Zaporizhia (that’s Запоро́жье in Cyrillic) is an industrial center in the Ukraine. Built on the banks of the Dnieper River, the city (whose name means “beyond the rapids”) is the 6th largest in the country and is fueled by a 1500 MW hydroelectric plant.
In 1947, as the city emerged from WWII, one company began building power transformers to help effectively distribute the electricity from the hydraulic plant—Zaporizhia Transformers. ZTR today still makes the equipment that supports power networks throughout theCommonwealth of Independent States and beyond. With sales in 85 countries, ZTR now provides transformers and electric shunt reactors that provide for and conform to the needs of its customers and their local regulators.
With all this business in so many countries, you can imagine that there is a lot of variation in the products ZTR delivers. Orders come in for different sizes and classes of product. Some customers need additional fire-fighting systems; others require equipment that can handle their unique seismic and climate conditions.
From the start, ZTR has needed well-managed manufacturing systems to stay on top of it all. But over the past few years, major new projects have demanded more and more efficiency from the company. As such, ZTR recently decided to step up and optimize its production cycle.
That’s where PTC Windchill and PTC Creo products come in. Working with the engineering company Technopolis Ltd, ZTR adopted PTC Windchill PDMLink. This helped ZTR develop a highly automated product development process and integrate part and BOM management between the company’s various manufacturing systems, including ERP.
PTC Windchill also provided seamless interaction with the company’s 3D CAD system, PTC Creo.
The results? The company says its data management efficiency has improved by 25%. Design errors are better addressed, as the approval process is more streamlined and internal collaboration improved. Consequently, product development is now 30% faster.
These outcomes all helped ZTR build an overall solution that has resulted in 2 to 4 times faster release to manufacturing time for the company.
To find out more about ZTR and its success with PTC Windchill and PTC Creo read the case study.
Images courtesy of ZTR.
ZTR Accelerates Product Development Time by 30% with PTC Windchill and PTC Creo
Zaporozhtransformator (ZTR) is one of the worldwide leaders of transformer production, supplying its products to 85 world countries.
Decrease design time, reduce time to market, develop more innovative products, collaborate between different departments, automate design and enterprise approval processes, manage CAD data, enable concurrent engineering, manage large assemblies, and enable ERP and CAPP integration
Working with Engineering Company Technopolis Ltd, an authorized PTC Reseller, ZTR adopted PTC Windchill PDMLink as an enterprise product data management (PDM) platform and PTC Windchill ProjectLink as an enterprise project management solution. This helps develop highly automated product development process and integrate part and BOM management processes between PTC Windchill PDMLink engineering database and Microsoft Dynamics AX and domestic CAPP Techcard manufacturing systems. ZTR also get greats value from united and seamless PTC Windchill and PTC Creo Elements/Pro.
Improved CAD data management efficiency by 25%
Accelerated product development time by 30%
Established an optimized product development process between engineering and manufacturing which speeds up release to manufacture 2-4 times
Eliminated design errors due to improvement in approval processes
Overall significant improvement in internal collaboration
Olaf Seger, an engineer at KTM, just reinvented the wheel.
That is, he designed a new wheel for the 2013 KTM 690 Duke, a powerful single-cylinder motorcycle used in racing and road riding.
“The KTM 690 wheel introduces a new generation to the product line,” says Seger. “Going forward, KTM will use these wheels on many of its new models.” The 2013 design is strong as ever. But visibly, you can see that the familiar 5-spoke design has been replaced with a less traditional configuration, a lighter one.
Previous KTM wheel design (left) and 2013 wheel design (right)
That’s no small accomplishment in the world of racing bikes. In fact, Seger says that redesigning the wheel was one of the greatest challenges on the 2013 model. Even microscopic changes to the design had enormous effects on the life of a wheel as well as its performance. One wrong dimension, even a small one, and the whole component can fail–dangerously.
KTM Wheel design in PTC Creo
On the other hand, with a smart tweak here and there, you get a lighter responsive wheel that helps maximize power to weight, lower potential vibration, improve stability and drive fuel efficiency up.
As you might expect, the new wheels required a lot of testing. So much testing that prototyping would have become prohibitively expensive and delayed development by months. Fortunately, Seger had PTC Creo Simulate.
“With PTC Creo Simulate, we save a lot of time because we can check within approximately an hour whether a design change was successful,” says Seger.
The design team can then repeat simulations easily, too. “If you set parameters accordingly, you don’t have to worry about ongoing design changes,” he says. “The program checks them automatically.”
Wheel Simulation with PTC Creo Simulate
With these frequent simulations, the team reduced expensive prototypes, experimented more, and ensured that they had created wheels that were both lightweight and would endure on the road for a very long time.
Detect Problems and Optimize Designs with PTC Creo
One of the biggest challenges to redesigning the wheels was synchronizing work with changes that were taking place in the rest of the bike. The seat, twin plug head, exhaust—nearly everything was reconsidered for this model. To help ensure that all those separate activities didn’t lead to conflicts, the KTM team used PTC Windchill data management.
“With PTC Windchill data management, we’re always up-to-date with the data and the work of the other engineers,” says Seger. The software helps engineers avoid mistakes, because “you usually realize pretty quickly what another engineer is currently working on, i.e., what his current design status is.”
Again, this saved KTM even more time during development.
“KTM would definitely not be able to put such good products on the market so quickly withoutPTC Creo, especially those products that draw heavily from the latest technological innovations.”
And Seger likes quick.
“Well, it’s fantastic to ride the bike you’ve helped design yourself, where you know how it came about. Every time you ride it, you’re filled with pleasure.”