DMU流程修改V1.2-20141209-修改.docx

管理制度 Management System 分发号：DMU流程DMU process文件编号Document No. :（参照流程管理文件规定）版 本Edition: C 发布日期Issue date： 2012年（YY）05月 （MM）04日（DD） 生效日期Effective date：2012年（YY）05月 （MM）04日（DD） 受控状态 Control Mode：编制Prepared by: 国刚 Guo Gang 蒋治军 Jiang Zhijun 陈琪 ChenQi 审核Reviewed by：魏忠宣Wei Zhongxuan 曾采德Zeng Caide 万飞 Wan Fei林少豪Lin Shaohao陈仕刚Chen Shigang苏新涛SuXintao 李洪波Li Hongbo袁子高Yuan Zigao王棋龙Wang Qilong 彭华东Peng Huadong批准Approved by： BORSANO Luca 苏宇 Su Yu 上汽依维柯红岩商用车有限公司流程文件 上汽依维柯红岩商用车有限公司 发布SAIC-IVECO HONGYAN COMMERCIAL VEHICLE CO.,LTD Process Document SAIC-IVECO HONGYAN COMMERCIAL VEHICLE CO.,LTD ISSUE DMU流程 文件编号：SIH-07-02-G/B 版/次号B/0 编制日期： 2012.5.4 修改日期：2013.1.10 更改记录Record of Amendment： 版次号Edition No.更改原因Reason for Amendment更改日期Amendment Date编制人Prepared byB/0（B版/首次）Edition B/First格式调整2014年1月10日陈琪Chen QiC/0（C版/首次）Edition C/First部分翻译内容校正2014年12月09日杨洪云Yang Hongyun目 录1.目的12.适用范围13.定义14.组织结构15.校核目标和关键校核工作76.职责77.规定128.支持文件329.附则3210.表单3211.附件321. 目的该文件描述了DMU流程、相关支持机构、DMU各项工作内容的流程图、问题管理以及系统/整车级校核。The document describes the DMU process, the organization to support it and the flowcharts of DMU activities, Issue Management and Systems / Full Vehicle Reviews。产品开发过程中，应用DMU，在先于实体样车装配前的很长时间里，实现对整车和（用于对整车进行生产/装配的）工具进行分析和展示。The DMU technology allows the display and analysis of vehicle assembly and equipment intended for manufacturing / assembling it during the product development phase (concurrent engineering) and a long time before any physical prototype can be available. DMU可以：DMU enables: 进行设计并保持整车各模块的持续受控状态To design and keep the vehicle packaging continuously under control; 实施实体零件仿真分析To carry out simulations of the physical product; 在设计的最初始阶段发现问题To individuate design errors since the real beginning of the activity; 在不同阶段对制造性、维修性等进行设计和分析To design and simulate the manufacturing, serviceability, etc during different phases.该流程着眼于在产品和工艺开发仿真检查过程中DMU的应用。This procedure concerns about all the utilization of DMU in the virtual check activities of product and process activities.2. 适用范围本流程适用于SIH所有新产品平台。This document is valid for all new SIH product Platforms。3. 定义3.1 电子样车（DMU）是指：一个车型结构化的、集中的、完整的3D数模。通过预先确定的更新流程来保证数据为最新状态。单件和总成数据在逻辑上是相互关联在一起的。Digital Mock-Up (DMU) means structured, centralized and complete data storage for all 3D data of a vehicle. Usage of a pre-defined update process guarantees always actual status of data. Data of single parts and assemblies are logically linked with each other. 3.2 问题管理:所有在DMU仿真分析中发现的问题都必须通过一个有效的信息系统进行跟踪和管理，该系统可以支持发现问题者和整改人之间的有效沟通。问题的整改结果需向总布置工程师/平台总师报告。Issues management: All the issues detected during virtual analyses on DMU must be tracked and monitored through an effective information system for supporting the communication between all the people involved between issues detection and resolution. The result should be reported to the Vehicle Architecture/Platform chief engineers.3.3 ICT：信息通信技术 Information and Communication Technology3.4 CAD：计算机辅助设计 Computer Aided Design 3.5 DMU：电子样车 Digital Mock-Up3.6 PMU：实体样车 Physical Mock-Up3.7 PDM：产品数据管理系统 Product Data Management3.8 FT：技术功能模块 Funzionalit Tecnica3.9 EBOM：工程物料清单 Engineering Bill Of Material3.10 TCAE：汽车设计中心系统 Team Center Automotive Edition - Team Center3.11 TCVIS： Team Center可视化工具Team Center Visualization3.12 JT：(JT格式) Jupiter / Jeff Trom (JT format)3.13 CGR：CATIA图形显示 CATIA Graphics Representation3.14 PSE：产品结构编辑器 Product Structure Editor4. 组织结构 DMU流程要求特定的组织形式，其中包含有不同的成员角色负责与传统直线职能中的成员（如FT负责人及设计员）进行沟通协作。DMU process requires a specific organization with different roles that interact with the classical line functions roles, like FT managers and Designers.在DMU流程中承担主要职责的团队是整车集成处，由几个DMU分析工程师和一个总布置工程师组成，其中的协调工作主要由总布置工程师负责。The team that has the responsibility of DMU process is called “Vehicle Integration” composed of DMU analysts and coordinated by a Vehicle Architects.平台经理/平台总师Platform manager/Platform Chief Engineer上面图表中所列的所有与DMU流程相关的成员角色，以下章节将进行细化，包括： 成员角色的描述；与DMU 流程相关的工作及其职责。In the following paragraphs, for each role of DMU process present in the above image, will be specified: the description of the role, the activities (only in the DMU process) and the responsibilities.5. 校核目标和关键校核内容 （无）6. 职责DMU模型的建立是通过集中各设计部门的CAD数据完成，进而对DMU模型进行仿真分析，因此所有的设计过程必须严格按照设计部门的规范和方法进行。DMU models are built gathering CAD models designed by engineering departments, so to enable virtual analyses on DMU models, all the design process must be regulated with standard rules and methodologies to be strictly observed by engineering departments. 6.1 总布置工程师 Vehicle Architects6.1.1角色 Role DMU团队的协调者，负责不同车型系统的整合，平台核心成员，代表各直线职能模块(即各专业组)。DMU team coordinator, responsible for the integration between the different vehicle systems，Members of the platform that represent the line functions。6.1.2工作内容Activities 6.1.2.1确定用于DMU检查的代表车型配置，Defining configurations for “pivot vehicles” to be checked in DMU process6.1.2.2负责为车型系列创建技术原型（概念DMU），确保车辆模块、变型最大化Create Technical Archetype for the vehicle family maximizing the modularity of the vehicle6.1.2.3负责核实不同模块之间的交互部分是否与已确定的方案一致Verify if interfaces between modules are compliant as decided6.1.2.4负责根据车型配置参数布置各功能模块的位置Define the positioning of Technical Functionalities depending of vehicle configuration parameters6.1.2.5计划、组织和管理“系统及整车级校核”会议Plan, arrange and manage Systems and Full Vehicle Review meetings6.1.3职责Responsibility 6.1.3.1确保车型的技术原型及总布置信息的可用性Guarantee availability of Technical Archetype and positioning information6.1.3.2确保在不同的车型配置中各系统的一致性及其与周围系统的正确交互，并突出各自的关键点Guarantee the consistence and correct interfacing of the vehicle systems in the different vehicle configurations highlighting critical aspects6.1.3.3确保系统间的交互信息、问题点及问题解决方案在不同的FT负责人间正确理解、流通Guarantee the correct information flow between the FT managers about interfaces, issues and proposal of solutions6.1.3.4确保车型结构和交互部分的模块化设计Guarantee modularity for vehicle structure and interfaces6.1.3.5如遇冲突，负责识别其中的利弊并寻找“平衡”的解决方案Identify and propose trade / off in case of dispute6.1.3.6落实并汇报技术进度和里程碑(PER、FER等)Verify and report engineering milestones(PER/FER) and progress6.1.3.7管理并持续监督跨功能系统的问题Manage and continuously monitor the issues across the functional systems6.2 FT负责人/系统负责人 FT Manager / System responsible6.2.1角色 Role 功能模块的设计协调者，负责达成功能、性能及所有的项目目标Technical Functionality design coordinator, responsible to achieve functional, performances and all the project targets 6.2.2工作内容Activities 6.2.2.1对不同车型配置中的每个FT定义其新的变化，并将识别此FT变化的零件号填入VCR/ICP的模块矩阵中Define new variants for each FT in the different vehicle configurations and fill-in the modularity matrixes in VCR / ICP with all the PNs that identify the FT variants6.2.2.2评估每个FT中使用沿用零部件的可能性，并在VCR/ICP的模块矩阵中插入选定的零件号Evaluate the possibility to use Carry-Over parts for each FT and insert the selected PNs in the modularity matrixes in VCR / ICP6.2.2.3对每个检查到的问题定义或评估可能的解决方案Define or evaluate possible solutions for the detected issues6.2.2.4参加“系统及整车级校核”会议并准备所有讨论问题所需要的材料Participate in Systems and Full Vehicle Reviews preparing all the documents needed to discuss the issues6.2.2.5协调其下属的设计员Coordinate the designers of his team6.2.3职责Responsibility 6.2.3.1确保每个FT的功能、性能及成本目标Guarantee functional, performances and costs targets for each FT6.2.3.2确保每个FT的EBOM和CAD模型及时完成Guarantee availability of EBOM and CAD models for each FT6.2.3.3确保CAD模型的共享（通过建立产品平台内同步工程所用的共同基线）Guarantee the sharing of CAD models creating baselines available for concurrent engineering in the platform6.3设计员Designer6.3.1角色 Role 设计每个FT（功能模块）的EBOM和CAD模型和/或管理与供应商的数据往来Design EBOM and CAD models for each FT and/or manage data exchange with suppliers 6.3.2工作内容Activities 6.3.2.1作为最终的功能负责人对所属的功能模块制定技术解决方案Define technical solutions for all the Technical Functionalities in the line function competence 6.3.2.2设计新零部件的EBOM和CAD模型，需考虑FT负责人加入的所有设计需求变量 Create EBOM parts and CAD models for new components developing all the variants inserted in the VCR by the FT managers6.3.2.3根据问题管理的反馈，更改现有的EBOM及CAD模型Modify the existing EBOM parts and CAD models based on feedbacks from issue management6.3.2.4共享CAD模型（通过建立产品平台内同步工程所用的共同基线）Share CAD models creating baselines available for concurrent engineering in the platform6.3.3职责Responsibility 6.3.3.1确保各项功能性要求（如安全性，人机工程和外观）落实到设计中Guarantee that functional specifications (e.g. Safety, Ergonomics & Appearance) are implemented in the design 6.3.3.2根据技术开发计划及时完成EBOM，CAD数据及基线Deliver on-time the EBOM, CAD data and baselines according to engineering plans6.3.3.3确保与供应商的正常数据交流Guarantee the respect of delivery from the suppliers6.4 DMU 分析工程师 DMU Analyst6.4.1角色 Role 6.4.1.1应用DMU“检查清单”进行仿真分析Execute virtual analyses using DMU check-lists6.4.1.2 DMU团队的一员，其中DMU团队不仅包含底盘、驾驶室、系统等所有功能模块的专家（对所有车型进行验证），还包含应用JACK (人体模型)从事人机工程校核的专家。Member of the DMU team that encompass all kind of functional experts in chassis, cabin and systems to validate over all vehicles and also dedicated experts performing ergonomics using JACK6.4.1.3他们对于整车的整体认识将有助于更好地遵循项目的设计要求（大纲），并在零部件的标准化和模块化方面给总布置工程师和其他设计处提供更好的建议Their overall vehicle knowledge will help to follow the design guideline for the project and helpful to provide suggestions like standardization and modularisation of components to vehicle architect and other functional departments6.4.2工作内容Activities 6.4.2.1基于代表车型的配置创建DMU并实施仿真分析Create DMU sessions based on pivot vehicles and execute virtual analyses6.4.2.2从设计员及FT负责人处获取阶段性冻结方案（baseline）, 在DMU的中期性工作中更新DMU校核内容Update DMU session at each DMU cycle getting the baselines created by designers and FT managers6.4.2.3在“问题管理系统”中开启问题，并提出问题处理建议供FT负责人评估Open the issues on the issue management systems and can define solution proposals to be evaluated by the FT manager6.4.2.4在核实问题确实得到了解决后，关闭问题Close the issues after verified that are really solved6.4.3职责Responsibility 6.4.3.1开启/关闭（DMU校核）所发现的问题Open / Close detected issues6.4.3.1汇报问题的处理进度Report progress on issues6.5 其他相关成员：价值工程，测试Other involved functions: value engineering, testing 公司其他职能部门需参与问题的管理和校核过程，加入问题描述及解决方案所需的相关信息Roles of other company functions are involved in the issue management and review processes to add information about issues and solution proposals. 价值工程的人员需全程参与，提供成本分析信息，下节流程中有详述Value Engineering people are involved in all the phases in which an evaluation of costs is required as described in the flows in the next chapter. 测试部门则可利用PDM系统中已就绪的DMU在下订单前核实零部件的状态和管理样车配置Testing department instead will use the DMU baselines available in the PDM systems to verify status of the components before ordering and manage the prototypes configurations.7. 规定本章列举了一些通用规则和方法，详述了进行DMU验证所必需的一些重要要求。In this chapter, general rules and methodologies references are specified and the most important requirements for DMU activities are detailed.7.1 开展DMU工作的需求 Requirements for DMU activities 设计部门根据基本的规则和方法进行设计Engineering department works based on basic rules and methodologies; 相应的信息系统和工具以有效支持仿真分析，问题管理和校核内容检查Information systems and tools that support efficiently virtual analyses, issues management and review activities.7.1.1 CAD建模过程中的“一个零件，一个数模”原则 CAD modeling with “One Part - One Model” paradigm每一个零件需进行单个CAD模型的建模。这一规则使得可以在DMU中对车型的每一个单独零件进行装配和拆卸检查。Each component must be modelled with a single CAD model. This simple rule enables DMU activities to simulate disassembly and assembly operations of each single component of the vehicle. 在这个大原则下也有部分例外：如一些来自供应商的复杂装配（如发动机&变速器），可作为一个单独零件进行仿真校核。Some exceptions at this general rule can be applied for some complex assemblies delivered by suppliers (e.g. Engine & Gear box) that can be considered as a single part for virtual validation.对这种类型的装配数据，只需要其外形数据即可，有时也强制要求只要其外形数据以便于获得更好的DMU分析性能。For this type of assemblies only an external skin is sufficient and sometime this is strictly required for having good performances in DMU activities.只需供应商提供外形数据的装配文件需单独提出。Suppliers assemblies which models have to be delivered as external skin must be explicitly declared. 附录A简单列出了该类装配的清单，但在每个平台内所有平台成员均同意的情况下可以有所不同。Annex A reports the general list of this assemblies but some different decisions on the subject can be taken in each engineering platform sharing the decisions with all the platform members.7.1.2 通过PDM系统实施CAD数据管理 CAD data management through PDM solutionDMU的创建要求能够方便快捷地收集CAD模型数据以进行仿真分析，且这些CAD数据的变更必须具有可跟踪性。DMU creation requires an easy and fast gathering of all the CAD models for virtual analyses and the traceability of all the changes to these CAD models.基于这个原因，采用PDM系统进行CAD数据管理对于DMU流程来说是非常重要。For this reason, the usage of a PDM solution to manage CAD data is a mandatory requirement for the DMU process.用“Team Center” PDM解决方案可以实现Team Center PDM solution allows to: 通过唯一的代号来识别每个CAD模型Identify each CAD model with a unique code; 通过版本和阶段性冻结方案管理跟踪CAD模型的变更记录Track the history of changes on CAD models through revisions and baselines management; 在同一项目中不同部门之间实现CAD数据的实时共享和更新，从而实现真正的并行工程Share always latest update of CAD models between all the departments involved in a project enabling a real concurrent engineering; 支持并行工程流程Support the concurrent engineering process.7.2 DMU流程图 Introduction to DMU processDMU流程主要分为如下3个子流程 The DMU process is divided in three main sub-processes: 设计和验证循环： DMU流程的核心内容，因为它包含了仿真分析工作以及FT(功能模块)的设计优化Cycles of design and verifications: represent the core of the DMU process because contains the virtual analyses activities and the execution of design optimization changes on the FT; 问题管理：包含从问题开启到问题解决整个过程中的问题管理工作。Issue Management: includes all the activities to manage the issues since they are opened until they are solved; 系统/整车级校核：包含准备和管理校核会议的所有工作，此会议所有相关的平台成员均需参加，以讨论并解决待定的问题。Systems / Full Vehicle Review: includes all the activities to prepare and manage a Review meeting with all the involved platform members to discuss and solve all the pending issues.上汽依维柯红岩商用车有限公司流程文件 上汽依维柯红岩商用车有限公司 发布SAIC-IVECO HONGYAN COMMERCIAL VEHICLE CO.,LTD Process Document SAIC-IVECO HONGYAN COMMERCIAL VEHICLE CO.,LTD ISSUE 10 DMU流程 文件编号：SIH-07-02-G/B 版/次号B/0 编制日期： 2012.5.4 修改日期：2013.1.10 DMU流程 文件编号：SIH-07-02-G/B 版/次号B/0 编制日期： 2012.5.4 修改日期：2013.1.10 7.3.1 DMU技术原型准备阶段 (A) Technical Archetype preparation for DMU (A) 节点 责任部门活动描述与管控要求输出关键控制点目标下节点备注1总布置工程师总布置工程师确定在DMU周期中用来做仿真分析的代表车型22总布置工程师总布置工程师创建每个代表车型的配置，并保证所创建的配置可为需要的部门所用（比如DMU创建部门）代表车型配置103总布置工程师基于VCR/ICP系统中的信息，总布置工程师在TeamCenter中创建技术原型。（在目前TeamCenter未实施的情况下，采用人工数据PDM管理实现）。这个技术原型将作为此产品平台内的设计员进行设计时确定设计框架的主要依据，也是DMU分析工程师进行DMU分析的主要参照标准。这个技术原型包含此车型每个FT(功能模块)的所有布置位置信息，配置不同有所不同概念DMU44总布置工程师总布置工程师将配置参数中FT变量的所有正确位置信息通过Excel表格填入（即定义变化的FT的位置信息）。此外，他们还负责定义不同FT交互部分的尺寸约束11NodeResponsibility departmentActivity description and control requirementOutputKey PointAimNext nodeRemark 1Vehicle layout EngineersThe Layout Engineers define the pivot vehicles to be analyzed with virtual analyses in the DMU cycles.22Vehicle layout EngineersThe Layout Engineers creates the configuration of each pivot vehicle that can be used and make them available for all the activities (e.g. DMU session creation) that requires a vehicle configuration to be executed.Vehicle pivot configurations103Vehicle layout EngineersThe Vehicle Architect prepares the technical archetype in TeamCenter starting from the information present in VCR/ICP systems(Before TeamCenter work, we use manual PDM system). This technical archetype will be used as main reference for the Design in Context and DMU activities by all the designers and DMU analysts of the platform, and it will contain all the information to position each FT of the vehicle depending on the vehicle configuration. DMU conception44Vehicle layout EngineersThe Vehicle Architect fill-in, using Excel tables, all the information for the correct positioning in the space of FT variants based on the configuration parameters. Moreover it is responsible to define the geometric constraints between interfaces of different FTs 117.3.2 设计阶段 (B) Design Phase (B)节点 责任部门活动描述与管控要求输出关键控制点目标下节点备注5FT负责人基于设计目标，FT负责人对每个FT可能的新变化进行评估。零部件清单6或76FT负责人确定沿用零件号87FT负责人如果是新零件，则需要创建新的零件号以识别变化88FT负责人需找到现有的零件号或新零件号并在VCR/ICP系统中将其插入对应的FT模块矩阵中1615设计员问题反馈1616设计员或者1717设计员设计员为每个FT的新变化创建CAD结构。如果在新结构上发现问题，设计员需要用CAD工具进行相应的更改。