Sony slashes package design times by 50% with Catia v5

Sony, the Japanese consumer electronics manufacturer, has reduced its package design times for its flat screen European WEGA 21-inch television monitors by 50-70% using IBM Dassault Systemes’ Catia v5 3D modelling software. Speaking at last months’ European Catia Forum in Berlin, Sony engineers said that the software’s new capabilities meant they were able to apply their technical advances to the product line more quickly as a result. “Catia v5 gave us very efficient means for design method compared to conventional design using 2D,” said Mr. Takeo Mitsui, assistant manager, Home Visual Company - Home Network Company - Sony. “Digital mock-up enabled us to evaluate the design earlier than with the former prototype-based process and to give feedback promptly to the design team … Accuracy of evaluation significantly improved. “Also, the module design method enabled a very quick and efficient evaluation of alternate designs to improve product quality. Unless entire design is changed, this method can be easily used for product model change.” Sony uses Catia v5 for design, analysis, rapid prototyping production and package design. And for the WEGA flat screens, Sony is using the software’s full 3D modelling capabilities, from the power button to the operation panel flap, including draft angles and fillets. In addition, reused parts such as outer shapes of the CRT and base plates were also precisely modelled in order to study and evaluate the interferences or assembly feasibility. Sony migrated from a 2D CAD system to a 3D one, and integrated both engineering and manufacturing processes, adopting a modular design methodology. This resulted in high effectiveness and a marked increase in design speed. The entire design flow also improved as concurrent design activities in adjacent departments (and even the die mouldmaker) took items off the critical path. Sony engineers now plan to exchange the 3D data and information from the design phase between the manufacturing, marketing, and sales divisions in true PLM (product lifecycle management) fashion.