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PDMBMW Group14.05.2007
1
Product Data Management
Optimized product engineering processes with mySAP PLM at BMW Group
Beate Koch, SAP ConsultingHelmut Hirsch, BMW AG
PDMBMW Group14.05.2007
2
What We’ll Cover ...
BMW Overview – Complexity Challenges
BMW Product Development Process – PEP with PDM
Solution based on SAP ERP
Main Challenges
Wrap-Up
PDMBMW Group14.05.2007
3
Expansion.Extending the Product Portfolio.
SuperLuxury
Luxury
Upper Midrange
Midrange
Compact
Small
Micro
Segment Saloon Coupé Touring Convertible Roadster Off-Road Van MPV
PDMBMW Group14.05.2007
4
Development and Production Network. A Basis For High Flexibility In Car Production.
PDMBMW Group14.05.2007
5
Complexity In Vehicle DevelopmentConsequence Of Premium Brand Strategy
Function complexity [fx]
Overall complexity
2001 2002 2003 2004 2005
7 Series
Z4
6 Series
1 Series
5 Series X3
2001 2002 2003 2004 2005
7 Series
Z4
6 Series
1 Series
5 Series X3
Product programm complexity
PDMBMW Group14.05.2007
6
What We’ll Cover ...
BMW Overview – Complexity Challenges
BMW Product Development Process – PEP with PDM
Solution based on SAP ERP
Main Challenges
Wrap-Up
PDMBMW Group14.05.2007
7
The BMW Group Produkt Development Prozess – PEP Effectiveness in the Early phase – Efficiency in the seriedevelopment phase
Series development
SOPSeries Development
Early phase
Strategyinput
Preliminary WorkPhase
Starting confirmationTarget agreementmodel line derivative
Application initial phasemodel line
*PEP – Product Development Process
Efficiency(Do things right)
Effectiveness(Do the right things)
PDMBMW Group14.05.2007
8
Our mission statement.“At any given time we have a transparently and bindingview in PEP* where the vehicle stands concerningproduct and process.’’
Series development
SOPSeries Development
Early phase
Strategyinput
Preliminary WorkPhase
Starting confirmationTarget agreementmodel line derivative
Application initial phasemodel line
*PEP – Product Development Process
PL
Continuous reference product structureas “PDM backbone.’’
PEP PDM aims for the implementation of theproduct data management based on a continuous product structure with selectionof configurations using SAP.
PDMBMW Group14.05.2007
9
PEP PDM in practice.The “PDM Core” is being used and important Processes are supported.
Management
Architecture
Configuration
DesignEngineering
Vitual Car
Purchase
Prototypebuilt
BMW-Partner
Conceptphase Series DevelopmentInnovation
First Configurattion ...... Changes .. ReleasePL
TargetsStatusprozesse
Functional, GeometricConcept
BOM
requirement specifications
Prototypes
Change Management
Change Mangement with partner
PL
PL
PL
PDMBMW Group14.05.2007
10
PEP PDM in figures.The “PDM Core” is being used and important Processes are supported.
PL
5.000 technical specifications20.000 new engineering
change requests
Documentations of test vehicles for4 Modeltypes
(>100 vehicles each type)
5 Model Lines
160 configuredModeltypes
20.000 Assemblies
300.000 ComponentVariants
aprox. 1.800 usersonline every day!
PDMBMW Group14.05.2007
11
ComponentDesign
Release
PEP PDM LS3.Business process overview.
Supplier
Product-structure
Workshop facilityDesign
Virtual Carprocess
T-Gate TAIS
Modular
BMW Legacy
BMW Legacy
BMW Legacy
PL
PDMBMW Group14.05.2007
12
PEP PDM LS3Virtual car process
Achieved target:– Virtual cars and hardware prototypes are built on common product data,
which is managed in the SAP backbone.
Design Virtual car processCreate virtual cars
PLPL
Providedesign data
PDMBMW Group14.05.2007
13
What We’ll Cover ...
BMW Overview – Complexity Challenges
BMW Product Development Process – PEP with PDM
Solution based on SAP ERP
Main Challenges
Wrap-Up
PDMBMW Group14.05.2007
14
BMW PEP PDMBased on integrated Product and Process Management in SAP ERP
Support different business processes
– Maintain product data– Consume product data
SAP ERP with iPPE– Product data needed for the PEP– Data backbone
SAP NetWeaver– Technology Platform– Integration Platform– Development Platform
ProductStructure
PDMBMW Group14.05.2007
15
SAP ERPUsed components to manage product complexity
SAP ERP: used componentsOverall complexity
2001 2002 2003 2004 2005
7 Series
Z4
6 Series
1 Series
5 Series X3
VariantConfiguration
2001 2002 2003 2004 2005
7 Series
Z4
6 Series
1 Series
5 Series X3All possible configurations
iPPE Product Structure management
cFolders Collaboration withsuppliers
DocumentManagement
StartUp-Binder EV-4Version 1.024.01.2002Seite 16
zur Freigabe
ZB Räder /Reifen
Räder /Reifen (Basis 4 Stück, fallsnicht anders angegeben)
ZB Radlager und Mitnehmerflansch
FunktionsgruppenUnterfunktionsgruppen
Detaillierung
Key-Code
Ko.-Gr
Requirement specificationAll kind of product data extracts
Classification Material masterDocuments, …
EngineeringChange Management
Vehicle lifecyclesBody types (sedan, convertible,…)
Interfaces
Add-Ons tocover BMWsbusiness needs
BMW enhancements
Numerousinterfaces toBMW legacysystems
PDMBMW Group14.05.2007
16
What We’ll Cover ...
BMW Overview – Complexity Challenges
BMW Product Development Process – PEP with PDM
Solution based on SAP ERP
Main Challenges
Wrap-Up
PDMBMW Group14.05.2007
17
Main challenges:Deployment and Management of Change
2002 2006
1.800userseveryday
Achieved Target– 10 Management and 45 communication events for users– 125 topic specific events– 2.230 users in training sessions– 6.600 accesses on the
PEP PDM intranet monthly
Challenges– Roll-Out of new process methods based on a new IT solution for every
new product line in the PEP-PDM solution– Present focus on maintaining product data, need to focus also on data
consumers– Many specific reports available, but more flexibility needed
PDMBMW Group14.05.2007
18
Main challenges:Complexity: Power User – Occasional User
Achieved Target– One consistent structure – one
system
Challenges– Manage complexity– More users with different roles on the
same product data– Support complex processes on
complex UIs for power user– Support specific process for
occasional users
Planned Response– Support Role specific UIs for
occasional users to reduce complexity
Power User
PDMBMW Group14.05.2007
19
Main challenges:Performance
Achieved Target– One consistent structure – one system
Challenges– Manage permanently increasing high data
volume for – Maintain product structure– Product structure reporting– Product structure explosion
Planned Response– Provide data for consumer processes in
various systems at night– Parallelization of explosion process on
different application servers– Manage raising requirements– Evaluate new methods– Simulate emerging data volume
PV010 PV020 PV030 PV040
PV010
PV010
PV030
For one vehicle product line:
Current number of component variants:
Total: 187.000Without history: 163.000
Expected volume increase:
Structure components will double every two years.
PDMBMW Group14.05.2007
20
What We’ll Cover ...
BMW Overview – Complexity Challenges
BMW Product Development Process – PEP with PDM
Solution based on SAP ERP
Main Challenges
Wrap-Up
PDMBMW Group14.05.2007
21
Summary
The “PDM Core” is being used and important processes are supported.
Our vision became reality - we have at any given time a transparently and binding view in PEP* where the vehicle stands concerning product and process.
Roll-Outs to further product lines are in planning.
We have an increasing number of users and processes on the provided product data.
We still have to work on reducing complexity, to get the product data accessible for all users.
We have to design the solution in order to cope with the continuously increasing data volume.
PDMBMW Group14.05.2007
22
PEP PDMProduct Data Management BMW Group
Thank you for your attention
PEP PDMPremium processes for premiumproducts