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Green Bikes International FSP Presentation

Final Presentation

PEP

Green Bikes International Team

Project Leader Manish Abraham

Engineering Manager Muna Abdulrahman

Systems Manager Haydee Capco Nina Asadi Moghadas

Design Engineer Abraham De Ochoa

Design Engineer Mahdi Baghban Pourasl

Systems Engineer Cristian Gidea

Systems Engineer Shakh Alauddin

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The Flow of the Presentation

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The Flow of the Presentation

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Development process (Conceptual design)

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Overall Project Plan

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Stakeholder Requirements
The E-bike shall be profitable after 100 units. The E-bike shall be made of at least 50% recycled materials. The E-bike shall run for at least 60 km on a full charge. The E-bike should be energy-autonomous.

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Stakeholder Requirements
The E-bike should be able to last at least 800 charge cycles. The E-bike's initial aesthetic design shall have at least a 50% approval rate from a focus group. The E-bike should be a silent bike. The E-bike should bring about a young and sporty feeling for the user.

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Initial Design Concepts

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Conceptual Design

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Development Process for the Conceptual Design

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Conceptual Data Model

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Nomenclature
Naming convention of system elements

All files/entry names were named starting with GB followed by the element name
All the levels were defined with L, numbered and separated with _.
E.g. GB_FC_L1.... (with levels)

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Nomenclature
Functions
System Definition
Stakeholder Requirements System Requirements Requirements Set Derived Requirements System Definition SD Procedure SD Physical

GB_FC_
GB_SD
GB_SH _ GB_SR_ GB_RS_ GB_DR_ GB_SD_ GB_PROC_ GB_PHY

SD Hardware
SD Software SD Interface Baseline Functions
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GB_HW
GB_SW GB_IF GB_BL_FC
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Nomenclature
Functions
Baseline SD Ordinal

GB_FC_
GB_BL_OD

Baselines Documents Baseline Parts Baseline Hardware

Baseline Software Baseline Collector Part Master Parts CAD Files Project Management Derived Requirements PDF Files Office Document File
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GB_BL_DOC GB_BL_PAR GB_BL_HW

GB_BL_SW GB_BL_COLLECTOR GB_PAR GB_CAD_ GB_PM_ GB_DR_ GB_PDF_ GB_DOX_
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System Engineering
Functional Decomposition Requirements Definition System Breakdown
Generic breakdown of the product from a system point of view.

Decomposition of the product with no specific solution in mind

Physical Interfaces

General Guidelines
Needs to be consistent with defined functions and requirements Follow consistent nomenclature rules Review and release items

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Functional Decomposition

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Creating Functions and Defining Functional Structure

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Requirements Definition
Functional Breakdown Physical Requirements

Requirement Management
Stakeholders Requirements Functional Breakdown System Requirement

Derived Requirements

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System Requirements

Inside CIM db
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Requirements Set:

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Linking Functions to Requirements

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System Breakdown

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System Definition (inside CIM Database)

Objects
System Definition Ordinal System Definition Procedure System Definition Physical System Definition Hardware System Definition Software System Definition Interfaces

Information
Nomenclature, Acronym, Description Project, Maturity, other descriptions

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System Definition Ordinal

Each system element is created and defined in CIM database. This will be the foundation for the detailed structured view of the system. Top level generic nomenclature and information.

Clear illustration and representation of the system

Gives the user a complete overview of the system for assessment and review.

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System Definition Ordinal

Tasks

SD-00000 - Data Sheet

Enter information of each system element into

its own SD datasheet in CIM database SD-00001 SD Structure Ordinal

System Architecture- Define/Link relationships

and levels of the system

Father-child relationships Top-down Structure

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System Definition Ordinal

Tasks

SD-00001 - System Definition to Requirement Set

Link to system requirement sets

SD-00001 - Files

Link files For easy access to related and relevant files

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System Definition Procedure

Collector of documents
Rules, standards, generic documents which are usually not directly related to the product For convenient reference

Task
Create SD Procedure entries and upload related files
Revisioning (Indexing/Issues)

Result
SD Procedures - SDPR-00002

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System Definition Physical

Abstract definition of the physical components
Provides the engineering department a system definition view of physical parts as reference when defining or creating specific parts

Task
Create general non-specific physical components of the system in CIM database Link to (specific) parts

Result
SD Parts

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System Definition Physical (example)

Reference in CIM database: SD physical---right click on item---SD physical to Part FSP

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System Definition Hardware

Refers exclusively to all computer hardware related to the system (product). Task
Create and define SD Hardware entries in the database

Result
SD Hardware

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System Definition Software

Refers exclusively to all computer software related to the system (product). Task Create and define SD Software entries in the database Result SD Software

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System Definition Interfaces

Defines horizontal relationships between system and gives the user a clear view of physical interfaces from a system view. Task Create and define Interfaces

Interfaces between systems

Result

SD Interfaces

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Physical Interface of Parts

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System Definition Ordinal Relationships

Tasks
SD-00000 - SD Ordinal to SD Procedure

Link system elements to related SD Procedure

SD-00001 - SD Ordinal to SD Physical

Link system elements to related SD Physical

elements

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System Definition Ordinal Relationships

Tasks
SD-00008 - SD Ordinal to SD Hardware

Link system elements to SD Hardware of the

system
SD-00008 - SD Ordinal to SD Software

Link system elements to SD Software of the

system

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System Engineering
Generating the Structure View
Integration of all information entered into the database Structured view of the whole system

View all links and relationships with one click

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Structure View Result

SD-00000 - System Definition System definition all relationships SD-00002/1 SDPH-000063/1

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Bill of Materials
Two types: Engineering Bill Of Materials (E-BOM) Manufacturing Bill Of Materials (M-BOM) The E-BOM and M-BOM contain the product knowledge of how to build and how to manufacture a product. They are presented as assembly trees that represent a hierarchical structure for the assemblies, subassemblies and parts that make up the product, whether purchased or manufactured.

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E-BOM vs. M-BOM

E-BOM
Defines and manages the components and structure of the product being manufactured. Contains the list of items, parts, components, sub-assemblies and assemblies in the product designed by engineering. Represents only the physical product being engineered, not the packaging or manufacturing consumables.

M-BOM
Contains details of the parts and assemblies required to build a complete and shippable product. (eg: Kits, Structures, Assembly processesetc.).
Reflects the manufacturing process, represents physical product, packaging and included documentation (CAD files, PDF,etc.).
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E-BOM vs. M-BOM example 1

(E-BOM)

(M-BOM)

Product
Assembly A Component B1 Component B2 Component C
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Product
Component B1 Component B2 Component C Component D
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E-BOM vs. M-BOM example 1.1

Part Number Part Name

000045 000046 000049 ... Head Tube Handle Bar Phone Holder

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Why is it important to have the two views?

E-BOM Supports better purchasing decisions, manufacturing process and logistics choices Extra and unnecessary changes in the manufacturing process can be avoided Disruptive last minute changes can be avoided with an accurate E-BOM because all the details including parts, items, components and quantities are correctly noted. Smoother hand-off to manufacturing
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M-BOM The information from the M-BOM feeds the business systems used to order parts and build the product Supports the successful management of manufacturing resources Enables the final transition from product concept to a concrete, touchable object

Saves time in assembly process

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Conceptual Design E-BOM and E-BOM

E B O M

M B O M

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Parts and BOMs in CIMDatabase

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Parts and BOMs in CIM Database cont.

Part Number
000007 000061 000014

Part Name
Rim Tire Spokes

000015

Valve

Reference in CIM database: Part Master---Double click on the part---select BOM tab in the pop up menu FSP
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Linking Parts to CAD documents

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Short Assembly Video

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Baselines
A snapshot of system defining objects at a certain point in time.
A stable reference for future work. Captured state of the project for use in assessing and analyzing the system and its components.

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Baseline Master
Collects created baselines to capture progress points within the system development life cycle. For convenient reference and traceability

Baseline SD Ordinal Baseline Functions Baseline Documents Baseline SD Physical Baseline Hardware Baseline Software

Baseline Master (Collector)

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System Engineering Relationships (CIM Database)

Stakeholders Requirements

Functional Structure
System Requirements

Requirement Set

Functions Functions

SD Ordinal
SD Structure SD Structure Ordinal Ordinal SD Procedures

Derived Requirements

SD Interfaces

Baseline Collector
Baseline SD Ordinal Baseline Functions

E-Bom
SD Physical Parts SD Hardware
Files

Baseline Documents Baseline SD Physical Baseline Software

SD Software

M-Bom

Baseline Hardware

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Benefits of PLM/PDM Solutions

Manageability of all product-related documents and files Accessibility of parts, documents and changes Traceability of product data

Change Management

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KEY EXPERIENCES GREEN BIKES INTERNATIONAL

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Few Thoughts about the Process

It was a nice experience to deal with all the steps that a team faces when creating a product. Even though our product is not a complex product, the process is very important and at some point it gets complex, because the team had to deal with every small detail of the bicycle. It was an interesting experience having an overall view of how to handle a product in its entire concept phase within a PLM environment. At first I felt the tasks were too time-consuming especially the database build-up phase. But once this was done, it was more fun exploring the system, seeing how all things are interconnected and related. But it also gave me an idea to how more complicated these systems are in a real working environment. And that is a bit intimidating.
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Few Thoughts about team work

It was always a nice experience to have a committed team in which everyone had their own responsibilities. It doesn't matter what nationalities the other members have, in the end it's all about teamwork. the more different views, the better the result. Team work was really interesting and effective. It made the work dynamic. Sometimes absence of some team member did not effect the overall work. Sometimes it was difficult to manage meetings and difficult to agree or arrive at a decision as a team because every one has a different opinion and wants their solution/idea to be used.
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Few Aha Experiences

It was surprising and interesting to learn on the way how simple details of the product get related at some point of the process. Something the system engineering is Aha experience. Because we know but we can not remember, when someone reminds this we remember. Many things worked on Trial and Error.

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Thank you for your attention!

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