Faurecia Cae PDF

9.
LS-DYNA Forum, Bamberg 2010 Keynote-Vortrge II
Faurecia Seating FEA Strategy
C. Lemaitre
Faurecia Siges dAutomobile
2010 Copyright by DYNAmore GmbH A - II - 1

Faurecia Automotive Seating FEA Strategy
Christophe LEMAITRE
Validation Director
christophe.lemaitre@faurecia.com
9th German LS-

LS-DYNA forum 2010
12th-
12th-13th October 2010, Bamberg, Germany
Property of Faurecia - Duplication prohibited
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Challenging CAE topics on a key automotive product !

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Our game field
Regulations : ECE 14 / ECE 17 / FMVSS210 / FMVSS201 / Low speed FMVSS202a /
Safety : Front crash / Rear crash / Luggage impact / Low speed Whiplash /
Functional : Static & Dynamic comfort / Mechanical resistance / Misuse / Climate ageing /
Cycling / Vibration ageing / Squeak & Rattles /
Red = simulable by FEA
Different materials behaviors : Steels / Foams / Plastics

Different modeling scales : seat frame / seat mechanisms
Integration of restraint systems
Integration of dummies
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Main OEMs expectations
Cheaper products :
More Product & Process design optimizations
Lower engineering costs (CAD, prototypes, testings
testings)
Shorter development time

DESIGN
Lighter parts
More product requirements : FEA

Regulations
Occupants safety (Ncap)
Comfort
HOW ?
Perceived quality
More quality / robustness : TESTING

Less PPM
Low product sensibility to Design & Manufacturing parameters

More product durability with time
Higher reactivity / adaptability towards market :

More product versions
More changes on styling / specifications / functions during development
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Our 5 Validation Fundamentals
(VALIDATION = FEA + TEST)
Focus FEA/Test pilots on results analysis & product design
High integration and involvement of FEA/Test pilots

into R&D projects
Use Innovative + Robust + Lean FEA/Test standards
High interaction between FEA and TESTING

Use FEA as an upfront design tool

(CAE CAD)
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From our 5 Validation Fundamentals
to our Validation roadmap
Validation on projects
FEA/Test Pilots Pilots skills Validation Project KPIs
organization development tools
Lab operations FEA operations

Labs Labs FEA OEMs FEA
equipments quality system equipments certifications
Standard OEMs lab Advanced FEA
test methods certifications FEA T&M LCC
FEA
Measurements Lean
uncertainties testing quality system
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FEA
Measurements Lean
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FEA and TEST people integration on R&D projects
Previous organization
Program Manager
Program Manufacturing Leader Program Buyer Program Sales Leader
Program Development Leader Program Quality Leader
w/ Design leaders and CAD

Program Controller
FEA Eng Test Eng
LCC FEA Test labs

Working modes: Consequences :

FEA Eng = FEA results provider Low motivation of FEA/Test Eng in project
Test Eng = Test results provider FEA used as validation tool more CAD cost
LCC FEA = meshing/models provider High risk of bad FEA/Test correlations
FEA/Test managed by 1 non expert leader Low FEA/Test interaction no cost optimization
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Organizational chart
FAS R&D / Validation Department
FEA
Central Services
Methods & Tools
Testing Methods
& Equipments
Quality & Lean
STRATEGY
&
STANDARDS
DELIVER INNOVATIVE + ROBUST + LEAN FEA and TEST STANDARDS
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FEA Validation Validation FEA Validation Validation Validation

Central Services
Methods & Tools France Germany Poland Brazil USA China
Testing Methods Cust. Validation FEA Engineers FEA & Test Pilots FEA Pilots FEA & Test Pilots
Cust. Validation
& Equipments FEA Engineers
Quality & Lean Test Operations Test Operations

FEA & Test Pilots FEA Pilots Test Pilots
Shanghai
Brires
FEA & Test Pilots Test Operations

Test Pilots Test Operations
Flers Wuxi
Test Operations
Test Operations
Brires/Sel.
STRATEGY
Test Operations
Flers OPERATIONS
&
STANDARDS
APPLICATION OF FEA and TEST STANDARDS ON PROJECTS

FEA + TEST PEOPLE IN 1 DEPARTMENT 1 UNIQUE MANAGER
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FEA Validation Validation FEA Validation Validation Validation

Central Services
Methods & Tools France Germany Poland Brazil USA China
Testing Methods Cust. Validation FEA Engineers FEA & Test Pilots FEA Pilots FEA & Test Pilots
Cust. Validation
& Equipments FEA Engineers
Quality & Lean Test Operations Test Operations

FEA & Test Pilots FEA Pilots Test Pilots
Shanghai
Brires
FEA & Test Pilots Test Operations

Test Pilots Test Operations
Flers Wuxi
Test Operations
Test Operations
Brires/Sel.
STRATEGY
Test Operations
Flers OPERATIONS
&
STANDARDS
FEA PILOTS + TEST PILOTS in 1 DEPARTMENT 1 UNIQUE DIRECT MANAGER
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Pilots integration on R&D projects
Current organization
Program Manager

Program Controller
FEA Pilot Test Pilot
LCC FEA Test labs


FEA Pilot = Design by FEA engineer High motivation of FEA/Test Pilots in project
Test Pilot = Design by Test engineer FEA used as design tool less CAD cost
LCC FEA = FEA Calculations & Analysis provider Low risk of bad FEA/Test correlations
FEA/TEST managed by 2 expert engineers High FEA/Test interaction cost optimization
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Pilots integration on R&D projects
Best organization
Program Manager

Program Controller
Validation Pilot
LCC CAE Test labs


Validation Pilot = Design by FEA/Test engineer High motivation of FEA/Test Pilots in project
LCC FEA = FEA Analysis & Design solutions provider FEA used as design tool less CAD cost
FEA/TEST managed by 1 expert engineer No risk of bad FEA/Test correlations
Automatic FEA/Test interaction cost optimization
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FEA LCC
What the FEA HCC think about FEA LCC ?
Need long email or Pure FEA provider, no

Dont understand my support on my design
powerpoint to explain
FEA request issues
my FEA request
Their FEA skill is too

weak, why should I
train them ?
Not reactive, quicker if
done by myself
FEA PILOT (HCC)

Quality is low
THEY ARE TAKING
MY JOB !
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FEA LCC
What the FEA LCC think about FEA HCC ?
Need long email or

Not able to formalize a
Always pressing me by powerpoint to ask
clear FEA request
giving short deadlines details on FEA request
Give me only basic FEA

operations : no results
analysis, no design
proposal
Dont want to give me
more data on the
project
FEA LCC Engineer (HCC)

Think I am not as WHY SHOULD I BE
skilled in FEA as him MORE PROACTIVE OR
MOTIVATED ?
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LCC FEA
HCC/LCC FEA new organization
PILOT MISSION :
1 Validation Pilot (HCC) By using FEA & Testing, to design a robust
product compliant with all requirements
(specifications, regulations, weight, cost, )
To minimize the prototyping and testing costs.
STANDARD FEA TOOLS & METHODS
1 standard for FEA hardware & softwares
1 FEA quality system w/ internal audits
PILOT FOCUS :
1 worldwide FEA database (dummies, raw materials, FEA and test results analysis
weldings, screws) Find design solutions by relaunching FEA or
1 efficient shared desktop tool testing
1 library of FEA training modules Communication w/ project team and customer
CONSEQUENCES for PILOT :

Need to outsource more key FEA tasks to LCC
Dedicated FEA Engineers (LCC) Need to get full involvement in his project
Need to get full proactivity on design
(Calculations / Analysis / Design)

Permanent communication
(goals, issues, decisions, OEM feedback
feedback)
is KEY SUCCESS FACTOR
FEA Pool (LCC)
(Meshing / Model preparation)
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LCC FEA
HCC/LCC FEA new organization
RESULT = WIN / WIN between FEA HCC and LCC engineers
Significant increase of key competencies :

Pilots : product design, project management, leadership, communication, negotiation,
customer relations management
FEA LCC engineers : FEA analysis, product design,
Higher project involvement and design proactivity
Less resignations and people turnover in LCC
Increase of LCC FEA on HCC projects X m dev. cost saving !

HCC pilots satisfaction on LCC FEA LCC engineers :

57% meet expectations
+ 25% above expectations
= 82% positive expectations
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FEA
Measurements Lean
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Pilots skills development
Targets :
to help integration of new people
to assess and manage skills
to help present people mobility
to standardize and improve skills of present people
to capture / structure / redeploy knowledge + know how + best practices
practices
Specific trainings modules :
FEA operations Product performances

Testing operations Product & Process design
Validation leading Soft skills
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Key document = FEA Pilot & Test Pilot

Pilot job guidelines :
To help pilots to run their job
To help integration and training of new pilots
To improve rigor and discipline in work execution
To standardize validation actions & deliverables on all projects
To increase robustness of our products development
To help projects follow up and review by management
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Secure FEA set up vs TEST set up
Secure parts definition before testing
Secure MFG process effects integration
Secure product robustness

/ DOE approach
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FEA
Measurements Lean
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FEA softwares strategy
2008 status
RADIOSS
PAM CRASH
LS DYNA
How to deliver the same FEA quality for all customers on all projects ?
How to reduce cost to get best FEA quality ? 27
2008 status
Consequences for faurecia :

Significant cost to maintain competencies on all softwares
Difficulties to manage differences in FEA results because softwares
FEA pilots spend more time in FEA issues than design products
No standardization FEA tools & methods & databases
No optimization of softwares licenses costs
Difficulties to capitalize correlations and best/bad practices
High cost to develop and deploy new advanced FEA
Inefficiencies to share and exchange FEA models between products
High cost to integrate new collaborators
High training cost
Less headcount flexibility between projects and sites

Consequences for customers :

Able to integrate directly faurecia FEA models
But not the best FEA models from faurecia
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Since 2009
1 WORLDWIDE STANDARD FEA SYSTEM
HYPERMESH LS DYNA HYPERVIEW
FAURECIA FEA SOFTWARES
FEA QUALITY SYSTEM
TRAINING MODULES
DATABASES
Key benefits :
Same FEA Quality for all customers on all projects
Huge possibilities for standardization / knowledge capitalization / FEA improvements
Costs reductions :
Training : -60%
Licences : -33%
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Since 2009
Dummies Database
Belts models
Body blocks
Material Database
Screws Database
Mechanisms Database
Efficiency Tools
Grojec
Stadthagen
Flers
Troy
Shanghai
Brieres
Pune
Quattro Barras
Same FEA IT environment

Master database
Automatically replicated databases (hardware / softwares / databases / models)
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Interface w/ customers
TRANSPARENCY and TRUST

Faurecia :
Uses its FEA system and is responsible of its results
Is responsible to design a seat compliant w/ specifications
Delivers FEA models compliant w/ customer requirements @ key
project milestones
Provides support for models conversion
But can not be responsible of differences in FEA results between
softwares
Organizes regular exchanges w/ customers to share FEA best
practices
Develops a policy of OEM FEA certifications
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FEA OEM certifications
Process = AUDIT + BLIND TEST
STEP 1 faurecia FEA system audit
FEA results Loadcase 1 FEA results Loadcase 2 FEA results Loadcase N

STEP 2
Compare FEA / test results Compare FEA / test results Compare FEA / test results
STEP 3 Loadcase 1 Loadcase 2 Loadcase N
Certification Loadcase 1 Certification Loadcase 2 Certification Loadcase N
Faurecia task
Customer task
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FEA OEM certifications
Faurecia benefits :
Strong competence recognition
Reduce sterile discussions about FEA results robustness
More responsibilities on FEA results
OEM benefits:
Deep knowledge of faurecia FEA robustnesss
Sort suppliers on FEA robustness
Reduce FEA cost by not remaking FEA already done faurecia
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FEA
Measurements Lean
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Standard test methods
Objectives :
To standardize execution of testing between labs
regulations
Same reading and understanding of OEMs specifications & regulati ons
Same test set up and measurements set up
Same testing execution
Same quality of testing deliveries
Same best practices
To reduce test results variability & uncertainty
To help people learning and integration
To improve test methods by capitalizing knowledge & experiences
Standardization process = TEAM WORK
Testing experts
FEA Tools & Methods team
Product performances experts

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Standard test methods
Test method content :

Faurecia test method = default method :
Recommended equipments
Test preparation and set up Available
Measurements preparation and set up

Standard test methods Front crash
Checklists before, during, after testing
Rear crash
Whiplash & FMVSS208
Specificities by OEM ECE 14 & FMVSS210
HRMD
Squeak & Rattles
3 quality levels :
ECE 17 backrest
Test for FEA correlation ECE 17 headrest
Application test ECE 17 luggage
COP test Luggage crash
Maximum recliner
torque
Technical internal audits to control 45/15
application standard test methods Acoustic measurements
Vibration durability
Modal analysis
Egress/Ingress
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FEA Quality System
1 Worldwide FEA quality system
Objectives :
To facilitate people learning & integration
To standardize FEA know how / processes / best practices
To reduce results variability induced by FEA people
To secure quality of FEA deliveries and design decisions
To improve correlations between FEA & Test results
To improve FEA quality by capitalizing knowledge & experiences
Tools :
Documents :
FEA guidelines
Standard FEA method
Technical internal audits to control application
of FEA quality system
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FEA Quality System
FEA Quality docs :
Available
Guidelines LS Dyna core guidelines

FEA audit process
FEA LCC outsourcing process
FEA report
Correlation process
DOE process

FEA method Front crash & Rear crash

Whiplash & FMVSS208
ECE 14 & FMVSS210
H point and HRMD
ECE 17 backrest
ECE 17 headrest
Static comfort and pressure mapping

Standard FEA method prerequisite = Standard Test method !

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FEA quality sytem + Standard test methods
1 QUALITY SYSTEM SAME FEA/TEST RESULTS BETWEEN R&D CENTERS

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Conclusions
Mindset change of R&D people
Huge steps towards FEA & Testing standardization
Same FEA / Test results and services between R&D centers
Very positive feedback from project teams and customers
Our original approach needs talented people join faurecia !

Significant testing costs reduction for evidences join 8th European LS-
DYNA Users Conference, 23rd-24th May 2011, Strasbourg, France
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THANK YOU
FOR YOUR LISTENING !
41

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9.

LS-DYNA Forum, Bamberg 2010 Keynote-Vortrge II

Faurecia Seating FEA Strategy

Faurecia Siges dAutomobile

2010 Copyright by DYNAmore GmbH A - II - 1

9th German LS-

Challenging CAE topics on a key automotive product !

Regulations : ECE 14 / ECE 17 / FMVSS210 / FMVSS201 / Low speed FMVSS202a /

Different materials behaviors : Steels / Foams / Plastics

Shorter development time

More product requirements : FEA

More quality / robustness : TESTING

Low product sensibility to Design & Manufacturing parameters

Higher reactivity / adaptability towards market :

Focus FEA/Test pilots on results analysis & product design

High integration and involvement of FEA/Test pilots

Use Innovative + Robust + Lean FEA/Test standards

High interaction between FEA and TESTING

Use FEA as an upfront design tool

Lab operations FEA operations

Standard OEMs lab Advanced FEA

test methods certifications FEA T&M LCC

Lab operations FEA operations

Standard OEMs lab Advanced FEA

test methods certifications FEA T&M LCC

Program Manufacturing Leader Program Buyer Program Sales Leader

Program Development Leader Program Quality Leader

w/ Design leaders and CAD

FEA Eng Test Eng

LCC FEA Test labs

Working modes: Consequences :

Methods & Tools

Quality & Lean

DELIVER INNOVATIVE + ROBUST + LEAN FEA and TEST STANDARDS

FEA Validation Validation FEA Validation Validation Validation

Methods & Tools France Germany Poland Brazil USA China

Quality & Lean Test Operations Test Operations

FEA & Test Pilots Test Operations

APPLICATION OF FEA and TEST STANDARDS ON PROJECTS

FEA Validation Validation FEA Validation Validation Validation

Methods & Tools France Germany Poland Brazil USA China

Quality & Lean Test Operations Test Operations

FEA & Test Pilots Test Operations

FEA PILOTS + TEST PILOTS in 1 DEPARTMENT 1 UNIQUE DIRECT MANAGER

Program Manufacturing Leader Program Buyer Program Sales Leader

Program Development Leader Program Quality Leader

w/ Design leaders and CAD

FEA Pilot Test Pilot

LCC FEA Test labs

Working modes: Consequences :

Program Manufacturing Leader Program Buyer Program Sales Leader

Program Development Leader Program Quality Leader

w/ Design leaders and CAD

LCC CAE Test labs

Working modes: Consequences :

Need long email or Pure FEA provider, no

Their FEA skill is too

FEA PILOT (HCC)

Need long email or

Give me only basic FEA

FEA LCC Engineer (HCC)

CONSEQUENCES for PILOT :

(Calculations / Analysis / Design)