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ECTR w/NX and how Molex is deploying PLM & PPM across New Product Development
SAP Manufacturing Industry Forum – The Westin Lombard
Lombard, IL | June 23-25, 2015
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 2 Confidential
Agenda
About Molex
Company
PLM Case Study & Success Tips
About GyanSys
Who we are
SAP Product Lifecycle Management (PLM)
Road Map & Overview of Functionality
Best Practices
Lessons Learned
Tips & Tricks
Live Demo
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 3 Confidential
Speaker Introductions
• John Koester – Molex Director of Molex Technical Information Systems
• John Hoover – GyanSys PLM/PPM Practice Director
About Molex
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 5 Confidential
Molex is a leading one-source supplier for total
interconnect solutions with over $4B in annual revenue
Our team of more than 40 thousand highly skilled
individuals are focused on the design, development and
distribution of innovative solutions critical to products
that touch virtually every walk of life.
We are a truly global company with 45 manufacturing locations in 17 countries
Our portfolio is among the world's largest with over 100,000 reliable products supporting the Automotive, InfoTech, Telecom, Mobile, Consumer Electronics, Industrial, Medical & Military Industries
Molex Today
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 6 Confidential
Products and Solutions to Meet the Needs of a Wide Range of Industries
LCD and TV Panel 1. Input/Output
2. FPC
3. Wire-to-Board
4. Backlight Wire-to-Board
5. Board-to-Board
6. Memory Card
7. Micro Coaxial
Mobile Phone 1. Internal Antenna
2. Microphone/Antenna
3. Keypad/Side Switch
4. Earpiece
5. LCD
6. Camera
7. Hinge
8. Speakers
9. Battery
10. Memory Card
11. SIM
12. Input/Output
Desktop Computer 1. Input/Output
2. Power Supply
3. CPU Socket
4. Storage Drive
5. Memory Module Socket
6. Edge Cards
7. Thermal Acoustic
8. Integrated Product
Car Audio 1. Detachable Board-to-Board
2. Floating Board-to-Board
3. Wire-to-Board
4. Power/Fuse
5. FFC/FPC
6. Back I/O
7. Front
Data/Com
Consumer
Telecom-Mobile
Automotive
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 7 Confidential
Why do over half of all PLM projects fail to meet their objectives, are not delivered on time, or cost more money than the budget planned for?
• A PLM Implementation is not a single project but a grouping of several interrelated projects and activities where the objectives, time commitments and costs can never be fully defined nor completely understood by all stakeholders at the start of the program.
• Successful implementations typically require changing how people work. This can be more of an art then a science, especially when the capabilities of the new technology are not fully understood at the beginning of the project.
What is the solution for success?
• Unfortunately, there is no simple answer. However, there are specific actions that can be taken during each phase of a PLM implementation that can help you overcome these challenges and greatly improve your probability of success.
Case Study
ID LIKE TO KICK OFF THE PROJECT BY
ASSIGNING BLAME FOR ITS EVENTUAL
FAILURE
“The beginning of knowledge is the discovery of something
that we do not understand”
Frank Herbert
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 8 Confidential
Organize the Program
Super User
Blue Printing
Team
Legend
Support & Training
Global Application
Owner
IPD
Configuration & Development
Change Management Deployment & Support
Finance CPD MPD
?
?
Global Engineering Council
ITC
Regional IT Support (AME, EUR, FES, FEN)
Ops Quality
Supply Chain
Sales
RIT
Product
Die
Mold
Automation/
Application Tooling
Data Quality Team
Project Manager
Functional Lead
Information Technology Coordinator’s
(Business Process Owner)
( Solution Architect )
– (Subject Matter Experts)
(Program Management)
(IT System Support)
Organize the Program by creating a Program Governance Model.
• Business Process Owner
• Program Management
• Solution Architect
• Subject matter expert(s)
• IT Support
Hire an experienced independent project manager from outside your organization to help keep the project on track.
Establish a cross functional team and utilize a Decision Matrix or Pugh Diagram to objectively measure and select the solution that is the best fit for your organization.
Identify and select the appropriate consulting resources to make your project a success.
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 9 Confidential
Estimate the total cost of your PLM program
• Create a 5 year Rough-cut cost analysis and share it with the team early on.
• Document all major costs including internal resources in your analysis.
• This is a good first step and ensures you have the commitment to support the initiative with the right balance of IT and business resources.
Define and agree on the scope of your PLM program.
• Create a roadmap to visually outline the timing of the major PLM initiatives in your program and review it regularly with all stakeholders.
• Utilize an effective project-sequencing methodology prior to creating your roadmap to identify the order and duration of each major activity
• This is key to breaking your program down into smaller more manageable deliverables that can be published on your roadmap.
Identify the costs and define the Scope
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 10 Confidential
Blueprint your solution
• Create a detailed description of your business processes and system requirements
• Don’t forget the business rules and engineering change management
Build the Foundation first
• Utilize an agile methodology
• Focus on what is absolutely needed to stand up the system for go-live.
• Don’t gold plate the system with changes or features out of the scope of the foundation.
• Separate the initial release to production from the go-live event.
Fine tune during implementation
• Once you are in production, walk through and tune up all “out of box” functionality utilizing inputs from the rest of the team.
• Integrate with other areas of your PLM landscape
• This provides a great opportunity for process harmonization across your organization.
Configure, Test and Validate
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 11 Confidential
Perform disciplined change management
• Meet regularly with your team & encourage them to bring up and discuss issues when they arise.
• Track and prioritize (L,M,H & SS) all issues using a defect tracking tool.
• Appropriately engage external consulting resource to resolve issues quickly
Optimize your testing process
• Improve quality and eliminate lag by adding an additional layer of testing (Development Testing) between development and QA testing.
• Don’t wait until the last day for test results. Implement “Virtual Conference Room Testing”
Improve software quality & delivery
• Establish a regular cadence for solution delivery and hit the date!
• Implement software version control (Subversion) to manage your source code
• Utilize application packaging (SCCM) to improve the quality and delivery of the solution.
Refine your process
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 12 Confidential
Train your users
• Set up a dedicated training environment avoid using QA
• Utilize a train the trainer approach for all basic training.
• Don’t under estimate the value of “Stick Time”.
• Supplement training with eLearning and lunch & learns
• Encourage your user community to attend off-site vendor workshops and seminars
Implement the solution
• Make sure your users understand their Role and Responsibilities with respect to the implementation.
• Regularly measure and communicate progress to all stakeholders
• Conduct focused user surveys to keep implementation on track
Communicate, communicate, communicate
• Be deliberate and plan your communication strategy.
• Utilize a communication matrix to provide information in the right format, at the right time, and with the right impact.
• Identify and share success stories with the rest of the user community
Train, Implement & Communicate
About GyanSys
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 14 Confidential
GyanSys Fact sheet
14
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 15 Confidential
15
2005: GyanSys
incorporated
2008: Became SAP
Services Partner
2010: Certified as
runSAP Partner
2011: Signed the Consulting Partnership
2012: Became SAP
Channel Partner
2013:
SAP’s Cloud Partners
2014: Certified as
PCoE
• Largest North American PLM 7.01 Ramp Up deployment
• GyanSys instructors provided several training at SAP Education Centers
• GyanSys employees became part of Ramp-Up testing of new product suites
SAP Relationship - Snapshot
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 16 Confidential
GyanSys - SAP PLM/PPM Practice
GyanSys has over a dozen successful PLM/PPM implementations, including Pulse Electronics, Bose Radio, Molex, Fujitsu, Hunter Douglas, Allison Transmissions, Haas, Avaya Profession Services, Scotts Miracle Grow, Wabash and Computer Associates.
Our US-based employee consultants have over 200 years combined experience in PLM/PPM area. We go beyond SAP and focus on best practices and business processes as part of our standard implementation methodology.
• Global Resources in PLM, PPM, EC, EH&S, RM, RD, CPM, NWBC (USA - Functional and Technical 25; India - Functional and Technical 25)
• 10 Demo servers to simulate almost any environment in PLM/PPM
• Recent Ramp Up Experience with PLM 7.03, PPM 6.1, Commercial Project Management (CPM 1.0)
SAP PLM
• PLM Roadmap & Overview
• Best Practices
• Lessons Learned
• Tips & Tricks
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 18 Confidential
PLM: A Journey from Start to End
As with any journey, we want to start out with a roadmap
The roadmap contains each functional area and a high-level timeline for
implementation tied to the sub modules
For each submodule, we will review a high-level understanding and benefits as we
go down the roadmap in order to understand the lessons learned at the end
Why would you want to start with a roadmap?
Organize what comes first, especially without a big bang
Perhaps your current PLM system is out of support?
Product or Project costing need (should cost)?
Now lets get moving down the roadmap
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 19 Confidential
Deployment 2
Where Used
DMS (Structure)
ECM/ECR/ECN
PSS
Redlining
Portfolio Management
Document
Storage (Instead
of SharePoint)
High-Level Resource/Cost
Planning/ Forecast
Project Cost
Automation
Portfolio Dashboards/
Analytics
Project Cost
MGMT
Service Management
BI/BW Integration
PLM/PDM
PPM
Legend
Capacity Planning (SCM)
DMS/Content
Server
(Unstructured)
PSM
Basis/IT
Business/
Data Prep
Timesheet
Tracking
Product Costing
Excess & Obsolete
Data Cleansing
EHP7 Upgrade
Content Server
Infrastructure
Deployment 1 Deployment 3 Deployment 5
Workflow/
Process Routes
Deployment 4
Plant
Maintenance
2015 2016
Resource
Management
Process
Cleansing
Data Conversion
Data Cleansing
Process
Cleansing
ECTR/CAD
Integration
Collaborative
Folders
SAP PLM Implementation Roadmap Example
Visual Enterprise
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 20 Confidential
PLM manages the process lifecycle of a new/existing product
PLM manages the data lifecycle of new/existing BOMs and Parts through PED/ECR
SAP will hold one single data repository for all PLM & PPM
Integrated Business Processes
Portfolio & Project Management (PPM)
Product Data Management (PDM)
Product Lifecycle Management (PLM)
PLM
PPM
NPD Project Cost Tracking
Portfolio Management
Project Schedule Tracking
ECR, DMS, PDM
eBOM – mBOM
Eng Change Management
Document Mgt
SAP PLM Simplified Module Stack
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 21 Confidential
Basis and Landscape
First things first: Basis!
What are the current versions and recommendations? Please do ask questions at
the end on this, as each customer landscape can be a mix of what is best for them.
Current versions: Dependency on some for EHP7
PPM 6.1
NWBC 7.4
PLM 7.03
DMS EHP7 for ECC
Content Server (Used for un-structured and structured documents)
TREX 7.1 (Auto-search/auto-fill)
SAP PLM
• Overview
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 23 Confidential
PPM Basis Component Install
Component Install or separate instance
Pros Cons
Integration with ECC: No need to set
up ALE/RFC connections
System performance depending on
data and other functionality; the
performance can be higher in a
separate instance (Non-HANA)
No extra configuration for instance
pointers
Landscape is tied to ECC
upgrades. If separate instance
outages/upgrades can be done at
any time without impacting ECC.
No separate server hardware,
monitoring, and maintenance
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 24 Confidential
PLM: SAP NetWeaver Business Client
It all starts with the new GUI for SAP NetWeaver® 7.4; much better than SAP GUI
With this, you do not need to deploy SAP GUI, as T-Codes can be added to the left navigation or tab for any older ECC transaction
Live reporting dashboards
Instant Excel extracts from most screens
Custom views
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 25 Confidential
Document Management System (DMS)
DMS is the foundation of PLM
SAP Document Management system is the single source for documents in SAP PLM if an SAP-centric solution is the target. DMS is capable of storing Engineering drawings and reference documents.
SAP DMS system is integrated with CAD throughout the new Engineering Control Center and will have object links available for these objects across SAP modules. DMS utilizes the underlying content server to store the originals in SAP.
Work center is a document dashboard available to user. This one screen will provide much functionality and queuing to the users.
Quick search and advance search is available
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 26 Confidential
Document Management System (DMS) (cont.)
Inbox for work Items is standard with workflow logging
Two Interfaces for DMS:
Document Browser: This application is available to all users for managing private
and public document folders. Expand and collapse document structure. Change or
create document on same screen.
Easy DMS: This application should be available to document Admins at minimum
for managing documents. Additional features of eDMS are offline access of
document and structure, Mass Check-in, drag and drop.
Document can have embedded viewer for design document visualization. Visual Viewer (VEG) can be used for design visualization and markup.
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 27 Confidential
Engineering Control Center (ECTR)
ECTR: what is it?
It integrates easily with VEG
DMS & XML is the configuration setup
Which CAD systems will it be available for?
PTC Creo, CATIA 5, AutoCAD, NX, SolidWorks, Solid Edge
Universal Ribbon in the desktop CAD
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 28 Confidential
Engineering Control Center (ECTR) (cont.)
Architecture summary (Plug in from third-party still required)
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 29 Confidential
Engineering Change Record (ECR/ECO)
If DMS is the foundation of PLM, ECR is the building on top
Attributes at the header and item level can be added/removed using the
configuration
Implement validations on required fields (attributes) at each status transition
Navigation to the change objects from Engineering Record
Effectivity dates!
Integration with Business Context View (BCV) would give 360 view of change object upon selection. This helps in approval process to make decisions.
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 30 Confidential
Engineering Change Record
Example of a ECR & ECO Status flow
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 31 Confidential
Workflows Using Process Routes
Predefined process route steps
Decide to process individually or load from a template
Dynamic workflow
Ad hoc additions
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 32 Confidential
Product Structure Synchronization (PSS)
Product Structure Synchronization is used to map source structure from one application area to another, such as Engineering to Manufacturing
Synchronization Unit created for source and target structure to reflect up-to-date data
Synchronization unit status gives quick info about the mBOM associated with the eBOM
If BOMS are in or not in alignment, it monitors and shows the structure synchronization and the conflict(s)
Resolving conflict using pre-defined, rule-based actions
Change Number can be used for BOM Synchronization
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 33 Confidential
PSS: How Do Structures (E-BOM, M-BOM) Evolve Over Time?
Product Development
Manufacturing
ECN1 Valid to
MCN1 Valid to
ECN2
MCN2
Handover Handover
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 34 Confidential
Portfolio and Project Management
Integrated to Product Development
NPDI Project Scheduling & Monitoring
HCM Integration & CATS Time tracking
PO integration via FICO internal orders or Project Systems
Actual project cost tracking with links to all ECR objects for product costing
RDS is available
Match PPM to your maturity of the PMO processes; it can grow with your company easily
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 35 Confidential
PPM with PLM NPD Summary Process
SAP PLM
• Best Practices
• Lessons Learned
• Tips & Tricks
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 37 Confidential
Lessons Learned: Data Conversion
Data conversion of in-flight documents, BOMs, projects should not be underestimated …
1. Start data cleansing ASAP
2. Archive old data if possible
3. Migrate non-WIP data early
The data conversion effort should start before the project kicks off
Plan to load data in several logical sets prior to go-live. Ensure a good delta process is maintained and tracked in the legacy system for new documents, BOMs, etc.
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 38 Confidential
Data Conversion (cont.)
Additional steps for a successful data conversion:
Attribute Cleansing: delete or mark obsolete any attributes no longer required in
legacy systems
Come up with the mapping of new (if needed) Document Classification/Types
Agree to the age of the product/documents to be migrated
Post-blueprint (design), map the documents and attributes to SAP fields
Agree to a data conversion plan, including mock go-live and dry runs in the QA
system. QA system should match the production system in size and processing
power to reduce risk of timings and other errors not captured correctly.
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 39 Confidential
Workflow Lessons
Clean up burdensome processes for approvals, e.g., if it takes 10 approvals to make a R&D part production-ready and 7 approvals for a $5,000,000 PO, you may want to look at that approval level
Avoid batch workflows; if you’re not reviewing each, why batch approve?
Avoid nested workflows, as these are too complex; keep it simple
Identify and assign a workflow business administrator
Use process routes and route templates where possible vs. hardcoding workflows. Sometimes, strict workflows are needed, but not always.
A process route can be changed/added to even when the workflow has already begun. A process route can be saved as template, which is a separate reusable object that provides basic functions that can be integrated into any application.
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 40 Confidential
PLM Team
Have the team be full-time. For example, if a team member is too valuable to miss their daily job duties, that is the person you want assigned to the project as much as possible.
Make sure to include representatives and subject matter experts, one from each of these areas for the project:
• Marketing
• Purchasing
• Engineering
• PMO
• Finance
• Service
• Manufacturing/Operations
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 41 Confidential
General PLM Project Lessons
Don’t go big bang; use the roadmap from earlier as a guide. You can pull items forward or push some out that you don’t need.
Start using the SAP solution in a meaningful way and retire the legacy system once you go-live
Do not try to run parallel production systems, as this puts strain on the business team and you risk have broken data in two systems. Fight through the bumps and do not be tempted to run parallel or roll back or you will never go forward from a legacy system.
Turn the legacy system to read-only at Go-Live
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 42 Confidential
General Project Tips
Conduct a kick-off meeting to get everyone on the same page for the project. This should include the roadmap discovery sessions and each project and phase of deployment.
Have weekly and, if needed, daily project lead rhythm meetings; a project slips one day at a time
Get at least some training early for project team members before the blueprint of the project. This is a true project accelerator.
© 2015 SAP SE or an SAP affiliate company. All rights reserved. 43 Confidential
7 Key Points to Take Home
1. Start with a roadmap for the journey!
2. Cleanse and normalize your data, including documents; start now
3. Plan several data conversion dry runs & a mock go-live
4. Take advantage of the project re-engineer your processes and workflow approvals
5. Break up large projects into manageable chunks, e.g., DMS, ECR, PPM vs. going big bang
6. Don’t underestimate the effort of a PLM project
7. Don’t run parallel production systems post go-live
© 2015 SAP SE or an SAP affiliate company. All rights reserved.
Contact information:
John Koester
John Hoover
480-215-4935
Thank you.
Q & A