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Product Development with SAP in the Automotive Industry
Learn everything you need to know about the three cornerstones of product development: project management, product data management, and product validation. A detailed introduction to each of these key areas provides you with a foundation that enables you to master product development quickly and effectively. Readers discover cross-company project management
using SAP Projects System and cProjects. Learn how integrated product and process engineering supports you while documenting complex products with many variants, and much more. In addition, special attention is given to product validation using SAP. Everything in this unique reference book is described from the viewpoint of the manufacturer as well as the supplier.
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
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