Overcoming Key Challenges in CAD Data Exchange
Given the high-stakes, fast-paced nature of modern automotive engineering, the exchange of CAD data between OEMs and their complex network of suppliers is a critical process. Missteps can lead to costly delays, frustrating errors, and strained relationships, ultimately impacting a project's bottom line and time-to-market.
To better understand these challenges, we invited Callum Watson, a Data Coordinator at Majenta, to give a “front line” perspective in a recent webinar. You can watch the full recording here: A Day in the Life of a Data Coordinator: Getting CAD Data Exchange Right
For more in-depth discussion on challenges in automotive data management, browse our schedule of upcoming webinars
Wrestling with CAD incompatibilities
One of the most persistent headaches in automotive data exchange is the sheer variety of CAD systems and formats in play. As Callum explained, OEMs and suppliers often operate using different native CAD software (like NX or Catia) and, to complicate matters further, various versions of that software. This inherent incompatibility creates an immediate challenge.
Converting data between these formats – whether from one native system to another (e.g., NX to Catia) or to a neutral format like STEP – is where many data exchange problems arise. The conversion process isn't always straightforward, and there’s always the potential for data loss, corruption, or subtle changes in geometry if not handled with care and expertise.
The Q&A that we conducted during the webinar supports this view, with "incompatible CAD formats" and "inefficient CAD conversion between formats" emerging as two of the most common concerns among industry attendees.
Keeping pace with diverse systems and standards
Each automotive OEM operates within its own ecosystem, with its own PLM systems, data submission protocols, and unique quality standards. For suppliers working with multiple OEMs, aligning to a range of PLM systems and the process complexities that sit behind them is a core challenge, requiring their teams to stay up to date on each software platform and understand the intricacies of each organisation's workflow, adapting their practices to suit.
Adding to the challenge, OEM requirements aren’t static, but continually evolving. Software versions get updated frequently, and compliance requirements change from project to project. There’s also the human factor to consider. Sometimes, the specific preferences of a lead engineer at an OEM or legacy practices within a particular department can deviate from official documented standards, presenting further hoops to jump through.
Without constant vigilance and a significant investment of time in continual learning and upskilling, suppliers can quickly find themselves non-compliant, leading to rejected data, project setbacks and ultimately even loss of business.
Avoiding costly errors and inaccuracies
Ensuring the integrity of CAD data as it moves between systems and organisations is like walking a tightrope – a single misstep can have significant consequences. Incorrect or missing metadata, such as part weights or material specifications, might seem like minor details, but as Callum emphasised in the webinar, these can lead to major downstream problems in manufacturing, assembly, and cost analysis.
Even more impactful are "silent errors", when data might appear to have been transferred or converted correctly, but subtle issues like surface failures on a 3D model or discrepancies in how drawings appear go unnoticed. Hidden flaws like these can cause major problems, leading to parts that don't fit or function as intended, so the role of an experienced data coordinator, able to nip these types of errors in the bud, is mission-critical.
Skills gaps, security worries, and bottlenecks
The specialised skills and dedicated resources needed to manage CAD data exchange effectively are not always available to suppliers, especially smaller firms or companies dealing with multiple OEMs. And even if the right skills are in place, changes to OEM practices or standards, or internal personnel changes can set a supplier back to square one, facing the laborious process of retraining staff on a new set of requirements.
There’s also a security aspect to consider. Sharing sensitive design data, particularly in joint ventures between OEMs or when collaborating with a wide array of partners, raises significant Intellectual Property (IP) and data protection concerns – and for smaller suppliers, ensuring data is processed and shared securely is an increasing challenge as OEM requirements around encryption, application hardening and disaster recveory become more exacting.
The inherent complexities and occasional "quirks" of the PLM systems themselves can also throw up roadblocks. As Callum admitted quite candidly, “Some days these systems work fine, and some days they don't," requiring data coordinators to apply their experience and deep system knowledge to navigate the issue and find suitable workarounds.
Outsource your data exchange challenges
If you don’t have the requisite skills and resources to navigate these challenges in-house, or you’d prefer to focus your engineering expertise where it matters, Majenta can support you. From consultancy, to training, to full managed data exchange services, including data coordination, CAD translation and secure data transfer platforms, we have the expertise to cut through the complexity. Get in touch using the link below to discuss the options available.
