9175-Dassault WEST VE - Atthis

ONERA: From virtual to real wind tunnel

4D PLM for Hydrocarbon Industry

Don Foster Technologies:Rallye-raid in 3D

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ContactT h e V 5 P L M M a g a z i n e

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V5 PLM Solutions, a RevolutionaryAdvance for Collaboration

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DASSAULT SYSTEMESVentes Indirectes - 368 Bureaux de la Colline

Bâtiment E - 7ème étage - F-92213 SAINT-CLOUD CedexTel: +33(0)1 40 99 35 05 - Fax: +33(0)1 40 99 33 62

e-mail: [email protected]

For Belgium

V 5 PLM solutions drive industrial collaboration in response to the chal-lenges of globalisation and innovation.

For some time now, multinationals have beenagain turning their attention to their principalareas of expertise where they have developeda high level of excellence and competitiveness.

The aim of industrial OEMs in all fields is to assemble and unite a col-laborative network within a short time to create new products at rea-sonable prices. But how does one put in place such a networkwithout incurring resultant structural costs?

Dassault Systèmes offers a V5 PLM virtual platform that will enableall actors to collaborate efficiently on projects from their home sites.The prime manufacturer and his partners are thus able to share dataand take quick decisions when developing new products. Thesenew methods of collaborative working ensure significant gains for our clients.

Collaborative work is of critical importance for small and mediumscale companies and industries which have now become moredynamic following acquisitions and the relocation of productionactivities. Dassault Systèmes offers them easy-to-implement V5 PLM packaged solutions that help increase productivity throughout product lifecycle with due regard for quality requirements.

Thanks to the Web, communication between personnel working in the research and design wings is now possible anddesigners can now ‘chat’ in real time about their models andassemblies and improve on innovation. The reader will findconcrete examples of the significant gains in collaboration and innovation that is a consequence of such modern communication methods throughout this issue. We wish youhappy reading…

International

in practice• ONERA: From the Virtual to the Real Mockup• Don Foster Technologies: How to Sell a 4x4 Rally-Raid

Industrial Project on a Computer Screen in 3D…• A Complete PLM Industrial Course • CADeSIS by François Henot, CEO CADeSIS

Editorial4

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Contact magThe V5 PLM Magazine published by Dassault Systèmes - 9 quai Marcel Dassault - 92150 Suresnes - France • Publication Executive: Denis Senpéré• Chief Editor: Gilles Kircher • Editorial Board: Céline Pérès, Carole Genolhac, Philippe Bonnard, Mike Crow, Frédéric Lefebvre, Achim Loehr, Laurent Valroff,Maryla Bachmann, Steffi Dondit, Jean-Marc Galea, Dmitry Isaev, David Treacher • Photo credits: Dassault Systèmes’customers and partners • Design and Production: Images et Formes • Printed in France - “ISSN applied for”

3Contact mag | n°2

nEWS• PLM Forum in Russia• PLM Forum in China• Software Partner: LMS

Solution spotlight• 4D PLM for Hydrocarbon Performances

feature• ‘PLM Solutions, a Revolutionary Advance for

Collaboration’• Collaboration for Complex Industrial Programs• Dassault Aviation and its World Partners

are Collaborating in Real Time on the Falcon 7X• Latécoère Optimises its Collaborative Environment

with the Help of CATIA V5 and ENOVIA V5• Boeing 787: Global Collaborative Environment

with Dassault Systèmes• GCT has Entered into the Collaboration Programme

of the Boeing 787• Airbus Optimises its Collaborative Environment

with the PLM Solutions of Dassault Systèmes• Air France Industries Gets Permission to Take off!

brand spotlight• SIMULIA: Inventing the Future for Realistic Simulation• PLM V5R16: Empowering your Innovation Network• CATIA V5: Improved Collaborative Design• DELMIA: Making Shipbuilding Fast and Simple!

LAURENT COUILLARD

Director, Channel PLM North Europe

Dassault Systèmes]

news

Software PartnerLive From our PLM Forums…

With the introduction of LMS Virtual.Lab in November 2001,LMS was the first CAA V5* Gold Software partner to delivera complete solution for virtual simulation that was entirely

based on the CAA V5 architecture. With the recently introduced LMSVirtual.Lab Designer, LMS now provides the same core set of LMSVirtual.Lab simulation capabilities as a fully embedded solution in CATIAV5. It enables CATIA users to efficiently perform simulation tasks by verifying the static and dynamic strength of their design, its system dynamics, acoustic behavior and fatigue-life performance, all from withinone single CATIA V5 session. “This solution eliminates time-consumingdata transfers and translations”, states Willy Bakkers, Executive Vice-President and General Manager of the LMS CAE Division, “it guarantees a full association between the CAD design and the simulationprocesses, and accelerates the analysis of multiple design options”.*CAA V5 = Component Application Architecture V5

For more information: www.3ds.com/alliances

By Dora Lainé]

How do you guarantee that a mechanical designperforms as expected, before signing it off toprototype testing? How do you ensure thatcomponents are fail-safe, but not over-designed?How can you optimize the acoustic performance ofyour products from the early design stagesonwards?

• Meet Dassault Systèmes, ESI and Magestic • Program and registration: www.jeccomposites.com/jec-show• JEC Composites Show is the world leading composite event

JEC Composites 2006 - March 28-30

• Meet Dassault Systèmes and partners at the Digital Factory • More information: www.dsag.delmia.de• The world’s leading technology event with more than 6 000 exhibitors from 60 countries

Hannover Messe 2006 – April 24 -28Location: Hannover (Germany) - Hall 16, Stand F21

Mark your calendar!Location: Paris Expo Porte de Versailles - Hall 1, Stand C39

5Contact mag | n°24 Contact mag | Dassault Systèmes

The PLM forum in Russia, one of the topthree PLM events organized byDassault Systèmes in Europe and CIS,

took place on October 27 in Moscow. Over 500people attended the one-day conference inau-gurated by Laurent Valroff, Director of DassaultSystèmes Russia. Founded in 2005, this latestaddition to the Dassault Systèmes ecosystemwill provide marketing, sales and technical support to business partners distributing PLMsolutions in Russia and CIS countries. Its goal isto strengthen collaboration between domesticand worldwide industries, to help develop inno-vation and to adapt the V5 PLM solutions to theRussian market by translating software anddocumentation.

Executives and leading technical specialistsfrom Russian companies in industry sectorssuch as energy and transportation, automotive,agricultural machinery, shipbuilding and aero-space participated in the forum. It was an oppor-tunity to show participants that the V5 PLMsolutions help companies reduce their designand production costs. From a business pers-pective, several major new PLM projects werediscussed with companies involved in all typesof industries, most of them in the Fabrication andAssembly sector.The technical fair was an opportunity for customers to meet with representatives of

participant companies, such as IBM, MSC.Software, Microsoft, Intel, Transcat PLM,LMS, Abaqus and TeSIS as well as with thethree local PLM Business Partners Bee Pitron,Hetnet and Mebius.

Dassault Systèmes executives presented thePLM strategy and the V5 PLM solution updatesthat contribute to achieving this strategy.Customers including Boeing, Bobst, JSC“Arsenal” and “TransElectroPribor” made presentations dedicated to the way they usePLM solutions in their companies.

“The objective of the PLM Forum was to presentthe three key factors of PLM - design, manufac-turing and collaboration and to demonstrateDassault Systèmes’ commitment to the Russianmarket,” said Francis Bernard, Founder andPresident Advisor of Dassault Systèmes.

… in Russia … in China

This year’s Product LifecycleManagement (PLM) China forum,based on the theme “Partnering for

Innovation” took place on October 20 & 21,2005. Over 500 people participated in thisyear’s edition, 30% more than last year. Theobjectives of this year’s forum were to enableparticipants to share their knowledge andexperiences, obtain the latest information on Dassault Systèmes PLM solutions and strategy, and elaborate on the PLM distribution model in China. The forum was amajor success for recently created DassaultSystèmes China founded in April 2004 andlocated in Beijing.

The Press was largely represented with over13 reporters covering the event and highligh-ted by interviews of key Dassault Systèmes executives. Philippe Forestier, Executive VicePresident Dassault Systèmes spoke of theinnovative passion driving Dassault Systèmesproduct development strategy and how this passion has inspired customers whoimplement our PLM solutions, helping themimprove their innovation capacity, efficiencyand product and process quality. “To increasethe value of PLM, Dassault Systèmes hasestablished relationships with partners that provide technology, training, products basedon the V5 open platform and services to customers around the world. We call this thePLM Ecosystem”, said Philippe Forestier. Heillustrated this by announcing a new strategic

alliance with CAXA in China, for the creation anddelivery of 2D design packages based on V5 PLMtechnology.

Christian Nardin, Dassault Systèmes APManaging Director spoke with DESIGN NEWSChina about the importance of using 3D techno-logy in order to fully benefit from true PLM.“Through our partner-ship with CAXA inChina we will helpcompanies that todayessentially use 2D designtechnology to planPLM layout in 2D toincrease the efficiencyof their manufacturingprocesses and thenprogressively accompany them to full 3D so thatthey can implement digital mock ups, interference and motion analyses as well as simulation”, saidMr. Nardin.

Partner turnout was double that of previous years with over 20 partners participating in the Technifair. They expressed their satisfaction withthe high customer turnout and confirmed theirintention to attend next year’s forum as well.

Customer testimonials drew great interest fromparticipants with 13 customers from industriessuch as automotive, AVIA, mold & die, shipbuil-ding, E&E providing testimonials on their use ofPLM solutions.

Dassault Systèmes’ CAA V5 DEVCON 2006 - June 27-28Location: CNIT La Défense / Paris

• Registration details and complete agenda: www.3ds.com/devcon• The DEVCON is the unique event for partners and customers, to receive latest information on V5 PLM

strategy and developments, gain technical insights and examples of practical application on CAA V5, discover new ways to grow your business, meet people and enhance your network.

7Contact mag | n°2

V5 PLM Solutions for theHydrocarbon industries

integrate safety, maintainabilityand environmental factors into

engineering design avoidingcostly last minute on site

changes during construction. The 4D approach of integrating

simulation directly into thegeometry helps improve the

maintenance process, reduceplant shutdown time and safely

train plant operators.

Dassault Systèmes’ solutions are apowerful offering for the hydrocarbonsindustry where safety, maintainability

and environmental concerns are of capitalimportance for refineries and gathering stations.V5 PLM integrate HSE (Health, Safety,Environment), maintenance and operationconstraints directly into the design process.Before, these constraints were usually takeninto account during plant construction forcingcompanies to make last minute or on-site struc-tural changes. V5 PLM solutions offer compa-nies a way to deliver a plant in operatingcondition faster and promote efficient costsaving solutions across the board.

In new plants, the existing 3D models containonly structural information. The V5 PLM offeringis a complementary solution to the one alreadyin place, from the end of the design phase all the

way to the operating and maintenance phase.The 4D approach, that of integrating the dimen-sion of simulation, is unique on the markettoday. Being able to simulate maintenance activities and HSE leaks propagation in theengineering phase helps companies anticipatepotential problems very early on and allowsengineers to correct their designs and imple-mentation, thus saving time and money duringplant construction.

OPTIMIZED SHUTDOWN PLANNINGAND OPERATOR TRAININGFor existing plants, designs usually exist as 2D drawings or process and instrumentationdiagrams. CATIA V5 makes it possible torecreate a 3D model and DELMIA V5 enablessimulation integration. Once the results are analyzed, the real maintenance process can be optimized and stored in the 3D model. That allows companies to save millions of dollars a day since plant shutdown time isconsiderably reduced.

Operator training is also a key consideration forplant owners. How do companies safely traintheir operators to deal with hazardous situa-tions? The answer is to virtually create problemsituations by simulating them in 3D with DELMIA Automation and teach them whatsteps to take to remedy the problem. V5 PLM solutions also provide the hydrocar-bons industry with a way to optimize day-to-dayoperations by increasing maintenance effi-ciency and operator knowledge. V5 PLM solu-tions help companies comply with safety

A V5 PLM reference:Sevan MarineSevan Marine is located in Norway andis specialized in a new type of FloatingProduction, Storage and Offloading(FPSO) units for offshore oil produc-tion, named SPP (Sevan StabilizedPlatform). Thanks to CATIA V5 andENOVIA V5, they reduce conceptualdesign time by up to 70 percent andwill collaborate seamlessly with sub-contractors, regulators, manufacturersand their clients to deliver innovativeplatforms on time and on budget.

4D PLM for Hydrocarbon Performances

solution spotlight

For more information contact: [email protected]

For more information contact: [email protected]

regulations, a prerequisite for obtaining a plantconformity certificate or a license to operate •)

By Marc Prido]


T his referential, this rich language is theDigital Mock Up (DMU) that makes itpossible to define most complex parts,

assemblies and routed systems, to classify allcomponents by discipline and to manufacturethem according to adapted technological processes. DMU increases the precision of the virtualassembly and facilitates evolution and configu-ration management.It even goes further by helping anticipate the structural behavior of the aircraft, its aerodynamics prior to wind tunnel testing, producing early ergonomics and maintainabilitystudies and automatically creating technicalpublications and shop floor instructions. DMUhas become the main way to monitor decisionsthroughout an aircraft program.

The way OEMs and Suppliers are all workingtogether is changing. Each stakeholder haseasy access to necessary and sufficient up-to-date data to perform his or her mission, thereby taking into account everybody’s work.The “design in context” is a major breakthroughin engineering practices.It is to extend the benefits of these new indus-

trial practices to all “Risk Sharing Partners” that the “Physical Platform” and the “VirtualPlatform” have been set-up. The fact that 60 to 70% of the aircraft value is designed andmanufactured by the cooperants has greatlycontributed to this transformation.

The Dassault Systèmes’ V5 PLM solutionsenable the deployment of such new practicesand are delivered through an integrated set ofservices to assist the customer and to ensure ahigh level of collaboration, while maintaining anadequate level of security for intellectual property.

This approach is today in place in major aircraftprograms. Both physical and virtual co-locationdramatically increases the efficiency of eachpartner’s contribution throughout the program.

It is no more a dream but the beginning of a newera with other evolutions to come, including the support of global systems engineering and digital manufacturing •)

Contact Mag: Why is the AerospaceIndustry based on cooperation?S. Albernhe: The Aerospace market is shared between a finite number of majorplayers who have acquired, over the years,the know-how and critical mass to build complex machines, such as airplanes.

Stringent technical, economic and environ-mental constraints make it extremely difficultfor any one company to support the strainand cost of an entire airplane alone. Designand production cycle times have to be shortened to remain competitive.

Thus, it is essential to go through a technolo-gical revolution in the way people work and

the way they think. As a result, major OEMsenter into a new mode of cooperation withhighly skilled suppliers. They ask them for bigger and more complex systems. Thisapproach requires more integrated cooperationin which first level suppliers take on the role of integrators of complex systems, and areknown as Major System Suppliers.

Today, cooperation has gone to furtherheights since the Major System Suppliers areexpected to be Risk Sharing Partners. Theynow share part of the financial risks associatedto an aircraft program and to participate in theearliest stages of the concept/system thusinfluencing the technical solutions adopted ina program.

Contact Mag: In what ways do PLMsolutions contribute to the collaborativeworking mode?S. A.: PLM solutions are instrumental in a physical platform because they help peopleshare information by ensuring that everyone hasaccess to the same up to date models anddata. In the case of a virtual platform, PLM solutions are even more important to make collaborative work efficient by allowing peopleto work together seamlessly on the same project, no matter where they are in the world.

Dassault Systèmes foresaw, very early on,the importance of allowing people to work ina collaborative way and developed the toolsthat would make it happen. What is unique and innovative with PLM solutions is that by virtually simulating downs-tream processes as early as during theconcept design phase, they make it possiblefor companies to make the right choices veryearly on in the process thus saving themconsiderable amounts of time.

This is an amazing technological breakthroughwhich helps companies reduce costs/cyclelead times and increase flexibility/reactivity. I believe the industry is just beginning to takefull measure of the impact this technology willhave on the way people develop products andI am convinced it will provoke major changesin the working principles and organizations indevelopment activities •)

feature

Optimizing collaboration for complex industrial programs is not a basicIT infrastructure issue, it is all about ‘Sharing’: sharing a rich designlanguage as well as industrial processes and a global PLM referentialwith the supply chain.

Optimize Collaboration for Complex Industrial Programs

Supplier with Data replication from OEM PLM environment

Supplier

Supplier

Supplier

Supplier

OEM

Extract/reconcileEngineering Packages

Supplier with connection to OEM PLM environment

for package Download/upload

Supplier with noconnection to OEM PLM environment

Supplier Hosted at OEM site

Supplier with direct connection to OEM PLM environment

For more information contact:[email protected]

Pre-Project - General Design1

Detailed Design2

Integration3

By Dora Lainé]By Bruno Puechoultres]

1/ Physical Platform: partners work together in the same location

2/ Virtual Platform: partners work together from their respective offices

3/ Physical Platform: partners regroup in the same location

Stephane Albernhe is a Senior Partner at RolandBerger Strategy Consultants in Paris, a worldwideleading strategy consulting firm. He is responsible forthe global Aerospace & Defense Competence Center.Contact Mag asked him about the need and value of optimizing the way aircraft manufacturers work in collaboration with their cooperants and suppliers.

Contact Mag: How do OEMs and MajorSystem Suppliers manage the risksgenerated by this new collaborative working mode?S. A.: To minimize the financial risks taken by OEMs and Major System Suppliers, thecollaborations must be optimized to thehighest possible level throughout the entirevalue chain. To achieve this they try to locateteams more and more on what we could callcollaborative working platforms. A platform isan entity that brings together the expertiseand know-how needed to do a specific job,either physically or virtually.

During the initial phase of the developmentprocess, it is necessary for required expertsto be physically present on the same plat-form. This is true for upstream applicationssuch as concept/system design.

After everyone agrees on what needs to bedone they can all return to their own offices or companies, in the case of subcontractors,to work on the Work Package they are responsible for. The platform then becomes virtual since people are no longer physicallylocated in the same place (as illustrated in the diagram below). Finally, when all actors have finished theirpart, they regroup once again on a physical platform where they make sure that everything that was supposed to fit togetherdoes so with no problem.

Interview of Stéphane Albernhe

‘PLM Solutions, a Revolutionary Advance for Collaboration


feature

Aerospace pioneer Dassault Aviation made history in 2002 by creating the world’s first virtual development platform basedDassault Systèmes V5 PLM solutions. By enabling its worldwidepartners to collaborate in real-time on the next-generation Falcon 7Xbusiness jet, the company has today made dramatic gains inproductivity. Today, 30 aircraft are already in production, and 70 have been ordered – an exceptional endorsement consideringthat the Falcon 7X will not be certified before the end of 2006.

COLLABORATING WITH PARTNERS- A GLOBAL CHALLENGETo maintain its lead in the highly aggressive exe-cutive jet market, Dassault Aviation mustconstantly innovate, and optimize its businessprocesses and operations. For the companytoday, this means developing its aircraft inconcert with a group of risk-sharing partnersscattered across the globe.

V5 PLM FOR A VIRTUAL PLATFORMTo optimize development of its new Falcon7X business jet, Dassault Aviation choseDassault Systèmes’ V5 PLM solutions tocreate the world’s first virtual developmentplatform. The goal of the virtual platform was to enable Dassault Aviation and its 27

partners in Europe, the USA, and Canada to concurrently design the Falcon 7X fromtheir home sites.The virtual platform is based on CATIA V4and V5 for product definition and digitalassembly, ENOVIA VPM for real-time sharingof the digital mock-up, and DELMIA for definition of maintenance operations.

In September 2002, Dassault Aviation linked itspartners through a single, virtual collaborativeworkspace in which they shared a common,configured, constantly-updated digital mock-up of the Falcon 7X.

DRAMATIC GAINSBy defining the parts and structure of the Falcon 7X digitally with its partners via the virtualplatform, Dassault Aviation dramatically reducedthe assembly time of the aircraft. “Previously, anassembly used to take us 16 months. For thefirst Falcon 7X, it took us only seven months,”said Jean-Claude Hironde, deputy senior vice-president, Research, Design and Engineering.

Through the virtual platform, Dassault Aviation’srisk-sharing partners were able to share andrefine the detailed design of their sections incontext of the Falcon 7X. This upstream co-development set the stage for a flawlessassembly. “We have eliminated assembly pro-blems by 100%,” said Hironde.

In addition, the digital mock-up configured withENOVIA is so precise that Dassault Aviation wasable to cut out the step of building a physicalprototype and to reduce tooling costs by two tothree times.

THE FUTURE WITH V5 PLMDassault Aviation is continuing to enhance its useof PLM by migrating from ENOVIA VPM toENOVIA V5. The company also plans to extenduse of the virtual platform to other projects suchas the Unmanned Combat Air Vehicle (UCAV) •)

About Dassault AviationFounded in 1936, Dassault Aviation Group isa world leader in the executive and militaryaircraft markets with business jets from itsFalcon series, and fighter jets such as theMirage and Rafale. www.dassault-aviation.com

Dassault Aviation and its WorldPartners are Collaborating in RealTime on the Falcon 7X By Michael Marshall]


Since 2003, Latécoère has been using a collaborative work environment with the help of CATIA and ENOVIA solutions to deal with client programmes.

Latécoère Optimises its Collaborative Environment with theHelp of CATIA V5 and ENOVIA V5

By Céline Pérès]

Atop-ranking partner of aircraft manufacturers such as Airbus,Boeing, Dassault Aviation, Embraer

and Bombardier, the Latécoère group alsohelps finance developmental phases of majorinternational aeronautical programmes.

Dassault Aviation’s partner in areas such asaerostructure and wiring, Latécoère investedin the technical development of the virtualplatform of the Falcon 7X programme in 2003.Since 2004, Latécoère has also been partici-pating in the 787 programme for which it has adopted the CATIA V5, ENOVIA V5 andDELMIA V5 software solutions and Boeing’sGCE (Global Collaborative Environment).

Partnering major aero-nautical manufacturersLatécoère strengthens its positions in two areas: - Aerostructures (70 % of turnover): fuselage sections and aircraft doors,

- Onboard wiring and systems (30 % of turnover): wiring, avionics bays and onboard systems

Site web: www.latecoere.fr


Developing the Falcon 7X virtual plateauInterview of Daniel Campistron, Program Director at Latécoère“This is a world first in collaborative work in the aviation industry. Thanks to the virtual plateau, a very powerful tool developed by Dassault Aviation using Dassault Systèmes’PLM solutions, the upstream preliminary design phase can be extended while retaining thesame interactivity between the different players. Despite the high degree of complexity and integration of the whole project, resulting in some major adjustments during the implementation phase in spring 2003, the Falcon 7X virtual plateau is now operational. It represents a true “democratization” of the digital mockup on a global scale, since thepartners of Dassault Aviation are located on several continents. Also, the resulting processoptimization meets the ever-tightening demands being imposed on the global aviation market by the prime contractors, particularly in terms of design lead times.”

Recently, Latécoère began implementing internalcollaborative solutions to better adapt to specific environments of its prime manufacturersand optimize its collaboration with contractors.As an initial step, Dassault Systèmes has finetuned its packaged solutions (that includespecial methods and preparametered servers)to help Latécoère accelerate its implementationof the ENOVIA V5 solution and manage theAirbus A400M project-related data. Latécoère’s desire to create a special collabo-rative environment is part of its strategy adopted in 2003. The project, named TOSCAcovers several departments (Research and Design Wing, Procurement, TechnicalDocumentation, Quality Control, Manufacture)

and integrates various IT tools (CAD, VPDM,ERP, EDM and the Manufacturing ProcessOperations) •)

For more information:www.gct.aero & www.garner.de

12 Contact mag | Dassault Systèmes 13Contact mag | n°2

feature

12 Contact mag | Dassault Systèmes

DIGITAL MODELING ON A GLOBAL SCALE“We broke new ground with the 777 for digital mockup and 3D presentation, but withthe 787 Program, we are going much furtherin terms of the digital technologies used andthe business model used to deploy themthroughout the Boeing Supply Chain.” saysMarcelo Lemos, president of Dassault

GCT focused early on building up thenecessary infrastructure and compe-tence required for the Boeing 787

GCE. Whether on-site at Boeing facilities or inthe GCT German office just outside Munich,GCT engineers are accessing the same 787product data through the Internet using theDassault Systèmes’ PLM Connector software.In line with the overall 787 Program goals, a keyelement in achieving Concurrent Design and inreducing lead-time for product development is the use of Relational Design where theCATIA/ENOVIA V5 parametric linking capabilitiesplay a vital role together with clearly defined design methodologies.

S ince its inception, Airbus has worked toharmonise its industrial processes,methods and tools. This policy covers

not only all Airbus sites but includes as far as possible the contracting network as well. Airbus’collaboration with its contractors has become all the more important now that the latter have become full-fledged industrial risk-sharing partners who are gradually being integrated into the Airbus environment.

The need to harmonise solutions, offer collabo-rative environments to all its engineers and pro-vide state-of-the-art technologies have led Airbusto gradually deploy the Dassault Systèmes solutions with CATIA V5, DELMIA and ENOVIA

VPM solutions. The collaborative work environ-ment is gradually extended to cover all Airbussites, notably in order to develop the A400M military transport airplane and the future A350.

The entire designing and manufacturing lifecycleshall benefit from increased data security and coherence, a simplified work environmentand improved tool integration •)

Systèmes of America. “We're moving beyondthe digital modeling of static parts and geometry; we are now addressing the behavior of the plane throughout its lifecycle,including its operations and maintenance.”Moving from part modeling to behavior modeling means that Boeing must rely on amuch more comprehensive set of designtools. In addition to CATIA V5, the projectteam employs a full suite of DassaultSystèmes PLM software including ENOVIA for lifecycle applications, DELMIA for digitalmanufacturing, and SMARTEAM for collaborative product data and lifecyclemanagement.But a digital project of this scale needs morethan just an adjustment in the suite of designtools used. Dassault Systèmes has also supported Boeing in revolutionizing the way it works with its partners and suppliers.Instead of some 10,000 items being assembled by Boeing for the 777, Boeing willassemble only 13 to 17 units. Many of thesesubassemblies will be wholly designed bypartners in various parts of the world. To address the challenges of bringing together such a diverse team of designers

and manufacturers, Boeing and Dassault Systèmes have created the GCE (GlobalCollaborative Environment) and set up aworldwide deployment project. ThroughGCE, all partners use the same set of PLMtools from Dassault Systèmes, and all of theappropriate design data reside in GCE

SHARING AND PROTECTING VITALKNOWLEDGE AND DATAIn the past, collaboration of this magnitudeoften snagged on the same hurdle: the needto share data in a central repository withoutcompromising proprietary design methodsand processes.Making that kind of decision for the manypartners involved has become easier thanksto Dassault Systèmes' role in the project. Inaddition to the suite of advanced PLM toolsbased on role-based configurations, DassaultSystèmes also brings training and support to all the partner’s design engineers. Thisensures that all the partners are given accessto the most appropriate design methods andprocesses based on the most up-to-datetools, with a very pragmatic and operationalskill ramp-up mechanism •)

Boeing and Dassault Systèmesare partnering on the next-generation aircraft project, the 787. The associated GlobalCollaborative Environment isforging new frontiers in the use of PLM technologies.

GCT is the first European Engineering Service Companywhich has successfully implemented the Dassault Systèmes’

CATIA V5 and ENOVIA V5 software suite specific to theBoeing 787 Global Collaborative Environment (GCE).

Over the past several years,companies such as Aerospatiale, BAE,

DASA, CASA and today Airbus(which was created from their

merger) have been deploying the most cutting-edge CFAO and

PLM solutions to respond to the challenge thrown up by technological

advances in sectors ranging fromelectronic designing to integrated

digital models. These solutionsenabled Airbus design magnificent

aircrafts such as the recent A380and the next-generation A350.

Boeing 787: Global Collaborative Environment with Dassault Systèmes

GCT has Entered into the Collaboration Programme

of the Boeing 787

Airbus Optimises its Collaborative Environment with the PLM Solutions of Dassault Systèmes By Pierre Villa]

More about AirbusAirbus is one of the world's leading aircraftmanufacturers, and it consistently capturesapproximately half or more of all orders forairliners with more than 100 seats. Airbus isan EADS joint company with BAE Systems.

More about Garner CAD TechnicGCTis an EASA 21J certified worldwideorganisation rendering engineering designservices to major aerospace customers allover the world. GCTis one of only ten transnational suppliers to Airbus Industries,engaged in all Airbus programs, fromconception to sustaining engineering.

in Dassault Systèmes’ softwares and servicesfor the GCE in the upcoming months •)

“GCT has gained extensive experience inusing CATIA V5 parametric capabilities duringthe last four years on various projects doneexclusively in CATIA V5. We were able toapply this experience directly to the 787Program, both for structure design work andfor the design of the 787 Hydraulic, Fuel andother Tubing Systems together with GCT’sstrategic partner PFW.” quotes Nigel Garner,Managing Director of GCT. To deal with theirinternal Product Data Management (PDM)needs, GCT has also selected and is currentlyimplementing the SMARTEAM Ready To GoSoftware. As GCT continues to ramp up for the787 design work, they will keep on investing

More about the Boeing787 DreamlinerThe Boeing 787 Dreamliner is a super-efficient airplane with new passenger-pleasing features. It will bring the economics of large jet transports to the middle of the market, using 20 percent lessfuel than any other airplane of its size.


brand spotlightFeature

T o alleviate this challenge, DassaultSystèmes (DS) developed simulationsolutions that enable engineering

teams to test real-world product performancein a virtual world. As simulation reduced theneed for physical testing, DS strove to acquireand develop leading technologies, integraterealistic simulation across multiple simulationdomains, make simulation more accessible toapplications beyond existing manufacturingmarkets and deliver a unified simulation plat-form for scientific applications.

THE ABAQUS ADVANTAGEIn 2005, DS acquired ABAQUS, Inc, developerof the world’s most-respected Finite ElementAnalysis (FEA) solutions for linear, non-linear,explicit and multi-body dynamics applications.ABAQUS’s strategy for Unified FEA fits naturallywith the DS strategy of meeting customers’requirements to consolidate the number of ana-lysis products they use. BMW recently adoptedABAQUS for crashworthiness thus demonstra-ting the range of simulation problems that userscan tackle using a unified FEA system.Another example is Boeing’s choice of ABAQUSto support the Virtual Crack Closure Technique

(VCCT), an advanced simulation method foranalyzing composites for the 787 Dreamliner.

SIMULIA – INVENTING THE FUTUREThe acquisition of ABAQUS led to the crea-tion of SIMULIA, DS’s new brand for coveringall DS simulation solutions, including formerCATIA Analysis applications. The next step isto leverage the V5 architecture to create anopen platform for multi-physics simulationthat can be used, not only by traditionalmanufacturers in automotive, aerospace,general machinery, and consumer products,but also by industries in areas such as biome-dical, electronics, geophysics, pharmaceuti-cals, and molecular sciences.

DS is rapidly developing the SIMULIA archi-tecture and data model to strengthen currentsimulation capabilities, improve performanceand ensure an open simulation environment.SIMULIA will enable tighter integration bet-ween solutions from our CAA Partners suchas OPTIS, to enable the coupling of mechani-cal & optical system simulation, Fluent, that iscombining its computational fluid dynamicssoftware with that of ABAQUS for fluid struc-

ture interaction solutions and LMS, that isembracing the SIMULIA vision for its world-class Noise & Vibration solutions.

By building on established technology, res-pected quality and superior customer service,SIMULIA will make realistic simulation forengineering and scientific applications moreaccessible, more powerful, and more criticalto the success of PLM initiatives •)

By Corinne Hirzel]

Air France Industries GetsPermission to Take off!

Dassault Systèmes developedsimulation solutions enablingmanufacturing companies to design“right the first time”. Over the past40 years, the mechanical simulationsoftware industry has evolved into afragmented landscape of nicheengineering applications, leavingmanufacturing companies withincompatible analysis software andprocesses from a variety of vendors.

SIMULIA: Inventing the Future for Realistic Simulation

Air France IndustriesLeading European airline Air France confides the maintenance of its aircraft to Air France Industries. Air France Industries is a leading multi-product aircraft maintenance provider witha worldwide network, a workforce of 10,000 and morethan 600 aircraft supported on long-term contractson behalf of approximately 100 major airlines. Holder of the European EASA PART21J/G(European Aviation Safety Agency)license, Air France Industries accords STCs (Supplemental Type Certification)with DOA (Design Organisation Approval). www.airfranceindustries.com For more information contact:

[email protected]

MAJOR ADVANTAGES OFFEREDBY PLM V5 SOLUTIONS• Excellent understanding of aeronautical

professions and needs• Solution pertinence and customised

adaptations• Major reference clients like United Airlines

and Korean Airlines

Air France Industrieshope to strengthen theirengineering innovationcapabilities and satisfyincreasing demands.

«

Only one year sufficed for the Air FranceIndustries and Dassault Systèmes SalesFrance teams to define specifications, implement a pilot platform and create customised solutions.

THE PLM V5 GAINS GROUND OVERRIVALSWith 40 seats each of the CATIA V5 and SMARTEAM solutions sold, it is the pertinenceand completeness of the Dassault Systèmessolutions that enabled it to win the project and beat rivals ARES (Autodesk Inventor) andPTC (Pro/Engineer and Windchill PDMLink) •)

By Corinne Hirzel]

By Gilles Kircher]

HIGH-FLYING OBJECTIVES Air France Industries are looking for a plat-form that will enable them to reduce costsand design time without compromising theirability to deliver optimum client service andstrengthen collaborative developmentalcapacities by optimising their regulatory procedures. Their ability to meet this challenge will be a key factor in increasingtheir competitiveness at the internationallevel.

A RACE AGAINST TIMESince obtaining the specifications sheet inFebruary 2005, the Dassault Systèmes Francecommercial and technical teams have workedto rapidly put in place specialised workshops todeal with mechanical engineering, associatedcalculations as well as electrical engineering andtechnical data management. These workshopsdemonstrated the value added by the suite of PLM V5 solutions created by DassaultSystèmes and its partners.

Air France Industries have opted for CATIA V5 and SMARTEAM solutions along with the Elsys electrical systems to optimise the quality and costs of its aircraft systems and commercial cabin modification/designactivities. By doing so, Air France Industries hope to strengthen their engineering innovation capabilities and satisfy increasing demands for its engineering services from Air France and its client airline companies.

BMW has selected ABAQUS to conduct a wide range ofcrashworthiness simulations, such as this full frontal impact simulation of a BMW 5-series accordingto USNCAPrequirements.

Boeing is using advanced methods and VCCTfor ABAQUS todetermine the load-carrying capacity of the structure by simulatinghow panel buckling drives crack propagation. The color contoursindicate surfaces that delaminate and debond due to active loading.


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Many of our customers are launching new pro-grams with V5R16, proof of the confidence theyplace in this latest release for its collaborativeengineering power in supporting the bestdesign practices on the market today.

COLLABORATIONV5R16 provides powerful new collaborationcapabilities by further facilitating the exchange ofentire engineering packages in a true concurrentengineering environment throughout the supplychain. New features in the SMARTEAM portfoliomake true relational design a reality by making it possible to reconcile CATIA data between any environment and SMARTEAM while preser-ving the complete product structure as well as the links between the parts. Major enhancements have been made with res-pect to the link between design and manufactu-ring information where engineering requirementssuch as tolerances or flag notes that are captu-red in 3D are directly usable within the V5

PLM V5R16 - Empowering your Innovation Network

Manufacturing Process Planning environment.DELMIA now directly reads tolerances stored inthe CATIA V5 model and uses this information toautomatically generate the manufacturing plans.Modifications are automatically propagatedthroughout the design and manufacturing chain.

SIMULATIONENOVIA’s new Product Simulation Managementproduct manages all data used for simulationactivities in the ENOVIA product structure. Thisensures that designers and simulation expertsshare the same most up to date information ina collaborative environment. V5R16 brings significant enhancements toENOVIA’s Enterprise Process Managementgiving companies greater flexibility and controlin defining and executing critical processes. This encourages collaboration by improving visibility of the innovation processes throu-ghout the extended enterprise.This new release delivers considerable perfor-

mance improvements since the entire PLMportfolio now supports Windows 64 bit archi-tecture. Designers and simulation engineerscan now work on large product assemblies orvery complex parts and simultaneously reducetheir development and simulation cycle times.

OPENNESSV5R16 promotes openness by facilitatingexchange of rich 3D information using theenhanced 3DXML format. Our customerscan now add PLM product data informationsuch as 3D attributes, annotations, dimen-sions and part animation to the existing 3D geometry format.

V5R16 brings the total number of industry-leading partners to over 130 with two new CAA partners, Platform Computing & Mtorres, recently on board and the numberof partner applications built on DassaultSystèmes open V5 architecture to 360. Thisaccomplishment was recently noted by majorindustry consultants who declared the V5 platform the most open system on the market today •)

Contact Mag: Can you illustrate howFunctional Modeling improves collabora-tive design? J. Leveillé: Functional Modeling, introducedin V5R12 provides a technological break-through for increased collaboration betweendesigners. This product offers a new paradigm shift in design based on a solidmodeling approach. Functional Modeling is different from solid modeling since the geometry is history free, that is, the resultinggeometry does not depend on the order bywhich it was created. Since features are defi-ned independently from their creation history,users can use a more intuitive approach whendesigning and thereby focus on WHAT theywant to model and not HOW to model it. This provided increased collaboration and inV5R14 we reinforced the functional modelingapproach by making Functional Modelingnatively collaborative where users canexchange features without having to worryabout where they should be placed in the history tree. These intelligent features knowhow to adapt to the part independently of the creation history. This is important for collaborative design where designers canexchange specifications as well as portions

of a part and reconcile them with one another. In V5R16 a designer can easily organize andlocate features in the specifications tree,especially in multi-body operations producinga clearer view of the design.

Contact Mag: How does CATIA V5 increaseinformation exchange and openness?J. L.: Dassault Systèmes defined a new stan-dard called 3D XML to exchange 3D informa-tion between all types of profiles such asproduct design, review or documentation.The scope of 3D XML goes beyond theDassault Systèmes solutions since it can beinserted, for example, with a simple drag anddrop in a Microsoft Office document. What is great about 3D XML is that it is extre-mely light thanks to a unique technologydeveloped in our R&D lab, it is extendable due to its rich semantics since product data information can be added to the 3D geometry and it is open since it is based onXML. Plus, by using the 3D XML player, usersget a full V5 3D experience with navigationand visualization capabilities all with a simpleclick of the mouse.

Contact Mag: What is new in V5R16 for 3D XML?J. L.: We added new product data informa-tion, useful for product review, such as 3Dfunctional tolerancing and annotations (FTA), sections, measurement or animation. We also made the 3D mesh geometry visiblein 3D XML by publishing its format so thatusers can use it for non CATIA applications.Plus, we integrated the 3D XML player in IBMLotus Notes & Domino Application suite the-reby extending the reach of 3D beyond tradi-tional PLM users and enabling them to sharelive, accurate 3D data quickly and easily •)

Improved Collaborative Design with CATIA V5Contact Mag asked Jacques Leveillé-Nizerolle, newly appointed CEO of the CATIA brand, to present some key contributions of CATIA V5 to collaborative design.

brand spotlight

Functional Modeling getsfocus on what designers wantto model, not how to model it.

Dassault Systèmes recently announced V5R16, its most up-to-datesuite of PLM solutions that address the value chain of a company and its partners. It is the platform of choice for customers wishing toimplement a higher level of collaboration and innovation than ever before.

By Yannick Wittner]


18 Contact mag | Dassault Systèmes 19Contact mag | n°2

brand spotlight

STATE-OF-THE-ART ROBOT OFF-LINE PROGRAMMING OF SHIP STRUCTUREEverything is big in a shipyard. Along with themammoth robot stations, it is not unusual to find 300 meters or more of weld in a ship block structure. A gantry robot can havetraveling lengths of even 200 m! Nowadayseverybody understands that on-line teachingof welding paths is not a viable option. OLP is an effective tool for generating robot programs at the shipyards when it comes tothe welding of complex 3D blocks.

There are both graphical and non-graphicalOLP tools on the market. Non-graphical sys-tems are based on large welding proceduredatabases and rules. They lack the ability tocheck the robot system for collisions before-hand, and reachability. They are also veryinflexible in terms of product type changes.Graphical, model-based systems, on theother hand, possess the capability to collide

About Delfoi Delfoi develops, markets and supportsDigital manufacturing solutions and rela-ted consulting and integration servicesfor the Product and Process LifecycleManagement (PLM). Delfoi has a 14year partnership with DELMIA as areseller and development partner. www.delfoi.com

UNDERSTANDING THE SHIP WELDING PROCESS AND ROBOTOFF-LINE PROGRAMMINGIt takes software development skills and adeep understanding of the robotized shipblock welding procedure to develop softwarefor a unique process in this industry segment.Delfoi’s and Pemamek’s union is a perfectmatch of software and process know-how.Pemamek, with products found in 40 coun-tries and all continents, has delivered severalrobots to shipyards globally. Twenty-five yearsof experience in arc welding and state-of-the-art robot off-line programming has laid a solid foundation for the co-operation. Co-partner Delfoi has more than 14 years of experience in delivering customer-tailored DELMIA IGRIP off-line programming applications. The first IGRIP arc welding application was implemented in Finland in1990. Since then, Delfoi has delivered morethan 60 IGRIP arc welding applications to more than 50 different companies.

Creating a robot program of hundreds of meters of weld should be fast and easy. Manualprogramming, on-line, though, would take days, whereas completing it off-line would only take aninstant. To accomplish the programming task of a huge arc welding robot at a shipyard has posed an immense challenge since the robots were introduced into the shipyards. Pemamek, a leading supplier of arc welding automation systems for shipyards, and Delfoi, business partner to DELMIA, havedeveloped a superior off-line programming (OLP) system based on DELMIA IGRIP software. The IGRIPShipbuilding Application is easy to use and fast in generating complete arc welding robot programs for a gantry type of robots. The application is for both flat and curved blocks in a ship steel structure.

easy-to-use approach to the welding task athand. This in turn guarantees incredibly shortstart-up periods and high utilization ratios ofthe robotic welding systems. At the end of theday, it is a question of how much weldingconsumables were used by the robots pershift and how much the customer has inves-ted to achieve this. With solutions offered byPemamek and Delfoi, customers can be surethat their robots are competitive compared to any other solution on the market today •)and check reachability. Graphical systems dif-

fer from each other in how they carry out thecollision checks and benefit from weld part fea-tures. Collision checks can be interactive, aswith IGRIP, or based on collision avoidancealgorithms as with some other systems.Graphical OLP systems benefit from featuresand topology. They differ from each other mainlyon the level of how the programming is automa-ted. The state-of-the-art shipbuilding OLPapplications utilize so-called “restriction rules”when they generate a robot program for a pre-set block feature and configuration. The crea-tion of programs is automated to a large extent.

IGRIP SHIPBUILDING APPLICATION– TECHNICAL FEATURES ANDWORKFLOWTo challenge the existing leader vendors,newcomers must override the ‘benchmark’

features of existing state-of-the-art software.Before starting the development of the newIGRIP Shipbuilding Application, Pemamekstudied the current status of OLP tools usedin shipyards and gained profound understan-ding about what should be done in order tobetter serve customers. For example, in thehandling of CAD data, controlling robot pro-gram length and welding parameters were re-evaluated and new practical approacheswere introduced.

PEMAMEK WILL PROVIDE THE NEW SYSTEM FOR THE MAJORSHIPBUILDERS GLOBALLYPemamek has been developing programmingsolutions for robotic welding stations for thepast few years. They brought an unbeatablerobotic solution for welding micro-panels, flatpanels and small parts to the market. Thissolution is based on the use of machinevision, eliminating the need for CAD models.However, with complex 3D structures, suchas double bottoms or curved panels, the rightsolution is to use OLP software. The IGRIParchitecture allows us to utilize the right levelof automation during the different phases ofthe programming, giving customers both aflexible and safe choice. The main feature onall the Pemamek systems is the practical and

Co-partner Delfoihas more than 14 yearsof experience in delivering customer-tailored DELMIA IGRIPoff-line programmingapplications.

«

About PemamekPemamek Oy Ltd specializes in industrialwork-piece handling, welding mechani-zation and automation. Their clienteleincludes enterprises from machineshops to shipyards and from windmillmanufacturers to power plant builders. www.pemamek.com

Making Shipbuilding Fast and Simple!

Process Documentation

Dear Readers,

As expected, 2005 was a

significant year for industrial

investments, in particular in

our field of PLM. Our clients have

now started migrating and imple-

menting V5 PLM collaborative environments with

SMARTEAM, and we have witnessed new successes in

companies which have implemented our 3D vision in order

to become even more competitive and innovating.

In the following pages you will discover reports from

various companies: first an S&MB in central France, Don

Foster Technologies, which uses CATIA V5 to develop and

sell its own products with the help of the powerful 3D

digital mockup. Secondly, a well-known company, the

ONERA, which designs and manufactures blowing tools

and mockups for wind tunnels for the aeronautics indus-

try. Finally, in the academic part, the Université de

Technologie de Troyes which now offers a course on

collaborative mechanical design based on Dassault

Systèmes’ V5 PLM solutions.

At last, we wish to introduce in these pages, our

Business Partners. You will discover in this issue the

CADeSIS company, whose expertise is mainly

dedicated to the multi-CAD environments, applied to

the automotive, aeronautics and special machines.

Enjoy the reading,

With best regards,

PIERRE BALZADirector, Channel Development

France, Benelux and North AfricaDassault Systèmes

in practice

ONERA: From the Virtual to the Real Mockup

Don Foster TechnologiesHow to Sell an IndustrialProject of 4x4 Rally-Raid on a Screen in 3D…

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West

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21Contact mag | n°2

CADeSIS by François Henot,

CEO CADeSIS

Université de Technologie de Troyes :A Complete PLM Industrial Course

More than 1,000 customers Worldwide within all industries use Q-Checkerto help designers to follow process requirements for geometry, standardsand methodology.

Creating high quality CAD models is one of themost time-consuming and costly parts of theproduct development process. Companies relyon these models to create products that are thelifeblood of their business. Given the complexityof design today, it is not surprising that errorsoccur regularly when creating new models.Overtime the same model is handled by otherdesigners, finite elements or mold specialists,thus increasing the requirement of high PDQ.Q-Checker CAA V5 based is a fully embed-ded solution in CATIA V5 extending the V5 PLM portfolio of Dassault Systèmes. Itadds Off-the-shelf quality rules and deliversready-to-use set of checks able to complywith international geometry quality standards as well as company specific standards.

CATIA V5 METHODOLOGYNew to Q-Checker for CATIA V5 are the“Methods Checks” making sure that all usersfollow company specific methods. Q-Checkerhelps to validate the proper data, suppressingthe tedious quality control work performed indownstream applications between OEM'sand its supply chain.

STANDARD INTEGRATIONS TO DATAMANAGEMENT AND DATA EXCHANGEQ-Checker’s batch mode can automaticallybe integrated at significant steps in the pro-cess. Beside the daily checks operated by thedesigners, data interchanged with partners

Advertorial

Transcat PLM – A Dassault Systèmes company

Contact Klaus Werling [email protected]

+49 721 9 70 43 75

www.transcat-plm.com and www.q-checker.com

can be evaluated. For release procedureswithin PDM, it is relevant to check the model.Within the Q-Checker solution, standardcomponents are available to plug Q-Checkerinto customers’ PLM environment.

A CONTINUOUS IMPROVEMENT PROCESSQ-Monitor makes PDQ visible throughout theentire process chain, providing results thatreflect either the current quality status and theprogress over time. Statistical PDQ results areavailable in either graphical interpretations ordata tables. The evaluation reports providehighly relevant feedback and highlight themost common errors that could be eliminatedwith training, support or new methodology.

WELL PROVENMore than 20 OEMs in all sectors and morethan 1,100 suppliers rely on Q-Checker. AGerman car manufacturer verifies more than150,000 models per year in a full automatedway. Results are communicated directly to sup-pliers, instant feedback is given through theweb. Q-Checker’s quality on its own guaran-tees stable audits with reliable results.

The Leading Solution for Product Data Quality (PDQ) and Process Compliance

Q-Checker helps• to ensure reusability, support concurrent

engineering, no repair downstream• to keep delivery dates on projects• management responsibilities for a proper

process and design• trust and reliability between OEM and suppliers


in practice

The ONERA (Office National d’Études etde Recherches Aérospatiales –National Agency for the Study and

Research for Aerospace) is a public industrialand commercial organization which is part ofthe French Ministry of Defense. Its role is to per-form theoretical and experimental research forthe civil or military aeronautics industry. TheONERA has over 1,750 employees, of whichtwo-thirds are engineers and researchers. Thehead office is located in Châtillon (Hauts-de-Seine), and it owns R&D and wind tunnel sitesin Lille, Modane, Toulouse, Palaiseau, Meudonand Salon de Provence. Its equipment per-forms industrial and research trials on wind tun-nels, with speeds from Mach 0.05 to Mach 12.

The Network, Engineering and Mock-upDepartment (DRIM) of the ONERA atChâtillon designs, manufactures and uses allthe active simulation components in windtunnels: mock-ups, frames, tooling, scalesand equipment. The DRIM was created in2003, and has five design, manufacturing,engineering and control departments,employing approximately 90 people. Its acti-vities range from studying the assembly com-ponents for a simple wind tunnel trial tooverseeing complex projects.

DESIGNING ALL THE COMPONENTSOF A MOCK-UP FOR WINDTUNNELSThe DRIM’s expertise is focused on industrialactivities at the service of international aero-nautics manufacturers and suppliers, as wellas the ONERA’s scientific departments. “Ourengineers’ and technicians’ expertise is mul-tidisciplinary,” explains Mr. Guy Boyet, theHead of the Central Engineering Departmentat Châtillon. “We often work in advance of thedevelopment of an aircraft to design or adapta mock-up to the measures which will beapplied. This work is meticulous, since wemust shape, inside a mock-up designed toscale, all the spaces where the scales will bepositioned, i.e. the part which receives thestress gauges to measure the six parameters(three forces and three torques) of the aero-dynamic efforts on the mock-up undergoingthe wind tunnel flow.”

This scale which is linked with a “line of stings”is a series of mechanical components linkingthe mock-up to a base located on the structurethat holds the mock-up. Hundreds of smallholes puncture the mock-up surface, allowingthe measure of the local air pressure on themock-up membrane.

“The tests we perform must be very thoroughsince they may involve modifications to theaerodynamics which will later be approved inflight. Imagine, when dropping missiles underthe wing of fighter plane, if a missile came backup instead of going down under the wing,” addsMr. Boyet. “The precision of our measurementsstrongly depends on the accuracy of the toolswe use to design this equipment. This is one ofthe reasons we have pursued our relationshipwith Dassault Systèmes and CATIA, and migra-ted from V4 to V5.”

IMMEDIATE PRODUCTION LAUNCHIn June 2004, following a year of testing on aCATIA V5 station, the entire EngineeringDepartment migrated to the Windows versionof CATIA. “After a week of training, our staff star-ted working with this brand new tool. Thechange to CATIA V5, in 3D and Windows-based, was very quickly adopted, including bythose who were designing in 2D in CATIA V4Unix-based or Autocad.”It therefore became necessary to redefine thedesign processes. “We were then able to workin a concurrent engineering mode between des-ign and manufacturing,” explains Mr. Grégoired’Ozouville, Project Engineer. “The operatorswith whom we work ‘in tandem’ on each project

CATIA V5enables our engineersto choose the workmethod which is appropriate to their project

«

also have CATIA V5 workstations. They send usback all the manufacturing constraints, so thatwe can safely program the milling programs forthe mock-ups or the electro-erosion machiningfor the scales. Everyone designs in 3D. With thesupport of ATTHIS technicians, we have wellcompleted the implementation of CATIA V5 atour Engineering Department.”

WITH CATIA V5, THINGS GO VERY FAST…Design methods can be very different from oneproject to another. “It is true that we emphasizethe quality of the final project, since our activityhas a very high added value,” states Mr. Boyet.“The consequences of a faulty design could be

dramatic and very expensive if problems wereto be detected in the wind tunnel. In addition,as CATIA V5 is on the verge of being deployedworldwide in the aeronautics industry, we arecertain to anticipate our clients’ requirements,whether they send us data originating fromCATIA V4 or other software applications. Therange of functionalities provided by CATIA V5enables our engineers to choose the workmethod which is appropriate to their project andtheir expertise. The designer has entire free-dom: knowing that what you want to do is possible opens all the channels and expandscreativity.”Many CATIA V5 functionalities are being usedat the ONERA, from traditional 3D mechani-cal design with manufacturing drawings, analysis, NC programming, to kinematics.“Our clients require a rapid response regar-ding the feasibility of a project. CATIA’s 3Denables us to explore several possibilitiesbefore proposing the best. This sometimesplays tricks on us as when the client sees our3D presentation, it is assumed that the project has been completed, when in fact weare still at the quotation stage. It is true that were-use many components from previous stu-dies, which allows us to focus on the addedvalue given to the ongoing projects.”

PROCEDURES THAT RUNSMOOTHLYThe DRIM engineers and technicians are ver-satile and capable of managing all the studiesof a project. “A standard directory is openedfor each new project. It includes all the sub- directories organized in such a manneras to classify information and access rightsaccording to the people working on theproject,” explains Mr. d’Ozouville. “We haveon average around 30 ongoing projects


In order to optimize its design and manufacturing times, and to gainin quality, the ONERA is migrating from CATIA V4 to CATIA V5for the design and simulation of the wind tunnel equipment itmanufactures for the international aeronautics industry.

❯❯



ranging from three weeks to three years. Wegenerally start from an engineering blueprintof the wind tunnel to design all the compo-nents for the trials. Specifications are provided by our wind tunnel engineers, indirect relationship with the client. We thenhave to shape the interior of the aircraftmock-up and design, in parallel, its measu-rement devices, as well as the structure (the line of stings) which will support it, all this in the virtual environment of the windtunnel flow.”The complete 3D assembly of the wind tun-nel mock-up allows gains in quality, and pro-vides groups of manufacturing drawingsdirectly extracted from CATIA V5. “CATIA V5is far superior to V4 in terms of approving 3Dassemblies,” adds Mr. Boyet. “We canquickly take the modifications into accountwithout disturbing the integrity of the geome-try, or re-launch the manufacturing of a

modification in the aero-dynamic design ofthe mock-up. The precision of the collisionsimulations and the dynamic cuts in CATIAV5 have a direct impact on a project’s deli-very time and its cost.”

AN OPENING TOWARDSDEVELOPMENTWith the integration of CATIA V5 in theWindows world, the DRIM EngineeringDepartment has customized its developmentenvironment: “We have developed manyVisual Basic macros, which enable us to haveour own design-aided tools,” explains Mr. d’Ozouville. “For instance, to standardizeour cartridges, manage the drawing versions,and generate our bills of materials, we havea Windows interface in CATIA V5 whichallows us to complete the compulsory information fields.”These internal developments are beingdeployed on the other ONERA sites that haveCATIA V5. Jean-François Bret, a design engi-neer at the DRIM adds, “CATIA V5 fits per-

fectly into the other Windows tools such asthe parts libraries by Trace Parts, and Samceffor the analysis. We also use it with the e-Drawings application to exchange projectdata with our clients working on PCs whichare not CAD registered. This allows us toannotate, measure and disassemble mock-ups to monitor the progress of a project. Weare in the process of extending the use of theanalysis module of CATIA V5 in order to maximize precision and transparency in thetransfer of CAD data.”

“The experimental approaches and the digi-tal simulation of the behavior of an aircraftundergoing a flow are complementary,which make the studies in wind tunnels allthe more complex, in configurations whichare impossible to create virtually,” concludesMr. Boyet. “Our projects, therefore, play animportant role in this context. CATIA V5 guarantees for our clients that our work willprovide the expected trial results. CATIA V5demonstrates on a daily basis that the soft-ware investment we made is paid back in thequality and reliability of our products, whichis our main priority.” •)

❯❯

Since its creation in 1980 the com-pany Don Foster Technologies hasspecialized in the design and manu-

facturing of fabricated parts and fine boilerwork for the automobile competition andaeronautical industries. Don FosterTechnologies is located near Vichy andemploys 50 people. The CEO, Mr. ChristianGIGOT, while consolidating his market sharesin the automotive sector, wished to diversifythe sub-contracting activities, particularly inthe aeronautical sector. “The industrial park inVichy includes many companies which aresub-contractors for the aeronautics industry,”explains Christian Gigot. “We have thereforemade available our experience and expertisein the field of structure welding, especially forprojects on drones (UAV), which require mas-tering titanium part welding techniques usingArgon Inert Gas.”

Working with fine metals requires expertise andexperience which, combined with technology,are a means to ensure quality, competitivenessand innovation. This is why Don FosterTechnologies chose CATIA V5 in 2002 to deve-lop its automotive activities: “The automotivemarket uses CATIA extensively, so we had totake this into account when making our choice.However, the software’s capability to adapt toall trades and projects, whether simple or com-plex, helped us confirm this choice. We tookinto account our need to develop our own pro-ducts while maintaining some autonomy in ourbusiness and total freedom to innovate.”

DEMANDING CLIENTSSix CATIA V5 CAD workstations are dividedbetween the Engineering and MethodsDepartments. The Engineering Department

(ED) is primarily responsible for the design ofracing car suspensions and chassis. Itsclients include world-famous names in carracing: Audi R8 Le Mans, Citroën Sport andPeugeot Sport in WRC, Mercedes-HWA,Courage Compétition, Renault Sport in Super1600, Toyota Motorsports in F1, Volkswagenin Rally-Raid and many other teams with pres-tigious track records, for which Don FosterTechnologies designed and developed wish-bones, engine subframes, wheel hubs, andquite often the entire rolling chassis.“We always work with the double constraintof part resistance and mass distribution,”explains Francis Blanchet, the Manager of theED. “We must take into account the vehicle’sdynamic response. Based on a 3D wire blue-print, we model the functional areas of a sys-tem in order to define its global architecture,

A French SMB is out toconquer new markets byapplying its expertise in 3Dwith CATIA V5.

❯❯

in practice

For more information:www.onera.fr

Don Foster TechnologiesHow to Sell a 4x4 Rally-Raid Industrial Project on a Computer Screen in 3D…


in practice

and then characterize the vehicule behaviour.Then, taking into account static, dynamic andkinematic parameters, we build the variousparts (tubes, suspensions, clampings, links,etc.) which will be manufactured in ourassembly shop. We also integrate the retailparts which we parameter and save withCATIA in our parts catalogues.” Every single part is drawn in order to generatecomplete bills of materials and avoid bad sur-prises when assembling. “Our cycle timesrequire us to get it right the first time. Todaywe do not encounter any problems whenassembling our chasses. The designmethods developed with the support ofDassault Systèmes combined with our colla-borators’ expertise produce results whichmeet our clients’ expectations.”

parts can be manufactured. The exploded 3Dviews and mounting simulations ensure thatthe manufacturing and assembly operationsare well understood.”For training and methodological support, theED has always been able to call on the closeassistance of DSF: “We can count on the sup-port of the Dassault Systèmes Lyons agencywhich gives us daily support and answers toour questions. Our “in context” workingmethodology was in fact developed during ourdesign optimization sessions,” adds FrancisBlanchet.

A DEVELOPMENT STRATEGY FORPROPRIETARY PRODUCTSA strategy for the development of their ownproducts is being put in place at Don FosterTechnologies. The last project goes back lessthan one year ago, when Christian Gigot andhis team came up with the concept of a 4x4Rally-Raid vehicle. The company from Vichyhad already been proposing its expertise toRally-Raid Teams (Lada, Mitsubishi, VW,BMW) for a long time.“The trigger was the success of our projectduring the Dakar 2005 Race with Nissan,”says Christian Gigot. “We had developed forthem a complete rolling chassis, and Nissanfinished 4th overall. But then Nissan decided

to pull out of rally competition, and since DonFoster Technologies did not have the expectedreturn on investment, we thought that this typeof simpler chassis could be used for other moreeconomical vehicles: so we had the idea of offe-ring a complete vehicle on which different engines and suspensions could be mounted.Our clients can customize their vehicle with thebodywork and engine of their choice on a com-mon platform.” This positioning on an intermediate market seg-ment, together with the capitalization of theirexperience and expertise, enabled Don FosterTechnologies to quickly find its first client: theIsuzu importer in Europe. “This meeting was areal turning point for us. All it took was one mee-ting in front of our CATIA V5 screens. We hadincorporated into the digital mockup all theparts of the car: chassis, engine, platform, axlesas well as all the professional parts used by themajor Teams (wheel rims, gearbox, dampers,braking systems, etc.). We even had the futuredriver Hubert Auriol, whom we had modeled inCATIA V5 after taking his measurements. I must say the client was so impressed with theresult that he signed his order for two completevehicles without having seen the least physicalprototype.”

The two vehicles of the Clay Regazzoni ISUZUteam were built at Don Foster Technologies inless than six months, including the bodyworkwhich was digitalized with a Faro arm, thenloaded into CATIA V5 using the ‘GenerativeSurface Design’ functions, and finally exten-ded and adapted to the dimensions of thechassis. A mold was then prepared in NC tomake the bodywork parts in fiberglass. These

For more information:www.donfoster-racing.fr www.4x4-rallye-raid.com

CATIA V5 is more than tremendous design software

«

TIGHT COLLABORATION WITH MANUFACTURINGUsing CATIA V5, the Methods Departmentprepares tooling and manufacturing proces-ses for the ED or directly for the client. For thispurpose it has two CATIA V5 workstations forMechanical Design and metal sheet develop-ment. Franck Bernière, Manager of theMethods Department, says: “As we mustreact quickly in our work, we need to adoptthe best and fastest methods. We alwayswork “in context” in CATIA V5 so as toconstantly update the digital mockup of partsor assemblies and to maintain the links bet-ween the tooling and the geometry in case theED requires modifications.”

The diversity of projects is an everyday issuein this business: “It is clear that we have to bevery strict with regard to our data manage-ment processes. We manage the links bet-ween parts and subassemblies in order toautomatically generate the drawings and billsof materials related to their manufacturingprocesses, and to guarantee the traceabilityof our material batches,” adds FranckBernière.

CATIA V5’s intuitive ease of use are recogni-zed in both Departments: “At one point wehad a young 14 year-old trainee who wasgiven an hour’s introduction to CATIA. By theend of the day he had designed three parts in3D,” says Francis Blanchet. “CATIA V5 is avery efficient tool for communicating with thepeople in the assembly shop. Their proximityallows us to get them involved very early in thedesign process in order to ensure that certain

cars have just completed their first Dakar racewith Hubert Auriol and Edi Orioli at the wheel.

With a shop floor of 2500 MÇ, equipped with 5-axis NC milling machines, NC lathes, electro-erosion tools plus the full spectrum ofsheetmetal machines as well as precision wel-ding centers, Don Foster Technologies is anSMB offering high technology expertise. “Our future depends a lot on how well we inte-grate our expertise with the design and manu-facturing solutions of Dassault Systèmes,”concludes Christian Gigot. “This is a key assetfor our activity, which until now was consideredto be craftsmanship. But CATIA V5 is more than

tremendous design software; it is also an effi-cient communication tool both internally andwith our suppliers and clients. It helps us struc-ture our processes, so that we can re-use pre-cious know-how and develop innovativeproducts. We are hoping that our new 4x4 pro-ject will get the success it deserves, and thatCATIA V5 will continue to help us sell, in 3D,many projects to our future clients.” •)

❯❯


in practice

The ‘Université de Technologie deTroyes’ offers engineering students acomplete computer aided design and

manufacturing program combining theoreticalcourses and practical hands on situations linked to real life industry applications. At theonset of the mechanical engineering program,students learn the basics of information tech-nology and are trained to use DassaultSystèmes’ CATIA V5 in the field of mechanicaldesign. To complement this user-oriented trai-ning they are also taught how to administer an

IT system as well. UTT mechanical engineeringstudents are confronted with real industrialissues linked to concurrent engineering andcollaborative working methods for the exten-ded enterprise. This is one of the reasons UTTchose to feature Dassault Systèmes’ ProductLifecycle Management (PLM) Solutions intheir curriculum with emphasis on CATIA V5,SMARTEAM and ENOVIA for digital mockupand configuration management. “In the last18 months of their training on InformationTechnology for Mechanical Engineering(Technologies de l’Information pour laMécanique) six months are dedicated to allo-wing students to capitalize on their initialCAD/CAM training by adopting a PLM mindsetearly on”, said Benoit Eynard, professor andresearcher at the department Génie desSystèmes Mécaniques at UTT. “Studentsreceive 40 hours of theoretical training and100 hours of practical hands on productdevelopment management making UTT oneof the few French universities to offer a substantial coverage of Dassault Systèmes’PLM solutions. We are also the only universityto include ENOVIA training in our curriculum,”adds Benoit Eynard.

AN INDUSTRIAL APPROACH TOTEACHINGGuest speakers from companies such asSNECMA or PSA frequently give lecturesduring classes where they exchange with students on the industry and economic issuescompanies face today and on how they haveimplemented PLM solutions throughout theirproduct development process to increasetheir productivity and competitiveness. “The various subjects treated during thesesessions can then be transformed intoresearch topics or student projects,” saidBenoit Eynard. “For example, one of our student’s research projects involved usingSMARTEAM applications in conjunction witha program whose function is to perform anassessment of the environment,” he added.

Subjects are selected in accordance with realindustry issues. A student can also choose asubject that interests a particular companyand even find him or herself offered a job inthat very company once they have receivedtheir degree.

Students are encouraged to put to practicaluse the theory they learn in class. An illustra-tion of a collaborative engineering approachcan be found in projects that some UTTstudents participate in with students from

the Université de Technologie de Belfort-Montbéliard or from ENSAM Châlons enChampagne and IFTS of Charleville-Mézières.For example, students from ENSAM Châlonsen Champagne and IFTS of Charleville-Mézières use Dassault Systèmes PLM solutionsand IBM Lotus Sametime to manage productinformation starting from conceptual designall the way to product industrialization and tocommunicate and share this product informationin a virtual environment. This initiates them,very early on, to the realities facing any company that needs to work with partnersand subcontractors located on different sites.

Students also spend time at Dassault Systèmesto gain work experience in the developmentand industrialization of the CATIA, SMARTEAMand ENOVIA solutions. UTT offers an averageof 3 to 4 work experience programs per year inthe research and development and industriali-zation departments of Dassault Systèmes to engineers interested in deepening theirknowledge in these areas.

THE DEMAND FOR PLM-TRAINEDENGINEERS IS GROWINGUTT’s track record for helping their studentsfind employment is very high. By the end oftheir “educational project”, half of the informa-tion technology for mechanical engineeringstudents have already signed up with anemployer. 65 % of those presenting their oralexams at the end of September have alreadyfound a job and this number increases to 90 % for those who have received theirdegrees end of November. The remaining 10 % consist of students who choose tocontinue on to an MBa, MSc or PhD program.

“We are often confronted with a situationwhere the demand exceeds the supply,” saidBenoit Eynard. “Companies are actively lookingfor students with PLM training which explainswhy our students generally have no problemfinding a job”•)

The ‘Université de Technologie de Troyes’ offers an information technology for mechanical engineeringcurriculum based on the use of Dassault Systèmes PLM solutions in real industry situations. The program includes a combination of theoretical training with practical hands on projects duringwhich students use the PLM solutions thereby providing them with a valuable advantage as they enter the workforce.

A Complete PLM Industrial Course

29Contact mag | n°2

For more information:Benoît Eynard Université de Technologie de [email protected]

CADeSIS was founded by agroup of people originating from“Renault Program Office”. Seven years ago this organization deployed SDRC I-DEAS/Metaphasesolutions at the RenaultTechnocentre.


CADeSIS was created when the “RenaultProgram Office” ended, after Renaultchose to replace I-DEAS by CATIA. We

wanted to start a new company that would bemotivated by sharing our experience, acquiredin the area of automotive design and extensivedeployment of CAE systems, with other indus-trial units.Since mid 2004, our business has evolvedtowards the sales of software applications;indeed CADeSIS has become an IBM/DassaultSystèmes Partner for the sales and support ofCATIA and SMARTEAM software solutions.

OUR MISSIONSCADeSIS’ team of 35 extremely experienced pro-poses a wide range of services and solutions thathelp businesses to facilitate and optimize thedeployment of Computer Aided Engineering tools

• Know-how with regard to the problems ofheterogeneous CAD, i.e. “multi-formats” and“multi-applications”• Audit and support for the deployment ofSMARTEAM PLM solutions. Our work in thisarea is focused on the organization of the data in Engineering Departments,connection with the ERP, codification rules.

Training sessions for the various trades aswell as the development of specific applications complement this approach •)

CADeSIS by François Henot, CEO CADeSIS

With 20 years experience in the areasof CAD and PDM, CADeSIS proposesan extensive range of services and solu-tions to help businesses install, optimizeand show a return on investment of theDassault Systèmes PLM tools (CAD,CAM, PDM and Process). www.cadesis.fr

More specifically, CADeSIS’s expertiseinvolves 5 areas:• Business competences In the following 4 sectors: automotive, aero-nautics, machine design and manufacturingindustries.• Our methodologies work! Our methodologies have been tried and testedto implement design processes, shared byspecialists from the company with our experts - a determining factor of success for aproject involving the implementation of CAESolutions.• Development of “generic models” Generic models help us to capitalize on com-pany expertise and automating the designrules, and thus producing significant gains indelivery time and improving quality by standar-dizing the design methods.

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A CATIA V5 USER? Instant Access to Any FunctionClick any of the programmablekeys on SpacePilot to accessany CATIA V5 function or macro,including keyboard modifierssuch as Ctrl, Shift, Alt and ESC.Useful functions can easily bemapped and customized insideCATIA using an easy drag-and-drop menu. Multiple sets of configurations keep a range of useful

commands right at your fingertips.

Sketcher ModeUse the mouse to sketch while simulta-neously using SpacePilot to optimallyposition the work plane and inspect your sketch from multiple positions.Initiate commands such as Normal View,Hide/Show, Swap Visible Space and ExitWorkbench with the programmable keys.Toggle rotation on and off with the 3Dlock button.

Part Modeling ModeView a model from different view angleswith SpacePilot while simultaneouslyadjusting the size of a feature with themouse. Drag and copy or drag and movefeatures using the mouse while positio-ning the part with the 3D controller.

Assembly ModeBuilding assemblies with SpacePilot issimple: position the complete assemblyas you insert components. Remove existing components just as easily. When using CATIA’s Snap function, usethe controller to find the optimum viewangle for selecting mating faces of components. Functions like Snap, InsertComponent, Reset Compass, Ctrl, Escand many others are all easily accessiblefrom SpacePilot.

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Pan

Zoom Rotate(Y axis)

Rotate(X-Z axis)

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