PLM World ‘06

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Digital Engineering Process at Isuzu

Author Yu (Fred) Homma / Naoki (Nick) NiiiCompany Isuzu Motors LimitedEmail yu_homma@notes.isuzu.co.jp

naoki_niii@notes.isuzu.co.jpPhone +81-466-45-9434

Index

· Company Outline & Products· Digital Engineering Concept· Achievement Summary· Next Step

· Establishment April 1937· Capital $283 M· President Yoshinori Ida· Sales $7,653 M· Employees 7,298· Major Product Trucks (H/M/L), Diesel Engines· Sales Units 233K units· Headquarters Oomori Tokyo· Assembly Plants Fujisawa, Kawasaki, Hokkaido, Poland, Ohio· Engineering Detroit, Bangkok· Office Gustavsburg

Company Outline & Products

1. Con-Current Development　Engineering Intent Visualization　DR by Experiments, ME, Service

2. Virtual Validation（ＶV）　Validation before Real Proto Type　Validate Vehicle variations

4. Shorten ME Activities　ME Validation by 3D data

ＳＯＰ

Experiments.

Imp.Design

ＣＡＰＥ

３ＤDesign

ProtRel.

ＣＡＥ

ＤＭＵＶ

V

Prod.Rel.

StyleFreeze

ProtAssy

ME/Pilot/Production Preparation

Ｖ

V

3. Early BOMEarly Product data DefinitionSpeedy Information Delivery

Early BOM

Digital Engineering Concept

DR: Design Review

Achievement Summary

· Achievement in Virtual Validation· Product Data Management by TcAE· Process Management by CAE Gate· Knowledge Management by CAE Standard

& CAE Automation· Tool Management by CAE Utilization

& CAE Integration· User Management by CAE Skill Up Training

· Result at Current Project· In Process CAE at Current Project· Excellent Quality of the First Real Prototype

Product Data Management by TcAE

Layout

Drawing

Per formance

Assembly

Manual

Design (Alias) Process

Catalogue

Manufacture

Regulation

TcAE

· Virtual Validation(VV) around the TcAE

DR

DR TcAE

Layout

Engineer ing

TestCAE

ME

Engineer ingEngineer ingConceptualConceptual ValidationValidation ProtoReleaseProto

Release

Major Par tLayout

LayoutCr iter ia

QualityCr iter ia

Vir tualValidation

Repor tAnalysis

Impr ovement

DetailEngineer ing

CAEValidation

CounterMeasure

CAPEValidation

CAE Gate

Suppor t

Assist

Confir m

DR

Eng.Plan

L/OPlan

DetailLayout

LO；Layout DR；Design Review ECR；Eng. Change Request

AssemblyCr iter ia

TestPlan

Mfg.Plan

Manufactur ingjudge

Eng.Release

CADValidation

ECR

Process Management by CAE Gate

Knowledge Management by CAE Standard

· Bullet 1· Bullet 2Vibration

SafetyAirflow

ManufacturingDurability

Combustion

· Over 400 CAE Standards

CAE Automation using the CAE Standard

· Bullet 1· Bullet 2 NX Process Studio

Automated CAE ToolStructural Process Studio

CAE Exp.Dept.

Design Eng.Dept.

Beginner

Specialist

Simple CAE ToolNX Scenar io

Ear ly CAE & CAE Val.Apply CAE Stds.

CAE Tool for Specialist

CAE DevelopmentCreate CAE Stds.

CAE Tool for Specialist

Single PartSimple Load

Simple Condition

AssemblyComplicated Load

Complicated Constrains

Tool Management by CAE Utilization

Parts model Full model

Nastr anAbaqus

AdamsStarCD

LsDynaPatran

HyperMesh

I-deasEASi

Prostar

NX Environment

NX1

NX2

NX3

NX4

NX5

Try out CAEEase of use

Conceptual CAECAE StandardizeNew functionality

Try out CAEHigh end functionality

Evaluation CAEHigh end functionality

Assembly model

Integrating CAE

SOFY

NX6-10

Tool CAE Integration on NX Env.

CAE Exp.Dept.

Design Eng.Dept.

Beginner

Specialist

User Management by CAE Skill Up Training

· 700 NX Scenario Users*· Japan· Thailand· USA**· China**

Step1 -- Basic1.　Virtual Development Process2.　Application3. Theory4.　Modeling5.　Verification 6.　CAE Standard7.　Reporting

Step2 -- Operation

Certification

* 500 users so far** form now on

Step3 -- Enhancement Training (by correspondence)

In Process CAE at Current Project

· Meet the Capacity Request

· Meet the Lead Time Request

Num

ber o

f C

AE

Rep

orts

Month

Month

CA

E L

ead

Tim

e (h

r)

Average (hr)

Excellent Quality of the First Real Proto.

ＯＫ Ongoing ＮＧ

Handling/Comfort

１２

Cooling

３１２

Idle Oscillation

３３

Cab NVH/Acoustic

１０８ ４

O/S mirror NV

３ ３

Bumper Rigidity/Durability

２５ ３

Steering NV

１４

Cab Rigidity/Durability

１８５４ １

Seat Rigidity/Durability

５７２３ １２

Panel Rigidity

７１８ ２

Door Rigidity/Durability

２１６ ６

Cab Parts Rigidity/Durability

３３５６ ８

RUP/FUP Regulation

１６９ ３

Seat Belt Anchor Strength

１３１２

Drive-ability

３１

Regulation

３

Fame Rigidity/Durability

７５４ ３Suspension Rigidity/Durability

５５１７ ３

Mount Rigidity/Durability

６１３ １

Mount Load

７２３ １

Chassis Parts NVH/Durability

４１６

Chassis Impact

４５ ２

Cab Crash

３７ １

Frame NVH

１１

Vehicle NVH

６54%9%

37%

Aero Dynamics

６ ６

Reduce Problem

· Front Loading by EDC· EDC:Engineering Design Communication· ECR:Engineering Change Request

Previous ProjectECR

Current ProjectECR

Current ProjectEDC

Next Step

· Expand the Virtual Validation· Increase Validation Items· Improvement Capability Level· Integrated System Level Analysis

· Automated Virtual Design· Optimization

Expand the Virtual Validation

· Integrated System Level Analysis

Proving Ground

Crash Laboratory

NVH

Aerodynamics

Cooling

Combustion

Piston/Crank Motion

Suspension Motion Heat Stress

Fatigue

Acoustic

Driver

Power Train Motion

Intake-port Flow

Automated Virtual Design

· Optimization

Shape Optimization

Topology Optimization

Topography Optimization

Morphing

Make Hole

Make Hole

Make Bead

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