... 33
5 3D-design..................................................................................................... 34
5.1 Axes and position in space ........................................................................................................ 34

5.2 Sketches ........................................................................................................................................ 34
5.3 Illustration in open position........................................................................................................ 34
5.4 Accuracies ..................................................................................................................................... 34
5.5 Layers.............................................................................................................................................. 34
5.6 Design tables ................................................................................................................................ 34

6 Aufnahme- und Spannplan (ASP)(= support & clamping plan) in

the Body-in-White technology............................................................................... 35
6.1 Generalities.................................................................................................................................... 35
6.2 Working method clamping point.............................................................................................. 36
6.3 Describing parameters in PowerCopy.................................................................................... 37
6.4 Designing the location bolts, support- and pressure pads ............................................... 40
6.4.1 Alternative 1 – Detailing within the Assembly............................................................. 40
6.4.2 Alternative 2 – Detailing within the ASP....................................................................... 41
7 Jig drawing execution ............................................................................... 44
7.1 Execution guidelines ................................................................................................................... 44

7.1.1 Basic model ......................................................................................................................... 44
7.1.2 Storage state ....................................................................................................................... 44
7.1.3 Drawing derivation.............................................................................................................. 44
7.1.4 Left- / right- / mirrored execution ................................................................................... 45
7.1.5 Standard parts..................................................................................................................... 45
7.1.6 Single part drawing ............................................................................................................ 45
7.1.7 Assembly drawing .............................................................................................................. 45
7.1.8 Rework drawing .................................................................................................................. 45
7.1.9 Invalid drawing sheets ....................................................................................................... 45
7.2 Drawing derivation of flame-cutting templates .................................................................... 46
8 Documentation............................................................................................ 47
8.1 Bill of Materials (BOM)................................................................................................................ 47

8.2 Shim documentation in the Body-in-White technology .................................................... 47
8.3 Identification label ........................................................................................................................ 47

List of changes
Version Chapter Comments
1.0 02/2003 Initial version – merging the TI- and TK-2-guideline into one document
General revision – Extension of the chapter “Construction & design methods in

1.1 03/2004
assembly context”
Documentation of new contents (new All.CATPart functionality, positioned

sketch, new naming convention of the Body-in-White assembly dept.; position
1.2 05/2004
number assignment for bill of materials, assembly mirroring, flame-cutting
template – new method, T-Basics LU1)
Editorial revision, adding the introduction, basic models for “Parts” and
1.3 07/2004
“Products”
General revision, new method “direct link flow“ (section 3.3), T-Basics LU2,
1.4 12/2004
integration ASP-creation (chapter 0), new editorial layout
Fundamental revision by merging the document with the OEM-overlapping

„Basic guideline for the construction & design of plants and devices using
CATIA V5“
This guideline documents the BMW specific contents only which represent a
2.0 03/2006
supplement to the basic guideline or describe deviations from the latter;
adaptation and/or synchronization of the structuring systematics
Adapting the document to T-Basics scope of supply 3 ( FKF package)
Adaptation to CARISMA (successor version of T-Basics)

2.1 10/2006 Extensions as to the belongings of the assembly technology dept.
Renaming of the document
Revision of chapter 6
2.2 10/2007 Integration of chapter “Detailing the component-contacting geometry in the
Body-in-White technology” to chapter 6 (formerly chapter 7.1.7)
Modifications in consequence of synchronization with version AE02 of the

2.3 06/2008 OEM-overlapping Basic guideline, admittance of the hyphen (2.2), extension of
chapter 3.5, general updates (contact persons, download paths, …)

1 Generalities
1.1 Application area and other valid documents
This guideline shall/must be used always together with the currently valid OEM-overlapping
basic guideline for the design of devices and jigs with CATIA V5. It is a supplement to the
aforementioned adding BMW specific aspects. The specifications made in both documents
are binding for constructions/designs for the Body-in-White technology and the assembly
technology departments.
For model structuring when designing standard, purchase and repetition parts special rules
shall apply being described in a proper guideline.
All guidelines and guidelines as well as any additional documents are made available in pdf-
format in the Internet. To view, please logon at:
https://b2b.bmw.com/ >> Departments >> Technologies >> Body-in-White >> Jig-Design >>
List of documents in jig design
https://b2b.bmw.com/ >> Departments >> Technologies >> Assembly >> Production tooling
and fixtures
(BMW-internally: https://b2b-portal.muc/ )
1.2 Harmonization of methods
Basically, it is possible to adapt the design method to the corresponding orders/projects on

prior consultation with the person(s) in charge of the project and the technical designer
responsible for the jig design. Any other procedure deviating from the aforementioned requires
a prior written consent to be given.
1.3 Contact persons
For any questions about the methods described in this guideline, please feel free to contact:
Plant Regensburg, Plant Leipzig,

Body-in-White and Assembly Body-in-White and Assembly
Andreas Kempke, phone (0941) 770-4276 Ronny Bartel, phone (0341) 445-32313
Andreas.Kempke@bmw.de Ronny.Bartel@bmw.de

Plant Munich, Body-in-White Plant Munich, Assembly

Georg Megele, phone (089) 382-24393 Florian Harnatt, phone (089) 382-58134
Geog.Megele@bmw.de Florian.Harnatt@bmw.de
Plant Dingolfing, Body-in-White Plant Dingolfing, Assembly

Johann Grundner, phone (08731) 76- Andreas Kampfl, phone (08731) 76-27247
21570 Andreas.Kampfl@bmw.de
Johann.Grundner@bmw.de
FIZ (R&D), Body-in-White FIZ (R&D), Assembly

Robert Näb, phone (089) 382-18788 Michael Rau, phone (089) 382-14423
Robert.Naeb@bmw.de Michael.RA.Rau@bmw.de
1.4 Qualification external engineering partners in the Body-in-White technology
For the cooperation of any external partners with the BMW Body-in-White department and
Assembly department, observance of the methodical basic principles described in the
guideline is an essential prerequisite. Proof of the corresponding know-how can be established
either by working together on the implementation of V5-projects or by a respective auditing.
New companies are admitted only after the Body-in-White department respectively Assembly
department having tested and checked the necessary qualifications and experience of such
new companies. All qualified engineering partner are taken over into a list of the respective
technology department. These companies are authorized and able to carry out projects with
CATIA V5 according to the BMW quality requirements.
For any further information or queries please contact:
FIZ (R&D), Body-in-White FIZ (R&D), Assembly

Johann Fertl, Phone (089) 382-47467, Michael Rau, phone (089) 382-14423
Johann.Fertl@bmw.de Michael.RA.Rau@bmw.de

2 Conventions and defaults
2.1 CATIA V5 Settings
In addition to section 2.1 of the basic guideline, BMW makes available a document including
detailed information. This document is titled “Technology specific V5 settings” and covers the
currently valid CATIA V5software version. You will find this document in the Internet logging on
at https://b2b.bmw.com/ >> Departments >> Technologies >> Body-in-White >> Jig-Design
>> List of documents in jig design.
For engineering and design in the Assembly technology without “control by adapters” (see also
section 3.3.2) – other than stated in the OEM basic guideline – the „Keep Link with selected
Object“ switch has to be disabled.
2.2 Naming convention
Within file- or directory names, only the following characters agreed upon on an OEM-
overlapping level must be used: [A - Z], [0 - 9], [ _ ] and hyphens [-]. As to details on the
systematic structure of file- and directory names, please refer to section 2.8 of this document.
2.3 Colors
Generally, model construction & design structured according to the color convention to enable
production process without drawings is not mandatory.
2.4 Drawing derivation
As to details on the drawing basic model, please refer to section 2.7.2 .

General questions regarding the drawing format & execution are answered in section 7.1 of this
document.
2.5 Data format
By default and according to the OEM basic guideline, all data are to be created in CATIA V5
Native. Integration of V4 data in the “*.model” format in CATIA V5 structures is not permitted.

2.6 Data quality, model preparation and archival
To check data quality, BMW uses the Q-Checker software. Given the fact that batch checking
of entire container structures is not possible, the use of the Q-Checker (existence of a valid test
seal) is not yet binding or prescribed for the engineering partners of the Body-in-White
technology nor the Assembly technology. Independent thereof data quality has to fulfill the
specifications made in this guideline.
Subcontractors /suppliers do not return product data (E-components) to BMW.
Within the assembly directories, all files not used must be deleted/removed.
In the CATProduct, all geometrical set geometries have to be put to the “Hide” mode before
final storage and all updates must be carried out. Ghost links within a CATProduct must be
removed (e.g. by use of the CATDUAV5 Application).
After having checked data quality and integrity, an “All.CATPart” has to be created in addition
for each item no. or assembly (see also section 2.6.1). The subcontractor undertakes to ensure
that this All.CATPart is up to date when passing it on to BMW.
For exchanging data and archiving jig designs in Prisma, the CARISMA software has to be
used in general (see section 2.10.2). In the Body-in-White technology the method “Karosserie
FM“ (=Body-in-White jig) and in the Assembly technology the method “Montage FM”
(=assembly jig) is used. Here for each item no. an own CARISMA container is to be archieved
in Prisma containing the following documents:
- Structure document for the container (ST)

- classified All.CATPart (5P)
- classified Drawing(s) (5D)
- Bill of materials document (SL)
- the real container contents (Parts and Products) packed with CARISMA (5Z)
Back-converted *.model files of the All.CATPart must not be archieved together with the
container structure!
2.6.1 Creating an “ALL.CATPart”
To secure sequential processes the CATIA V5 data per each item no. (i.e. per container) have
to be summarized in one single CATPart. This CATPart then contains the entire product
geometry. The so-called “All.CATPart” is to be classified while packing it with the CARISMA
software and consequently will be filed explicitly as 5P document when importing it into Prisma.

For creating this “All.CATPart”, the software offers the function “Generate CATPart from
Product” to be found in the assembly workbench on the “Tools” menu. In the window that
pops up on the screen now, the user has to select the product to be converted. In this context,
please pay attention to the fact that each “Part” of the Product becomes a “Body” in the
All.CATPart with the names of the “Parts” being adopted as “Body” names. Each “Body”
contains a “Solid”.
With this function, all those elements of the “Product” that are in the “Show” mode are
converted into the All.CATPart. Elements that are in the “Hide” mode or that have not been
loaded, are not adopted into the All.CATPart.
2.6.2 Supply to the DZA (= Digitales Zeichnungsarchiv = digital drawing archive)
When using CARISMA, no substitute formats (such as CGM-files) have to be created for
supply to the DZA. Beyond that, it is no longer necessary to manually fill in the title blocks in a
drawing.
The necessary meta data (title block contents or Prisma attributes) are administered in
CARISMA. After executing a “Sheet enumeration Dialog“, title blocks can be stamped on the
drawings temporarily for print- and viewing purposes both at the external partner’s facilities and
at BMW’s with the ZKUtil application. The current meta data are transferred to Prisma during
import. When the state of maturity increases correspondingly (FMFF), aforementioned data are
copied onto the drawings by means of a stamping automatism and the DZA will be filled with
input.
For more detailed information on the drawing process, please refer to the CARIMSA user
documentation logging on at https://b2b.bmw.com/ >> Departments >> Technologies >>
Body-in-White >> Jig-Design >> List of documents in jig design.
2.7 BMW Start- and basic models
2.7.1 Start models for CATPart and CATProduct
The following part no. is used for start models: G000198 for CATParts and G000199 for
CATProducts.
When working with the CARISMA structure manager – the use of which is in general binding
for the creation of jig structures – these start models will be used automatically.
The start models already contain the bill of materials parameter (BOMs parameter) for an
automatic filling in of the FM Stüli later both as parameter set in the tree and in the properties

of the file (Figure 2-1). Completion is effected exclusively via the bill of materials parameter set
in the tree, whereas these entries are adopted automatically into the properties.
When using the start model, the part no., designation and position no. are read out from the file
name automatically, thus it is not necessary to enter them a second time.
Furthermore, the start model features an implemented check function displaying a

message/warning in case the fundamental naming convention has not been observed (see
section 2.8).
Figure 2-1 BOMs parameters and -properties
2.7.2 Basic model for CATDrawing
The basic model has been given the part no. G000060. When working with the CARISMA
structure manager – the use of which is in general binding for the creation of jig structures –
this basic model will be used automatically.

Since the “Body-in-White department” and “assembly department” –specific basic model was
developed out of a general BMW basic model, please carefully read and observe the notes and
information given on the B2B-portal about how to handle the basic model: Please refer to:
https://b2b.bmw.com/ >> Departments>> Technologies >> Body-in-White >> Jig-Design >>
Downloads >> Applications
2.8 BMW-specific naming convention
In combination with CARISMA, certain structure categories are allocated to the CATIA files
depending on which different naming conventions shall be valid. A substantial feature here is
whether it is dealt with “structuring”, i.e. container-creating files or whether they have to be
handled only within a container.
For container-creating files or the directories associated herewith the naming convention has
the following generic structure:
Partno.__Dwg.index__DocumentPart__Alternative__Designation.Extension
(7 digits) (1 or 2 digits) (1 or 2 digits) (1 digit) (max. 35 digits)
e.g. ../5678901__A__1__A__EXAMPLE/for the directory and

5678901__A__1__A__EXAMPLE.CATProduct
For single files within a container, the generic structure will be as follows:
Part no. (of the container)__Position no. of BOM__Designation.Extension

(7 digits) (4 or 9 digits) (max. 35 digits)
e.g. 5678901__0101__EXAMPLE.CATPart
As to the definition of number ranges for the allocation of position numbers please refer to
section 2.9.
The single parts of a name are separated in general by two underscores; according to the OEM
basic guideline and in conformity to the Prisma rules, the designation to be in upper case
letters. The “Part Number” in CATIA is basically identical to the file name except for the file
extension.

In the Body-in-White technology, there are the following structure categories incl.
associated file types and naming conventions:
Structure Category: Naming convention:
ASP Identical to the structure category “assembly with part number”; only
(ASP) difference here: no working product is created by CARISMA, e.g.
5432107__C__1__A__ASP.CATProduct
Assembly with Assemblies (BGs) that are given an own part number, e.g.
Partnumber 5432109__C__1__A__GRUNDRAHMEN.CATProduct
(Baugruppe mit
Sachnummer)
Assembly without Sub-assemblies/modules like weld parts or similar, e.g.

Partnumber 5432109__0001__SCHWEISSBAUGRUPPE.CATProduct
(Baugruppe ohne
Sachnummer)
Part without For parts to be produced, i.e. single parts to be designed within the
Partnumber assembly, e.g. 5432113__0101__GRUNDPLATTE.CATPart, or
(Einzelteil ohne if this part is part of a module e.g.
Sachnummer) 5432109__0001.0105__RIPPE.CATPart
Catalog Part Single parts of the NuW-libraries made available by BMW. Part
(Katalogteil) number, position number and designation are definitely fix; version
control does not take place; in case of design-relevant changes a new
part number will be assigned, e.g.
3744785__1090__WINKEL_FUER_AUFNAHMEBOLZEN.CATPART
Working Product Except for the prefix WP, corresponds to the naming convention of
assemblies that are given an own part number, e.g.
WP__5432109__C__1__A__GRUNDRAHMEN.CATProduct
Drawing Corresponds to the naming convention of assemblies being given an

(Zeichnung) own part number except for the file extension, e.g.
5432109__C__1__A__GRUNDRAHMEN.CATDrawing

In the Assembly technology, the following structure categories incl. associated file types and
naming conventions exist:
Strukturkategorie Naming convention:

(Structure
Category):
Main Adapter Identical to the structure category “assembly with part number”; only
(Hauptadapter) difference here: CARISMA does not create a Working Product, e.g.
5432107__C__1__A__ADAPTER.CATProduct
Assembly with Assemblies (BGs) being given an own part number, e.g.
Partnumber 5432109__C__1__A__GRUNDRAHMEN.CATProduct
(Baugruppe mit
Sachnummer)
Assembly without Sub-assemblies/modules such as weld parts or similar, e.g.

Partnumber 5432109__0001__GRUNDGESTELL.CATProduct
(Baugruppe ohne
Sachnummer)
Part For parts to be produced, i.e. single parts to be designed within the
(Einzelteil) assembly, e.g. 5432113__0101__GRUNDPLATTE.CATPart, or
if this part is part of a module e.g.
5432109__0001.0105__RIPPE.CATPart
Drawing Corresponds to the naming convention of assemblies that are being

(Zeichnung) given an own part number – except for the file extension, e.g.
5432109__C__1__A__GRUNDRAHMEN.CATDrawing
Catalog Part Single parts of the NuW-libraries made available by BMW. Part
(Katalogteil) number, position number and designation are definitely fix; version
control does not take place; in case of design-relevant changes a new
part number will be assigned, e.g.
3744785__1090__WINKEL_FUER_AUFNAHMEBOLZEN.CATPART
category is also used for parts with other origin (refer to section 3.5.2)
In addition to the naming conventions described above, it has to be paid attention to the fact
that a parameter called “Source” has been integrated into the start model for CATParts which
has an influence on the file name and especially on checks therefore (see Figure 2-2).

Three values are possible for this parameter namely:

1. Production part (=Fertigungsteil)(default setting), for single parts belonging to the assembly
Name systematics: AssemblyPartNumber__PositonNumber__designation.CATPart
2. Standard part (=Normteil), for purchase- and standard parts not being contained in the
NuW-libraries. The geometry of aforementioned parts e.g. can be also copied to the basic
model from Internet-libraries.
Name systematics: free name can be selected without restrictions and check
3. Catalog part (=Katalogteil), for single parts from NuW-catalogs that are made available by
BMW, Name systematics: own part number__fix position number__designation.CATPart.
Figure 2-2 Parameter Source (=Quelle) in the start model for parts
The following figure depicts an example of how an assembly is structured (Figure 2-3).
Figure 2-3 Tree structure with naming convention
When creating jig strucutres and the files used herein by means of using the CARISMA
structure manager, observation and adherence to the naming convention will be ensured
automatically (see section 3.1).

2.9 Position number systematics
2.9.1 Bill of materials position numbers
Position numbers are always 4-digit numbers, single parts in modules 9-digits (refer to Figure
2-3). For catalogue parts (=Katalogteile), the position numbers have been already determined
by BMW. For in-house production parts (=Eigenfertigungsteile), only the area is defined,
whereas the position number is freely assigned by the technical designer pursuant /according
to the following illustration (see Figure 2-4).
Figure 2-4 Position numbers
Please note: Adapters are always given the position number 0000 !
2.9.2 Listing components in the bill of materials
To make sure that the components are displayed in the bill of materials, it is absolutely
necessary to tick the check box titled ”Visualize in the Bill of Materials“ in the “Properties”
window, section “Component”. Usually, this check box is ticked automatically (see Figure 2-5).

Figure 2-5 Properties „Visualize in the Bill of Material“ (BOM)
If you do not wish the component to figure on the bill of materials, tick off the respective check
box to deactivate. This makes sense, if – for example – only the superset component, but not
the single parts represent a “bill-of-materials”-relevant position (as this is the case e.g. with
purchased parts available as product).
For adapters, this check box has to be always disabled! Proceeding this way, adapters will not
be viewed in the bill of materials (adapters are not a “bill-of-materials”-relevant position).
2.10 Software requirements
To allow a trouble-free cooperation with external partners, it is necessary to ensure that these
partners use the corresponding BMW software environment (especially with respect to
identical versions). For this purpose, the BMW Group makes available the software and
documentation described in the following sections.
2.10.1 CATIA V5
The licensed basic software incl. the modules required can be obtained from the respective
business partner. For information about BMW specific service packs, hotfixes and area-
overlapping documentations, please consult the Internet logging on at: https://b2b.bmw.com/
>> Departments>> Development >> Applications >> CATIA V5 >> “News” respective “BMW
Standards and Applications”.
2.10.2 CARISMA Software
For data management and administration of CATIA V5 data, the CARISMA software
(successor of T-Basics Software) was developed. CARISMA is a CAA-application integrated in

CATIA V5 supporting the file-based creation and modification of jig structures using the BMW
start models. It offers further functionalities such as version control, alternating as well as
reusing jig structures. Beyond that, the software supports scanning of manually created CA-
data, generating a “basic bill of materials” for the data created in CATIA in xml-format (which
can be opened and further processed in the bill of materials program FM-Stüli) as well as
packing and unpacking containers how they are necessary for archival in Prisma. Besides these
core modules, the software contains – among other things – also functionalities for stamping
the meta data administered in the structure manager on/in the title blocks and automated DZA-
supply (see section 2.6.2).
BMW-internally, the CARISMA software integrated with the “Immersive Client” program is
available. This allows direct access to Prisma from CATIA V5. Except for the direct access to
Prisma by means of the immersive client program, the subcontractor version is identical.
The program package incl. installation instructions is made available to the subcontractors on
the B2B-Portal: https://b2b.bmw.com/ >> Departments>> Technologies >> Body-in-White >>
Jig-Design >> Downloads >> Applications.
Logging on at https://b2b.bmw.com/ >> Departments>> Technologies >> Body-in-White >>

Jig-Design >> List of documents in jig design, you are offered advanced and car body
manufacture specific user documentations for CARISMA.
2.10.3 PRISMA bill of materials
For the computer-aided creation/generation of the jig BOMs, the program “FM-Stückliste” (=
jig BOM) is made available in German and English. BMW-internally, this program is made
available in WindowsXP via the “Start” button or via the BMW IAP (IAP = Integrierter
ArbeitsPlatz = integrated workstation). For the external use, the software can be downloaded
via the B2B-Portal.
https://b2b.bmw.com/ >> Departments>> Development >> Applications >> FM-Stüli.
2.11 Making data available by BMW
BMW provides the CAD-data necessary for engineering & design in the formats CATIA V4
(*.model) or V5 via OFTP data exchange. Any forms of data provision deviating form the
aforementioned are to be agreed upon for each specific individual project. An authorization for
data exchange is to be applied for by the engineering & design partner. Furthermore, the
necessary infrastructure must exist on the part of the engineering & design partner.
Jigs in CATIA V5 format (already existing components or example constructions) are offered in
the CARISMA container format via data export function from Prisma or in single cases on CD-

ROM / DVD. For further details, please refer to the user documentation regarding data
exchange for CARISMA.
Libraries for standard- and repetition parts are offered in CARISMA container format as well on
CD-ROM , DVD and in PRISMA having the following numbers:
catalog KER B7 (design elements Body-in-White, BMW-assembling parts): 5330801

catalog KER B8 (design elements Body-in-White, BMW-welding parts): 5330802
catalog KER K7 (design elements Body-in-White, purchase parts): 5330803
catalog Modular Console: 5330804
catalog Euro Handling Tooling: 5330805
catalog welding gun: 5330806
catalog electric: 5330808
catalog projection welding: 5330809
Unpacking is done using the CARISMA software. To that end, the “unpack as catalog” switch
has to be enabled in the CARISMA dialog box “Unpack container(s)“.
The system supplier is responsible to check and to ensure that the surface connecting- and
space-describing geometry is up to date.
For the Assembly department the most important vehicle components in touch with the tooling
have to be administered in CARISMA as Reference Parts.

3 Structuring CATIA V5 assemblies
3.1 General information
For creating a new product structure, the use of the Structure Manager which is part of the
CARISMA software is binding.
File structures have to be created analogously to the jig structure (one directory per assembly)
observing thereby the naming convention rules. The basic, vital tool for this is the structure
manager (see Figure 3-1).
Figure 3-1 CARISMA Structure Manager (STM)
When generating the structure, both the directories and CATIA documents and the CATIA tree
structure with links are generated in a file-based manner (Figure 3-2).

Figure 3-2 Creating structures automatically (CATIA tree and file system)
3.2 Input data and preparation of data
In the Body-in-White technology, the ASP (German abbreviation for Aufnahme- und Spannplan
= support & clamping plan) is to be understood as main adapter representing the central
control element for all input data. For further details, please also refer to chapter 6.
3.3 Control by adapters
3.3.1 Body-in-White technology
No supplement to the OEM basic guideline.
3.3.2 Assembly technology
Besides the control by adapters described in the OEM basic guideline, in the Assembly
technology a construction can be also built-up via Assembly Constraints. In this connection, all
CATParts used are determined as to their position by these Assembly Constraints or

conditions. However, the continued use of shape-giving references of other CATParts without
active link is possible.
The links to the external references are not kept. The reference geometries are copied
automatically into the CATPart to be created in the “Hide” area and the external references are
isolated. No attention has to be paid to a special reference flow of the links.
The design method to be used in the corresponding orders/projects requires prior consultation
with the technical designer responsible for the jig design or the person(s) in charge of the
project.
Prerequisites and settings
Deactivating the setting “Keep link with selected object” constitutes the prerequisite for
designing a CATPart in CATProduct context by means of any external referencing to other
CATParts. This setting can be found on the “Options” menu, menu item “Tools” in the
“Infrastructure / Part Infrastructure” column. The reference geometries can be selected without
prior publication. (See: Tools - Options - Infrastructure/Part Infrastructure - Restrict external
selection with link to published elements; Figure 3-3).
Figure 3-3 Settings under “Tools – Options”

Assembly constraints in assembly design
After having created the CATParts, the latter have to be implemented into the assembly in the
workbench assembly design by means of assembly constraints. Here, only one vehicle
component touching CATPart is fixed in space using the “Fix” constraint. Otherwise it can be
dimesioned respective to a postion-adapter fixed in zero position. In the end, the position of the
complete tooling must be defined in vehicle coordinate system coherent to the reference parts
(see section 5.1). The left vehicle side thereby serves as reference side. When the vehicle
component contacting CATPart is part of an assembly, the superior CATProduct has to be
fixed in zero position. For all other assemblies the relevant CATPart for positioning should be
fixed within the CATProduct. All CATParts and CATProducts are pasted (starting with the
vehicle component contacting CATPart) using the assembly constraints e.g. Coincidence,
Contact, Offset, Angle / Parallelism / Perpendicularity etc. The constraint “fix together” is only
allowed in well-founded exceptional cases.
The constraints have to be structured in meaningful named sets. For purpose of tracking it has
to be assured, that the instance-name is coincident to the Partnumber.
Assembly-overlapping parametrics
Within a CATProducts having an own part number, parameters have to added for assembly
constraints permitting a kinematic jig movement such as e.g. travel path of a carrier of opening
angle of a claming fixture. These parameters have to be named such to include the prefix
“KIN”, the name of the movement function and indicating the possible path area or path
position e.g.
KIN_Spanner_unten_rechts_(0°to45°)
KIN_Schieber_(-10mm,20mm,30mm)
In the dialog box “Edit parameter”, the value range has to be limited to the constructive limits of
movement by means using the context menu and the “Add Range” option. When changing the
driving constraints no inconsitency is allowed. For large toolings with sub-assemblies an
explanatory overview of the driving Parameters has to be added.
3.4 Link flow with control by adapters
Figure 3-4 depicts the assembly structure and the link flow showing an example.

Figure 3-4 Example for the link flow
The clamping point elements of the ASPs/main adapters are copied to the assembly adapter
and then published. Support- and pressure pads are referenced to these clamping point
elements (see Figure 3-5). In the assembly adapter, a support- /pressure pad plane has to be
created in addition, if possible, based on even dimensions in the vehicle grid. For positioning
the contour pieces, reference elements in contour pieces (intersection planes, clamping points
and connecting plane) are exchanged for identical clamping mark references of the assembly
adapter. Please pay attention to a grid-precise construction/design of the contour pieces.
Positioning has to be done by manually replacing the reference elements in the geometrical set
“Control elements adapter”.

Figure 3-5 Referencing to published elements
For the further assembly design, reference elements of the corresponding support- and
pressure pads or location bolts shall be used (e.g. connecting contours, hole axes, intersection
plane supports, etc.)., but no clamp mark reference elements.
Important note:
The use of clamp mark references of the assembly adapter for the remaining assembly design
shall be avoided. Higher-ranking, superset references such as e.g. tool design planes are taken
from the ASP/ main adapter.
3.4.1 Direct link flow in the Body-in-White technology
Within an assembly, Parts are allowed to directly exchange their published references. Here, no
link flow via the assembly adapter is obligatory or mandatory.

Hole patterns/geometry contours for referencing the subsequent assemblies can be controlled
via surface connecting contours or dotted sketches. Proceeding this way, it is possible to use
points defined in an additional sketch for creating the hole patterns/drilling patterns. By means
of publishing the sketch, references can be e.g. transferred to a tool plate (the dotted sketch
offers the advantage that the holes can be made without constraints to be generated
manually).
In an assembly, it is useful to first position a clamping fixture, since the structure of the
assembly has to be related to the clamping fixture references, e.g. the clamping fixture
intersection plane shall be used as sketch plane. In any case, references of the clamp unit shall
be preferred.
Prior to the drawing derivation, the clamping fixture or another geometry-determining standard
component will be fixed in a last step despite the already defined position of the clamping
fixture. This fixed component is also called geometry node since the latter allows controlling a
large part of the other CATParts designed of the assembly. The additional fixing of the
clamping unit has to be renamed to “GEOMETRIESICHERUNG“ (= safeguarding geometry).
Since the references for the assembly design relate to the geometry-defining standard
component, the fixing prevents the assembly from being modified unintentionally.
The hole pattern/drilling pattern of the assembly has to be transferred to assembly adapter of
to the tool plate/ screw-down surfaces by means of a published surface connecting contour or
sketch with points.
Conclusion:
Modeling CATParts that have to be newly created is done in context or in connection with the
entire CATProducts to which the CATPart belongs. Here, the CATParts are designed based
on the other CATParts such as e.g. single jig parts, vehicle components or based on the
assembly adapter and then their position and shape is defined/determined via external
references. Standard- and repetition parts (NuWs) are an exception here – they are pasted via
assembly constraints.
3.5 Integration of NUW (NuW = standard- and repetition parts)
For the Body-in-White technology, the standard- and repetition parts (NuWs) are to be taken
from the catalogues (NuW) made available by BMW. Within the Assembly technology the use
of the BMW catalogues is to be verified for each specific individual project.
In the event of a purchased part - that has been already released in the Body-in-White
technology purchased parts list and that is required several times – not being available in the
NuW-catalogue yet, this part is to be created within a project order according to the
requirements defined in the „Guideline for the design of standard- and repetition parts with

CATIA V5”. Further details are to be agreed upon with the BMW planner in charge of the
project and the CAD-library team (rohbau.standardkomponenten@bmw.de).
All the used standard- and repetition parts at a project (= tooling designs, even a single device)
need to be included by data exchange. The archieved contents have to be complete,
consistent and free of links to centrally saved libraries.
Clash relevant standard parts such as nuts and bolts must be shown in the design. For the
Body-in-White technology only the relevant part of the geometry like bolt heads, nuts and
washers should be represented simplified.
For each device a sub-folder called “NuW” has to be created by the design engineer under the
“root-folder”, containing all standard- and repetition parts of the device.
Advantage of this method: NuW data are only saved once per device. This way, the data
exchange volume and the data quantity to be archived in Prisma are considerably reduced.
3.5.1 Integration from BMW libraries
All standard- and repetition parts (NuW = Norm- und Wiederholteile) that are integrated into
this device first have to be copied from the catalogues (B7, B8, K7, Modular Console etc.)
made available through Prisma to the NuW-directory/folder. Once being in the NuW folder,
they have to be integrated into the various assemblies as “Existing Component”. Alternatively,
it is also possible to work during the design phase with the option “with link to a centrally saved
catalog”. Prior to terminating the design, the standard- and repetition parts used then have to
be detached from the catalog and saved in the NuW-folder.
Utilization of parameterized standard- and repetition parts with preallocated

position number 9999:
For NuW parts, offered in various dimensions, only one value per type or size is available as
CATPart (profiles, axle support, guides etc.). Designed is always the shortest length.
Systematics of partnumber and filename is as follows:

3699413__9999__AXLE_SUPPORT_WITH_BOLT_L40
First of all the NuW part has to be copied to the folder of the assembly. Subsequently the
position number 9999 needs to be replaced with a consecutive position number between
3601 and 4000 and the desired length designation in the part- and filename has to be
changed. e.g.
3699413__3601__ AXLE_SUPPORT_WITH_BOLT_L45

Finally in the CAD model, the value/length of the given parameter in the parameter-set
“Geometriesteuerung” (=geometry control) has to be adjusted.
Method for parts that have to be reworked:
When using catalog parts as basis for parts that have to be reworked, the NuW part has to be
copied to the folder of the assembly.
Afterwards the default NuW position number needs to be replaced with a consecutive position
number between 0601 and 1000 (see Figure 2-4). The SAP-Ident number and the US-Ident
number must be deleted. The given part number remains unchanged. These entries have to
be checked in the bill of materials parameter set and if applicable to be adjusted manually.
3.5.2 Integration from other sources
The use of standard- and repetition parts from other sources (e.g. purchase part libraries from
the supplier, CADENAS, DIN/ISO-parts from part servers, …) is permitted. The workflow is
equivalent to BMW library parts with saving to the NuW folder. The position numbers should be
selected from the following number range: 9501 – 9998. If theses NuW parts have to be
reworked, make sure to use the correct position numbers (see section 3.5.1).
To enable automatic derivation of the bill of materials (SL document in Prisma), the BMW start
models and the catalog parts have a parameter-set “Stückliste”. When NuW parts which do not
have these parameters yet should be used in a design, one of the following methods has to be
applied:
• After the NuW part was added to the CATIA Structure at the appropriate position with the
function “insert existing component”, the first step is to assign the structure category
“Catalog part” with the CARISMA Structure Manager. The input boxes “Name” and “BOM
pos. number” are filled, the input box “Catalog part number” remains empty. A
synchronization with “save and update” leads to a partnumber and filename in terms of
__9501__PURCHASE_PART.CATPart or __0001.9501__PURCHASE_PART.CATPart
respectively.
Hereupon the macro „Ergänzen_der_Stuecklisten-Parameter_20080428.CATScript“

should be started. It checks all CATParts of the CATIA structure whether bill of materials
parameters are missing, completes them if necessary and fills in by automatism the
attributes “name” and “position number”. You will find the macro in the Internet logging on
at https://b2b.bmw.com/ >> Departments >> Technologies >> Body-in-White >> Jig-
Design >> Downloads.
The identical method may be used for “old” CATParts of existing designs, created without
start models. The only difference is the categorization as “part without partnumber”.

• As an alternative the geometry can be copied to the start model G000198, which is
provided at https://b2b.bmw.com/ >> Departments >> Technologies >> Body-in-White >>
Jig-Design >> Downloads.
The filename is freely selectable. For this purpose, it is possible to disable/deactivate the
preset naming convention check of the start model by selecting the option „Normteil“
(standard part) (Figure 3-6).
Figure 3-6 Disabling the naming convention check
The position number (number range from 9501 to 9998) and the designation has to be filled in
the bill of materials parameter-set. A definition of a structure category and free attributes within
the CARISMA Structure Manager is not necessary then.
3.5.3 Assembly-overlapping re-use of in-house production parts
For the Body-in-white technology parts of that kind have to be given an own part number
and must be archieved in Prisma together with a separate detail drawing. During tooling design,
theses parts are handled like NuW parts. As alternative, the part is designed as an usual in-
house production part in the context of the assembly where it is used for the first time. For all
other utilizations, the part has to be copied independently by “file – new from” to the other
assemblies. Then, for each usage a detail drawing is necessary.
For the Assembly technology a in-house production part has to be copied to the NuW
folder, when it is used in more than one assembly of the device. Insertion of such parts in
further assemblies is handled by instantiation in CATIA (link to the original in the NuW
folder),i.e. the part keeps its Attributes like the part number of the assembly where it was used
for the first time. Within this assembly exists a detailing/drawing of the part, but not in the other
assemblies. Just a meaningful reference to the respective assembly drawing is necessary.
3.5.4 Integrating a NuW-CATPart with constraints into an assembly
This method represents the normal case scenario and is to be employed, if NuW parts do not
change as to their geometry. Please take into account that constraints are to be created only
within an assembly, best from the NuW part to the set points in the adapter, or directly to the
reference part.

The creation of constraints shall be always effected by way of selecting the published
elements. This way, the risk of errors is considerably reduced.
Using already existing reference elements in standard parts for the further design is possible
thanks to the admitted link flow. This means the part-overlapping use of “surface connecting
contours”, “hole patterns/drilling patterns”, etc. without the necessity of using an adapter.
The standard parts B7/B8 and the purchased parts are equipped with identical reference
elements. Reference elements such as surface connecting contours, drilling axes, drilling
template points, construction planes, intersection planes, etc. shall be used for designing the
assemblies (see Figure 3-5 and Figure 3-7).
Figure 3-7 Constraints to published elements of the same name
3.6 Working Products
The use of Working Products is suggestive, if several design engineers are working on one and
the same design scope or if the scope renders it obvious to better split the scope to increase
performance.

3.7 Mirroring Parts and Products
The macro “Mirror_Part.catvbs” can be obtained from https://b2b.bmw.com/ >>

Departments>> Technologies >> Body-in-White >> Jig-Design >> Downloads.
BMW-internally, the macro can be selected from the following path:
L:\cat\v5\rohbau\v5_powercopies_makros\allgemeine\ (Windows XP) or
cat/v5/rohbau/v5_powercopies_makros/allgemein/ (UNIX)

4 Structuring CATIA-V5 in-house production parts
4.1 Basics
Basically, all parts being assigned an own bill of materials entry are to be designed as separate
CATPart. In doing so, various problems can be avoided when creating the drawing derivation
such as e.g. the possibility of different hatching of the parts and carrying along parameters for
the bill of materials („Bill of Materials“ – BOM).
In general, when designing a part, the result has to be a “Solid”. Structuring the part as surface
model has to be avoided, if possible. In the event of a surface model being absolutely required,
a “Solid” has to be derived thereof. Only proceeding this way, a faultless conversion for follow-
up systems can be granted.
4.2 Body structure
Same as with SOLID E in CATIA V4, also in PartDesign of CATIA V5 a clearly structured
specification tree is an indispensable prerequisite for a perfect, faultless construction, trouble-
free updates and sufficient clarity. Basically, the following applies: the more features are used
up and integrated into in the “Part”, the more importance shall be attached to structuring the
specification tree via additional “Bodies” to ensure that even technical designers not having
participated in the design of the part are given a quick orientation basis allowing them to
eventually carry out necessary modifications.
For more complex parts, thus the body structure - as saved in the start model and as described
in the OEM basic guideline in chapter 4 - shall be used. The start model for CATParts contains
an already prepared body structure including color coding for the different machining
processes such as smoothening, rough-machining etc. (see section 2.3). Using these bodies is
not mandatory at BMW, but desired because of the better clarity (Figure 4-1).
Many “Parts” in the jig design are only composed of some features. Here, it is not necessary to
choose a special tree structure. All features can be created in the PartBody.
Parts based on flame-cutting templates are to be designed in accordance with the

specifications made in the OEM basic guideline concerning this matter.

Figure 4-1 CATPart with body structure according to OEM basic guideline
4.3 Output elements
As synonym to “Output“ or “Output elements” BMW uses also the term “transfer features”
(=Weitergabeelemente).

5 3D-design
5.1 Axes and position in space
All CATParts that are designed by means of external references shall be in vehicle position.
5.2 Sketches
5.3 Illustration in open position
For illustrating the “open position” state, the Body-in-White technology department in general
recommends variant 2 (Component) of the OEM basic guideline.
For the Assembly technology, all working positions are generated and made available as
ALLCATParts. The ALLCATPart – representing the working position – is used as document
part 1, e.g.
5678901__A__1__A__EXAMPLE_ALLCATPART.CATPart.
Further positions are created with consecutive documents parts such as e.g.
5678901__A__2__A__EXAMPLE_ALLCATPART.CATPart.
When classifying in CARISMA, document comments are filled with the description of the
respective position, e.g. working position or open position.
5.4 Accuracies
Unlike V4, model accuracy in V5 is no longer adjusted. Consequently, 3D always works with
the V5 accuracy.
5.5 Layers
5.6 Design tables

6 Aufnahme- und Spannplan (ASP)(= support & clamping plan)

in the Body-in-White technology
6.1 Generalities
The ASP (German abbreviation for Aufnahme- und Spannplan = support & clamping plan)
forms the basis for each jig of an assembly sequence. This plan shows the component-
touching geometry (location bolts as well as support & pressure pads). Consequently, it has to
be considered as a jig-component. The following description relates to the CAD-model that
has to be provided for manufacturing the clamping pieces.
For the preliminary states required during the planning process (basic ASP), the degree of
detailing (itemization) has to be defined together with the planner in charge of the project.
For the ASP of one device/station a CATProduct is created. This CATProduct includes a
CATPart including the so-called clamping marks. The components to which the ASP
references are directly in the ASP-Product as well, if applicable/necessary, collected in a
SubProduct (Figure 6-1). On top of this, there is another CATPart for each support- and
pressure pad or each location bolt.
Figure 6-1 CATIA specification tree of the ASP

6.2 Working method clamping point
The support- and pressure pads (contour pads, clamping pads, clamping blocks, …..) are
intersected with the parameterized clamp marks (= Spannmarken) of the ASP which represent
a clipping/cutout of the component surface. To create a clamp mark, the corresponding
component has to be loaded and the CATPart of the ASP has to be the active part. The clamp
marks are generated using “Powercopy 2_Spannmarken_xxDatumxx.CATPart“ made available
by BMW.
The “PowerCopy” as well as the “Renaming Macro” (see below) can be obtained from the
Internet logging on at https://b2b.bmw.com/ >> Departments>> Technologies >> Body-in-
White >> Jig-Design >> Downloads. BMW-internally, these files can be also selected from the
following path: L:\cat\v5\rohbau\v5_powercopies_makros\Serien-ASP (Windows XP) or
cat/v5/rohbau/v5_powercopies_makros/ Serien-ASP / (UNIX)
The PowerCopy requires the component, a reference plane, a clamping point (= Spannpunkt) –
determining the position of the clamp mark – and an intersection plane (= Schnittebene).
The specification features for the PowerCopy are generated in the body “Control features
adapter” (=Steuerelemente Adapter) and named as follows:
Clamping points: SPP_XXXX, where XXXX is numbered consecutively from 0001 to 9999.
Intersection planes: SPLN_XXXX, where XXXX is numbered consecutively from 0001 to 9999.
The elements generated with the PowerCopy have to be renamed and published according to
the “Vorgabeelemente” (=specification features). The generated parameter sets also have to
be renamed according to the “Vorgabeelemente” (= specification features) (see Figure 6-2).
Important: Each time when generating clamp marks, parameter sets have to be renamed at
once, because otherwise it is very difficult to later assign the parameter sets to the respective
clamp marks. As a support, BMW makes available “Umbenennenmakro_2_Spann-
marken_xxDatumxx.catvbs“ under above mentioned paths.
In the “Body” “Weitergabeelemente” (= transfer features) e.g. the tool mounting plane is
defined.
Advice: instead of separate execution of Powercopy and renaming-macro BMW offers on

demand a start-script, which combines these two steps and simplifies the execution. For that,
the KT1 license for CATIA V5 is required.

Figure 6-2 Clamp marks generated with the PowerCopy, parameter sets and
published features of the clamp mark
6.3 Describing parameters in PowerCopy
The clamp mark PowerCopy contains some parameters and rules the properties of which will
be explained in the following (see Figure 6-3).

Figure 6-3 Parameter set of clamping mark PowerCopy
Width of clamp mark (=Breite_Spannmarke) and length of clamp mark (=Laenge_Spannmarke):

Here, the user may change the size of the clamp mark (Figure 6-4).
Figure 6-4 Adapting width- and length of the clamp mark
Rotation angle clamp mark (=Drehwinkel_Spannmarke): This option allows rotating the clamp
mark around its own axis (see Figure 6-5).

Figure 6-5 Adapting the rotating angle of the clamp mark
Projection angle (=Projektionswinkel): Here, the projection angle can be tilted from the clamp
point onto the component (Figure 6-6).
Figure 6-6 Adapting the projection angle of the clamp mark
Automatic selection of production type (=Autom. Fertigungswahl):

Usually “No” is set as parameter value by default and should be used as such in general.
Proceeding this way, the clamp mark always corresponds exactly to the component surface.
The information about the production method to be employed is to be stated when creating
the drawing. Under these boundary conditions, the parameters Tolerance (=Toleranz),
Clamping pad manufacture (=Spannklotzfertigung) and Allow inclined plane (=Schiefe Ebene
erlauben) are irrelevant.
Extrapolation and extrapolation clamp mark
The parameter “Extrapolation“ allows the user to select whether the clamp mark shall be
extrapolated or not. An extrapolation may be especially necessary at component edges, if the
clamp mark itself is too small for cutting the contour piece. Thanks to the parameter
“Extrapolation_clamp mark“ the user may select how far the extrapolation should go. These
parameters can be set separately for both clamp marks generated.

6.4 Designing the location bolts, support- and pressure pads
Two alternatives for the design of location bolts (pins), support- and pressure pads (clamping
pieces) are permitted.
6.4.1 Alternative 1 – Detailing within the Assembly
With alternative 1, generally all location bolts (pins), support- and pressure pads (clamping
pieces) are designed and detailed/itemized (drawing derivation) in the respective assemblies.
Only 3D geometries are pasted into the ASP as instances.
After copying all CATParts of the location bolts as well as support & pressure pads from the
assemblies to the ASP CATProduct, the user may now start with the drawing derivation. Since
only the “ASP CATProduct” summarizes the entire component-contacting geometry, an ASP
overview drawing has to be generated analogously to an assembly overview drawing.
Drawing contents of the ASP in case of alternative 1 (sheet 1 and continuation sheets, if
situation requires so):
• Overview of the support- and pressure pads as well as component geometry. Depending
on clarity of the component-join, the component geometry can be either derived from the
ASP CATPart or from a geometrical set in the ASP CATPart with boundaries.
• Assembly part numbers of the location bolts or support- and pressure pads
• Vehicle grid
Figure 6-7 Clipping of an ASP overview drawing

6.4.2 Alternative 2 – Detailing within the ASP
Alternative 2 means, that all location bolts (pins), support- and pressure pads (clamping pieces)
are designed in 3D either in the respective assemblies or directly in the ASP provided that it is
a new design.
If the all location bolts (pins), support- und pressure pads (clamping pieces) are designed in the
respective assemblies, all CATParts of the bolts (pins), support- und pressure pads (clamping
pieces) have to be copied from the assembly folder to the folder of the ASP. A (filebased)
renaming to the part number of the ASP is necessary. Afterwards they are integrated to the
CATIA structure of the ASP.CATProduct (“insert existing component“). The next time the
CARISMA Structure Manager is opend, the CATParts will be scanned. Finally the structure
category “Part without Partnumber” has to be assigned. In the assembly, the bolts (pins),
support- und pressure pads (clamping pieces) are changed to the “hide” mode.
If an assembly is taken over, new bolts (pins), support- and pressure pads (clamping pieces) are
always to be designed 3D within the ASP.
Basically all location bolts (pins), support- and pressure pads (clamping pieces) are given the
part number of the ASP and are also detailed (drawing derivation) in the ASP.
Drawing contents of the ASP in case of alternative 2
Sheet 1
• Overview of the support- and pressure pads as well as component geometry. Depending
on clarity of the component-join, the component geometry can be either derived from the
ASP CATPart or from a geometrical set in the ASP CATPart with boundaries.
• Corresponding assembly part numbers of the location bolts respectively support- and
pressure pads
• Vehicle grid
• Sectional views

Figure 6-8 overview sheet
Sheet 2 and/or furthercontinuation sheets
• Cross sections of the support- and clamping points

• Position numbers of the single parts
• Vehicle grid incl. position of the single parts
• If clarity of the drawing is not impaired, the cross section views can be dimensioned. If not,
a detail drawing has to be derived. In such case, a vehicle grid will not be necessary.
• For NC-machining, the “DATENSATZFLÄCHE” detail has to be used. This detail has to be
filled in and provided with an arrow showing the component-contacting contour piece
edge.

Abbildung 6-9 continuation sheet with detailing

7 Jig drawing execution

This chapter is a supplement to the generally valid drawing guideline BV-Z0.
7.1 Execution guidelines
For all 3D-models created in CATIA V5, drawing derivation as well is done in CATIA V5.
7.1.1 Basic model
In general, the basic model with the part no. G000060 is to be used for all drawings
(CATDrawings) (please refer also to section 2.7.2). Working with the CARISMA application this
basic model will be used automatically.
7.1.2 Storage state
The drawing has to be saved in the “Working Views” mode with sheet01 (=Blatt01) being
active. All frames have to be created using the frame application made available by BMW.
Drawings must not be provided with title blocks, they are generated by automation in
Prisma/DZA. To guarantee automated supply to the DZA, each CATDrawing has to be
classified and the “Enumeration Sheet Dialog” in the structure manager has to be performed
(see section 2.6.2). All 2D details must be detached from the external catalogues (Expose 2D).
Details originating from the basic model don’t have to be “exposed”.
7.1.3 Drawing derivation
Default sheet size is DIN A0. On one sheet, several individual parts are to be detailed; a
CATDrawing consists of one or several sheets being named “Sheet01”, “Sheet02”, “Sheet03”
etc. As a rule, each part number should only feature one CATDrawing. Splitting the drawing
into several CATDrawings for performance reasons is permitted in well-founded exceptional
cases only. Deriving an assembly drawing has to be done form the assembly-forming
CATProduct. With detail drawings, the respective CATPart has to be selected from the product
structure. Deriving a drawing form a WorkingProduct is not permitted.

7.1.4 Left- / right- / mirrored execution
For components existing in the vehicle on the left and on the right side, e.g. doors, side frames
etc. a part number will be required for each side. Thus, also one part number each is needed
also for each corresponding jig. In the event of the jig of the right side being the mirror-inverted
image of the left side, only the left data record will be created. This procedure is to be clearly
marked on sheet 1 of the drawing.
5 555 555 B7 left as drawn

5 555 556 B7 right, mirror-inverted
It is to be aimed at using an odd part no. for the left side and the subsequent even part number
for the right side.
7.1.5 Standard parts
The customary DIN- or ISO-parts such as bolts, nuts, washers or parallel pins do not figure on
the BOM (bill of materials). Entering a note into the drawing, e.g. at the centre line will be
sufficient.
7.1.6 Single part drawing
Each single part has to be provided with a single part title box that exists on the detail sheet of
the basic model.
7.1.7 Assembly drawing
On the 2D-views, the mounting dimensions and the assembly numbers are entered.
7.1.8 Rework drawing
If purchase parts and standard parts are changed, the comment “Rework” has to be entered
into the BOM (bill of materials) under remarks/comments. In the detail drawing, only those
dimensions have to be entered which are necessary for the later rework.
7.1.9 Invalid drawing sheets
In the event of a sheet becoming invalid, it has to be carried on as empty sheet and can be
again used with a later version. The existing sheets keep their sheet number and the number of

sheets on the main title block remains correct. Furthermore, the entries in the BOM column
E/Z (E = Einzelteil = single part, Z = Zusammenbau = assembly) do not need to be corrected. In
the sheet overview history, you will be given the assignment of the sheets per version.
History sheet overview (sample):
5 Continuation sheet – single parts
4 Continuation sheet – single parts
3 Empty sheet
2 Continuation sheet – intersections
1 Main sheet
7.2 Drawing derivation of flame-cutting templates
According to the OEM basic guideline, flame-cutting template drawings are derived from the
Body “function part” (Funktionsteil). In general, CATDrawings have to be created for flame-
cutting templates which are not classified (no supply to DZA). The flame-cutting templates
have to be made out without drawing frame. Data formats to be derived thereof (e.g. DXF) have
to be agreed upon and coordinated with the device/system supplier.

8 Documentation
8.1 Bill of Materials (BOM)
After initial creation of the BOM in CATIA V5 using CARISMA, the BOM – if the situation
requires so – needs to be completed using the BOM-Editor (FM-Stüli) (see section 2.10.3).
The position numbers defined are adopted. For any further information about the bill of
materials, please consult the guideline for the application of Prisma jig part list. To do so, log on
at https://b2b.bmw.com/ >> Departments >> Technologies >> Body-in-White >> Jig-Design
>> List of documents in jig design.
An own bill of materials will be created for the right side. In that case the following rule shall be
considered:
On the “right side” bill of materials, always a reference to the set of drawings has to be entered.
In case the BOM-no. and the drawing no. are not identical, we are talking about the bill of
materials of a right device that is to be manufactured in laterally reversed manner from the
drawn left side.
8.2 Shim documentation in the Body-in-White technology
Besides each dimension defining KER adapter plates package, a label with the jig part number
3 491 999 B7 is positioned as 3D-detail for the shim documentation. The assembly part
number assigned and the associated KER adapter plate package no. is engraved on this label.
These information have to be clearly stated in the drawing. The manufacturer has to enter the
ACTUAL-values of the shims in an associated EXCEL spreadsheet. For more information,
please see also the B7 production equipment specification.
8.3 Identification label
All assemblies are given the label with the part number 3 491 998. The information to figure on
the label are to be taken from the title box of the drawing.
All coordinates of the existing calibration holes have to be identified on the label with the part
number 3 491 997.

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BMW Group BMW specific supplement to the

Body-in-white technology „Basic guideline for the design of

Guideline for the design

Created by : Working group „jig design“

Status: June 2008

Version 2.3; date of creation 06/2008 page 1 of 47

1.1 Application area and other valid documents............................................................................6

2 Conventions and defaults ...........................................................................8

2.1 CATIA V5 Settings .........................................................................................................................8

Version 2.3; date of creation 06/2008 page 2 of 47

3 Structuring CATIA V5 assemblies......................................................... 20

3.1 General information ..................................................................................................................... 20

4 Structuring CATIA-V5 in-house production parts ............................ 32

5.1 Axes and position in space ........................................................................................................ 34

Version 2.3; date of creation 06/2008 page 3 of 47

6 Aufnahme- und Spannplan (ASP)(= support & clamping plan) in

7 Jig drawing execution ............................................................................... 44

7.1 Execution guidelines ................................................................................................................... 44

8.1 Bill of Materials (BOM)................................................................................................................ 47

Version 2.3; date of creation 06/2008 page 4 of 47

Version Chapter Comments

General revision – Extension of the chapter “Construction & design methods in

Documentation of new contents (new All.CATPart functionality, positioned

Fundamental revision by merging the document with the OEM-overlapping

Adaptation to CARISMA (successor version of T-Basics)

Modifications in consequence of synchronization with version AE02 of the

Version 2.3; date of creation 06/2008 page 5 of 47

1.1 Application area and other valid documents

1.2 Harmonization of methods

Basically, it is possible to adapt the design method to the corresponding orders/projects on

1.3 Contact persons

Plant Regensburg, Plant Leipzig,

Version 2.3; date of creation 06/2008 page 6 of 47

Plant Munich, Body-in-White Plant Munich, Assembly

Plant Dingolfing, Body-in-White Plant Dingolfing, Assembly

FIZ (R&D), Body-in-White FIZ (R&D), Assembly

1.4 Qualification external engineering partners in the Body-in-White technology

For any further information or queries please contact:

FIZ (R&D), Body-in-White FIZ (R&D), Assembly

Version 2.3; date of creation 06/2008 page 7 of 47

2 Conventions and defaults

2.1 CATIA V5 Settings

2.2 Naming convention

2.4 Drawing derivation

As to details on the drawing basic model, please refer to section 2.7.2 .

2.5 Data format

Version 2.3; date of creation 06/2008 page 8 of 47

2.6 Data quality, model preparation and archival

Subcontractors /suppliers do not return product data (E-components) to BMW.

- Structure document for the container (ST)

2.6.1 Creating an “ALL.CATPart”

Version 2.3; date of creation 06/2008 page 9 of 47

2.6.2 Supply to the DZA (= Digitales Zeichnungsarchiv = digital drawing archive)

2.7 BMW Start- and basic models

2.7.1 Start models for CATPart and CATProduct

Version 2.3; date of creation 06/2008 page 10 of 47

Furthermore, the start model features an implemented check function displaying a

Figure 2-1 BOMs parameters and -properties

2.7.2 Basic model for CATDrawing

Version 2.3; date of creation 06/2008 page 11 of 47

2.8 BMW-specific naming convention

e.g. ../5678901__A__1__A__EXAMPLE/for the directory and

Part no. (of the container)__Position no. of BOM__Designation.Extension

e.g. ../5678901A1AEXAMPLE/for the directory and

Part no. (of the container)Position no. of BOMDesignation.Extension