Product Development in the Automotive Industry with SAP

1 Introduction ... 21

Part I Project Management in Product Development in the Automotive Industry

2 Introduction to Project Management ... 31
... 2.1 Motivation ... 31
... 2.2 Methods of Project Management ... 34

3 Structuring of Projects ... 41
... 3.1 Project Structuring in Development Projects ... 41
... 3.2 Project Structuring for Investment Projects ... 58

4 Project Planning ... 61
... 4.1 Project Cost Planning and Budgeting ... 62
... 4.2 Scheduling ... 75
... 4.3 Resource Planning ... 85

5 Project Execution ... 93
... 5.1 Project Execution ... 93
... 5.2 Project Progress and Project Reporting ... 108
... 5.3 Project Deviations ... 113

6 Cross-Company Aspects of Project Management ... 117
... 6.1 Cross-Company Collaboration in Projects ... 117
... 6.2 Quotation Management in the Project Environment ... 135

Part II Product Data Management in Product Development in the Automotive Industry

7 Introduction to Product Data Management ... 153

8 Basic Functions of Product Data Management ... 157
... 8.1 Parts Master (Material Master) ... 157
... 8.2 Document Management ... 161
... 8.3 Simple Bill of Materials ... 169

9 Supporting Functions in Product Data Management ... 175
... 9.1 The Classification System ... 175
... 9.2 Variant Configuration ... 184
... 9.3 Engineering Change Management ... 200

10 Interfaces and Data Exchange ... 209
... 10.1 CAD Integration-Management of Geometric Data ... 210
... 10.2 Data Exchange with External Business Partners and cFolders ... 217

11 Integrated Product Documentation ... 225
... 11.1 Integrated Product and Process Engineering ... 226
... 11.2 The iPPE Product Structure ... 230
... 11.3 Product Classes of the iPPE Product Structure ... 231
... 11.4 Product Variant Structure in the iPPE Product Structure ... 233
... 11.5 Assemblies ... 235
... 11.6 Building Blocks of the iPPE Product Structure ... 236
... 11.7 Object Dependency in the Product Variant Structure ... 240
... 11.8 Maintaining a Multi-Level Product Structure ... 243
... 11.9 Change Management in the iPPE Product Structure ... 256
... 11.10 Evaluation in the iPPE Product Structure ... 259
... 11.11 Management of Concepts ... 263
... 11.12 Integration Aspects of the iPPE Product Structure ... 264

12 Engineering Change Management ... 271
... 12.1 Extended Functions of Change Management in the SAP System ... 273
... 12.2 Change Management Using Notifications ... 277
... 12.3 Change Management Using SAP Records Management ... 279

13 Substance Data in Product Data Management ... 285
... 13.1 Used-Vehicle Regulations ... 285
... 13.2 The SAP Environment, Health & Safety Component ... 287
... 13.3 Substance Data Management in the Automotive Industry ... 291

14 Product Cost Planning and Concurrent Costing ... 297
... 14.1 Multi-Level Unit Costing ... 301
... 14.2 Concurrent Costing-Product Design Cost Estimate ... 303

Part III Product Validation

15 Introduction to Product Validation ... 311

16 Product Validation Methods ... 317
... 16.1 Failure Mode and Effect Analysis (FMEA) ... 318
... 16.2 Design of Experiments (DoE) ... 324

17 Product Validation Planning ... 333
... 17.1 Requirement Management in Product Validation ... 334
... 17.2 Product Validation Plan ... 337
... 17.3 Prototype Planning ... 342

18 Prototype Production ... 357
... 18.1 Introduction ... 357
... 18.2 Planning and Order Management ... 361
... 18.3 Determination and Management of Prototype Contents ... 366
... 18.4 Representing Design Status in Logistics ... 368
... 18.5 Procurement of Prototype Parts ... 373
... 18.6 Production of Prototypes ... 380

19 Prototype Life Cycle Management ... 385
... 19.1 Introduction ... 385
... 19.2 Prototype Documentation ... 387
... 19.3 Test Cycle ... 395
... 19.4 Vehicle Rebuild ... 399

20 Product Validation Procedure ... 405
... 20.1 Individual Test Planning and Execution ... 405
... 20.2 Test Evaluation ... 412

21 Asset Management in Production Process Planning ... 417
... 21.1 Engineer-to-Order Production in Tooling Manufacture ... 419
... 21.2 Maintenance of Assets, Tooling and Equipment ... 426

Part IV Customer Implementations

22 Customer Examples ... 437
... 22.1 Use of the SAP System at the Audi Tool Shop ... 437
... 22.2 PEP PDM at BMW ... 442
... 22.3 Material Data Sheet Generation at Continental Teves ... 445
... 22.4 Development and Investment Controlling at General Motors Europe ... 450
... 22.5 Project and Parts Management at Karmann ... 455
... 22.6 Prototype Manufacture at the OPEL Technical Design Center ... 460
... 22.7 Electronic Variant Parts List at Volkswagen ... 465

Appendix ... 469

... A Bibliography ... 471
... B The Author ... 473
... Index ... 475