An all-digital machinery development process accelerates newproduct introduction, promotes development team collaborationand fosters an environment of continuous innovation that keepsyou a step ahead of competition.

Digital product developmentMachinery

www.siemens.com/plmSiemens PLM Software

Increasingly complexbusiness challenges

Industrial machinery is so criticalto a company’s success that it hasbeen called “the lifeblood of theproduction process.” Becausecompanies can’t thrive withoutfast, reliable, state-of-the-artmachines to manufacture theirproduct innovations, they placeextreme demands on theirmachinery suppliers and in-housemachinery developers.

If you’re in the business ofproducing industrial machinery,you know about these extremedemands: nearly impossibledelivery schedules, increasingquality requirements and lowerprice expectations, to name a few.As you work to meet thesedemands, you face your ownchallenges as well.

In many cases, you’re facingnew competition, forcing youto reduce prices and delivermore value. By now you probablyhave a supply chain that’s spreadthroughout the world, whichhelps reduce costs but brings itsown challenges.You may also haveyour own global design andmanufacturing facilities you needto integrate. And as you strive tomeet these challenges, you muststill be able to respond quickly tonew conditions in local marketswith timely and winning proposalsand quotes.

Digital product developmentmeets the challenge

Digital product development canhelp you meet and excel at allof these challenges. An all-digitalmachinery development processenables you to accelerate theintroduction of new productswhile still promoting innovationand maintaining the flexibilityand speed to react to changingrequirements.Working digitallywithin a managed productdevelopment environment, yourentire development team cancollaborate from a continuouslyup-to-date digital product model.This eliminates a high percentageof development costs that arecurrently wasted, and removesactivities that don’t add value.And,most importantly, digitalproduct development helps youfoster an environment ofcontinuous innovation – anenvironment that consistentlyresults in products and servicesthat clearly differentiate youfrom your competitors.

Siemens PLM Softwareproduction-proven applicationsand process automation toolsgive machinery developerseverything they need to manage,automate and optimize productdevelopment. In the followingpages, we’ll show you how digitalproduct development basedon Siemens’ applications cantransform each step in themachinery development process.

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Knowing where, when and how to competeDigital product development is not just a process that beginswith the CAD modeling of a new machine. Digital productdevelopment encompasses the entire range of developmentactivities, including business planning. By providing a singlesource of product information in a format that makes sense foreach individual user, digital product development optimizesdecision making.

For example, the Executive Dashboard, powered by Teamcenter®

Community software, provides senior management with real-timevisibility into the business information they need.With an instantsnapshot of current operations, managers can see whether criticalworkflows have been executed as planned, whether deliverableshave been met and where the bottlenecks are.They can use thesesame tools to measure the success of completed programs.Did the programs meet cost and delivery schedules? Did theysatisfy requirements for performance, safety, reliability and othercompliance metrics?

Digital product development brings the ability to implementrequirements-driven design, where product requirements flowthrough the product development process and directly influence allproduct development decisions. In many cases, requirements-drivendesign begins with a request for proposal or quote. Let’s look athow this is handled in a digital product development environment.

Faster responses to customer requestsWhen a bid request comes in, it is entered into Teamcenterand forwarded to the appropriate executive.The new request iscolor-coded for immediate attention. Most bids contain multipledocuments such as functional specifications for the new machine,general terms and conditions of the project and sometimes otherinformation such as a CAD file showing site layout.

Using the Executive Dashboard to review current and historicaldata, the executive makes the decision whether or not tofollow up on this RFQ.Then the executive assigns a routingslip (a standard template) to the relevant manager, asking themanager to perform a feasibility study and prepare a responsefor the RFQ.

Once managers log in to their own workspace, they can view thefeasibility analysis as a new task. In the managed developmentenvironment, the necessary information to support this requesthas been automatically routed to the manager, eliminating time thatwould otherwise have been wasted searching for it or waiting forsomeone to collect and send it.This is a major factor supportinglean design initiatives. As a result of these streamlined workflowsand captured knowledge for best practices, the feasibility studyis completed very quickly.The project is ready to move on to thenext step, concept engineering.

“We have a lot of competition, so we always haveto be one step ahead in terms of product development.Our knowledge of customers' needs, combined withthe managed development environment we have withTeamcenterand NX, helps us do that.”

SylvainTalbotDesigner and Teamcenter Implementation LeaderRotobec

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Concept engineering in the managed development environment

The managed development environment keeps the project movingalong and on schedule by ensuring that all necessary informationautomatically travels to the next participant in the process,at this point typically a product engineer. As individual engineersreview this information, they can search the product informationdatabase, where they might find that a similar machine has beenbuilt in the past. Up to this point, it’s possible that the engineerhasn’t even worked in the CAD system. And if the job is simplya matter of configuring the machine to order, with no requiredengineering work, it would be unnecessary to enter the CADsystem at all, thanks to Teamcenter’s digital mockup capabilities.

If the customer’s request requires some conceptual design work,NX® software allows the designer to get started quickly with aplatform engineering approach. Platform engineering works with atemplate containing only the components and geometry that willbecome common to all variations of a machine. It provides an easilyconfigured starting point that is enough for preliminary designinvestigations. Later, this template will also be used to drive thedetailed assembly design.

The platform engineering capability of NXdiffers from mostCAD systems, which encourage designers to dive into detailsat an early stage, linking geometry, adding constraints and drivingmultiple dimensions and variables with little regard for downstreamapplication of the model.With this uncontrolled approach,product-level issues only become apparent relatively late in theprocess when the digital mockup is well populated and changesbecome difficult and costly.

Fast feasibility studiesWith NX, proposed machine layouts are captured in theVisualEditor, which allows the engineer to input different dimensionalinformation and perform “what if” analyses. Once the drivingparameters are entered, the engineer can propagate changes to theentire assembly in a controlled manner. For even greater control,NX can provide visual feedback of the before and after states,so designers can easily determine the impact of any changes.

It could be that certain modules meeting the specificationsand requirements for the new machine already exist in thedatabase. It is easy for the engineer to find and attach them tothe preliminary machine configuration because Teamcenter allowscomponents and modules to be saved and searched based onfunctional requirements and purpose. Also, if the customer’s requestincludes specifications created in a different product developmentsystem, such as an AutoCAD drawing of the proposed machine’slocation in a factory, Siemens’open systems philosophy allows accessto this data, regardless of its source, without the need for costly andrisky data translation.

With the feasibility stages complete, the engineer signs off andapproves the next step in the development of this new machine.It is now time to begin the detailed design.

Sauer-Danfoss, Inc. leverages the NX open applicationprogramming interface – called NX Open – to developcustom applications using many of today's most popularprogramming languages.The result is an environment thatenables virtual product optimization.

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Detailing the designAfter getting off to a rapid start with platform engineering andhaving confidence that the product direction is feasible, the nextstep is detail design. At Siemens, we recognize that in manycompanies product design fuels the entire development effort and,with this in mind, we continue to invest heavily in the ergonomicsof our software to deliver the most intuitive user interface thatcan be used out-of-the-box. But we also make sure that NXhas the flexibility to be tailored to the individual preferencesof each designer.

The NX user interaction model uses dynamic techniques forfeature creation and editing, so designers can concentrate oncreating the geometry they need without being forced to interactwith obtrusive windows and dialogs.Through this approach, NXoffers productivity through ease of use that is typically associatedwith less sophisticated systems, while removing the traditionalbarriers to learning the kinds of advanced functionality thatNX delivers.

A significant advantage of digital product development is theability to establish a managed parts library.This helps ensurethat any component used in a design meetscompany and program requirements.Once components have beenclassified in a partdictionary,

they can be identified and located quickly.This not only eliminatesredundant component design efforts but also accelerates designcycle time and sourcing lead time by re-using preferred parts andexisting supplier relationships. Inventory costs can also be reducedby minimizing part proliferation, lowering inventory levels andeliminating excess and obsolete inventory.

Creating virtual assembliesNX offers proven assembly management tools that makeworking with the large and complex assemblies typical ofmachinery development easy and efficient. For example, a numberof innovative selection and display options make it possible toeliminate clutter and quickly isolate focused design areas.

With virtual assemblies, machine designers can optimize not just thefit, but also the function of moving components. NX offers a fullyscalable solution ranging from simple motion studies withclash and clearance detection to full analysis of mechanisms withjoint considerations, linked to structural analysis for loadingstudies. Because these simulation tools are fully integrated withNX, this motion analysis can be done as part of the design effort,rather than waiting until the design has developed to the point thatengineering changes are costly in terms of both time and money.

Another important part of digital product development is the useof NX DesignLogic, which lets engineers embed design knowledgeand engineering rules into NX models, rather like having a built-

in engineering handbook to monitor, check, advise andvalidate critical engineering features and components ineach design. And, unlike most capabilities with this level ofsophistication, they can do this on the fly, without resortingto custom programming. Once created, these knowledge-

enabled design features can then be made available to theentire development team. DesignLogic allows companies tocapture lessons learned for potential re-use, promoting the useof best practices without placing additional burdens onthe designers.

“In the past it took up to a month to create an assemblydrawing that now takes only one day in NX.”

Daniel NielsenTechnical Designer,Instruction Books DepartmentMAN B&W Diesel

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Simulating and validating the designWith digital product development, it is possible to simulate andvalidate products early in the design process, while the machinestill exists only in software. NX Simulation Process Studio helpscompanies reduce their reliance on expert analysts for commondesign simulation tasks. Once analysts have created templates inSimulation Process Studio, the templates can be easily used by lessexperienced users.Templates are instantly loaded and automaticallyexecuted as stored processes. Designers follow the prompts of awizard-like tool to run the preferred simulation process.

Moving simulation activities into the upfront design process allowsmore concepts to be reviewed, reduces direct costs associatedwith expensive physical prototypes and enables faster, moreinformed decisions.The result is better performing productsand higher margins.

Documenting the designWith digital product development, the task of creating drawingstakes advantage of all the product information that has beencaptured in previous stages. For example, while a machine isbeing designed, NX continually promotes the re-use of anyinformation necessary for manufacturing and downstreamapplications. It does this through the use of advanced toolsfor creating “smart models” that include annotation andproduct characteristics such as material and surfacefinish embedded into the design data. In fact, Siemensleads the development of standards for 3Dmodel annotation.

This product manufacturing information (PMI) streamlinesand simplifies the production of engineering drawings andcan also promote the use of drawingless design processes.

When drawings are necessary, NX facilitates the processthrough the use of drag-and-drop drawing templates, simplified viewcreation, interactive previews and multiple options for displayingthe model. NX drafting tools support all major national andinternational standards for engineering drawings.

Once the views are in place, the designer can extract the productmanufacturing information with a single command.This not onlyreduces the amount of annotation work required but greatlyreduces the potential for errors by improving communicationfrom engineering and design through manufacturing and inspection.

“The implementation of NX, Teamcenter and Tecnomatix™

has resulted in a variety of benefits, including the realizationof a global development environment, greater quality,increased security and the reduction of hassles and errorsrelated to data transfer.”

Toshiaki Sukada, Group ManagerEngineering GroupProduction Systems GroupSI DivisionHitachi Kenki Business Frontier Co., Ltd.

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Options and variantsTo leverage long “service life” from a new machine, many companiescreate options, derivatives and variants from an existing platform.This is a good way to create a cost-effective mix of products andmaximize revenue potential. Digital product development in NXsupports this practice, providing all the functionality needed toquickly develop a series of related products from the same platform.

Throughout digital product development, system-level parametersand intelligent interfaces are established between the varioussystems making up a new machine design.Changes in productconfiguration are simply and easily managed, and interacting partscontinue to fit and function together properly.

Once created, any new options and variants can be saved witha new name and description, making the new platform availablefor other development teams in the future. As the platform andmodule database grows in size and intelligence, it becomes eveneasier for development teams to find and re-use product, processand manufacturing information.

SourcingThe benefits of digital product development extend beyond thecompany to its interactions with its supply chain.The key toeffective communication with suppliers is overcoming thedifferences in development systems and surmounting problems withdata exchange.Truly effective communication includes all necessaryproduct information, not just drawings and model geometry.Thiscan include specifications, proposals, images and other documents.

XpresReview from Siemens PLM Software supports this critical stepin digital product development. XpresReview solves the problem ofhow to share multiple documents in a collaborative environmentusing the concept of packaged collaboration files. Designers create“packages” for suppliers containing items such as: lightweightrepresentations of drawings and models, including all productmanufacturing information; spreadsheets containing specifications;pdf files, image files and so on.

Sending a package file from XpresReview is similar to creating ameeting request in Microsoft Outlook. An email is automaticallygenerated, and the package file is automatically attached to thatemail.The recipient can then use the viewing, measuring andsectioning tools in XpresReview to interrogate the contents ofthe file, add some markup and comments along with additionalfiles if necessary and return the whole package.

The ease and openness of XpresReview allows extendedparticipants (such as sales and marketing organizations, partners,suppliers and customers) to take part in the concept designprocess early and often without incurring the cost or complexityof lengthy review cycles.

“In addition to helping compete in the internationalCNC machine market,NX has helped open the doorfor ANCA to make a move into other areas such asmedical equipment.”

Dave McPhersonEngineering ManagerANCA

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Manufacturing in digital product development

Machining applications are fully integrated in digital productdevelopment, leveraging existing design data for accurate and timelycreation of production tooling and machining toolpaths.There is noneed to translate, transfer or duplicate data and effort, which meansthere is less likelihood of introducing errors.

NX machining applications incorporate highly automated toolpathprogramming techniques that can reduce programming time by upto 90 percent compared to traditional methods. NX also providesfully integrated tools for simulation and validation of the entiremachining process.The solution is scalable from toolpath display,through dynamic material removal, to full machine simulation.

Just as with design components,Teamcenter allows manufacturingorganizations to organize and classify tools, fixtures, processes andother manufacturing information so they can be easily accessed andre-used on multiple different projects. In addition, the combinationof NX with Teamcenter manufacturing applications offers a highly

effective capability for part process planning.The Part Plannerapplication allows the manufacturing engineer to create a processplan defining all steps in the manufacturing process, and to associateand assign resources and to create a variety of reports.Thissolution helps provide overall process direction and management,reduce errors, improve repeatability and increase the effective re-use of proven methods.

Digital product development brings important benefits to bearon the manufacturing process. In addition to leveraging designdata and eliminating data translation and duplication, digital productdevelopment makes it possible for companies to understand theimpact of design changes on manufacturing resources and tooptimize manufacturing resources.

“After a comprehensive benchmark between our twoCAD/CAM/CAE legacy systems,we selected Siemensand its NX software to create a unified developmentenvironment.NX met or exceeded most of ourexpectations. Additionally, the success of Siemenssolutions in the machinery marketplace gave usadditional confidence in our decision.”

Manfred JurkewitzHead, Sheetfed Research and DevelopmentHeidelberger Druckmaschinen AG

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Transforming product development

Digital product development transforms every step of industrialmachinery development by providing a unified solution that coversthe entire process, from responding to a proposal, through designand manufacturing of the machine, to leveraging the platform forother uses. Digital product development is built on five keyelements of NX:

Unified product development solution. Seamless integrationof NX applications rapidly propagates changes of product andprocess information, replacing point solutions with a unifieddevelopment system, from concept to manufacturing, ensuringthat design changes are accurately reflected in everydownstream process.

The managed development environment. NX solutionsinclude fully integrated, synchronized management of all productdata and process knowledge to transform product developmentwith a structured collaborative environment.This enables companiesto increase the re-use of product data and supportslean processes by eliminating duplicate effort.

Knowledge-driven automation.With NX, companies canapply product and process knowledge across all elements ofproduct development to automate processes and maximizere-use, streamlining the product development process.

Simulation, validation and optimization. Comprehensivesimulation and validation tools in NX automatically checkperformance and manufacturability at every step of thedevelopment process for closed-loop, continuous,repeatable validation.

System-level engineering. NX-structured conceptual modelsstandardize design practices and allow rapid creation of variants,transforming development from component-based design to asystems engineering approach.

Siemens in the machinery marketSiemens PLM Software has been transforming product developmentprocesses for machinery companies worldwide for more than5 years.We have more than 18,000 customers who design andmanufacture industrial machinery and more than 15,000 engineeringusers working in this industry.

There are significant installations of Siemens software in everycategory of the machinery market, including custom/specialequipment, commercial equipment, heavy industry and so on.Companies in these industries rely on digital productdevelopment to help them compete.

“We have a lot of competition so we always have to be onestep ahead in terms of product development,” says Sylvain Talbot,lead designer at Rotobec, a manufacturer of continuous rotationforestry attachments (grapples) based in Quebec.“Our knowledgeof customers’ needs, combined with the managed developmentenvironment we have with Teamcenter and NX, helps us do that.”

“NC programming is now a captured, repeatable processinstead of the ‘black art’ it was in the past.We are nowissuing NC programs, first time as proved,which require nofurther engineering support.”

Gordon LanesPrincipal Manufacturing EngineerRotor GroupDemag Delaval IndustrialTurbomachinery Ltd.

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Business challenges resolved

With digital product development, industrial machinerymanufacturers have a comprehensive solution to the businesschallenges they face.

Globalization and global development. Managed developmentenvironments allow fast access to widely divergent types of productand process knowledge generated by otherwise incompatibleapplications and ensure up-to-date information flows on time tousers in all areas of a business.

The bidding/RFx process. Knowledge-rich templates automatethe bidding process for faster and more accurate response.Thesetemplates manage the entire development process and improveunderstanding of resources, costs and profitability.The modularapproach drives fast and accurate configuration of alternatives.

Modularization, standardization and re-use. A systems-based approach structures complex assembly design projects intofunctionally self-contained modules that can plug and play. Manageddevelopment environments make it easy for developers to findand re-use product, process, manufacturing and service informationand re-use assets across multiple take-to-market programs.

Optimized or “lean” development. A unified developmentsolution streamlines processes from concept to manufacturingand serviceability. It also helps companies avoid delays and errorsthat result from data re-creation; by removing collaborationbarriers, it facilitates more effective data sharing.With a unifieddevelopment solution, it is possible to re-use designs acrossproduct platforms and automatically communicate changes todownstream processes.

Product quality and conformance. Requirements-drivendesign transforms product requirements into quantifiableconstraints that are monitored and validated throughout theentire development process.

Aftermarket business opportunities. Platform engineeringand modularization allows rapid delivery of product enhancements,derivatives, niche offerings and add-ons. Managed developmentenvironments provide on-demand information for teams thatmaintain, repair and overhaul machines in service.

Supplier integration. An open systems philosophy enablesbetter communication and collaboration in the supply chain andunites disjointed partners around product information. It enablesearly supply chain participation in the product development process.

Cost of ownership for new technologies. Scalable solutionspermit a company to begin by addressing a specific issue or areaof the product lifecycle and build upon that foundation. Opensystems maximize the value of current information and technologyinvestments. Prepackaged solutions consolidate and integratedisparate systems and limit implementation costs and risks.

Throughout its broad product applicationsuite, NX leverages key attributes that helpmachinery companies achieve business objectivesof waste reduction, quality improvement, shortercycle times and greater product innovation.These unique attributes directly support businessprocess initiatives aimed at transformingproduct development:

Unified product development solutionSeamless integration of NX applications rapidlypropagates changes of product and processinformation, replacing point solutions with aunified development system, from conceptto manufacturing.

Managed development environmentNX solutions include fully integrated, synchronizedmanagement of all product data and processknowledge to transform product developmentwith a structured collaborative environment.

Knowledge-driven automationWith NX, companies can apply product andprocess knowledge across all elements ofproduct development to automate processesand maximize re-use.

Simulation, validation and optimizationComprehensive simulation and validation toolsin NX automatically check performance andmanufacturability at every step of the developmentprocess for closed-loop, continuous, repeatablevalidation.

System-level engineeringNX-structured conceptual models standardizedesign practices and allow rapid creation of variants,transforming development from component-baseddesign to a systems engineering approach.

The NX advantage

© 2007. Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. Teamcenter, NX, Solid Edge,Tecnomatix,Parasolid, Femap, I-deas, JT, UGSVelocity Series, Geolus and the Signs of Innovation trade dress are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc.or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.

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About Siemens PLM SoftwareSiemens PLM Software, a division ofSiemens Automation and Drives (A&D),is a leading global provider of productlifecycle management (PLM) softwareand services with 4.3 million licensedseats and 47,000 customers worldwide.Headquartered in Plano,Texas, SiemensPLM Software’s open enterprise solutionsenable a world where organizations andtheir partners collaborate through GlobalInnovation Networks to deliver world-classproducts and services. For more informationon Siemens PLM Software products andservices, visit www.siemens.com/plm.

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