Product Life-Cycle Management II - RWTH Aachen … Management II (Prof. Schuh) Product Life Cycle Management II Lecture 9 PM II L9 Page 2 ©WZL IT-Systems in the field of Production

Production Management II (Prof. Schuh)

Product Life Cycle Management II

Lecture 9

PM II L9 Page 1

WZL©

Production Management II- Lecture 9 -

Product Life-Cycle Management II

Contact:Dipl.-Ing. Wolfgang [email protected] 53B Raum 507Tel.: 80 - 28 469

Objective of the Lecture:

• Overview of Product-Data-Management-Systems

• Evolution of CAD- and ERP-Systems to PDM-Systems

• Structure and Functions of PDM-Systems

• Benefit of PDM-Systems



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IT-Systems in the field of Production Management

Market Engineering ProcessEngineering

ProductionPlanning

ManufacturingAssembly Distribution Service

MaintenanceDisassembly

Recycling

CAD

CAM

CRM

SCMCAP

CAE

PLM-Meta-Data Pool (Links of Product Data)

CAO

CAD: Computer Aided DesignCAE: Computer Aided EngineeringCAM: Computer Aided Manufacturing

CAO: Computer Aided OfficeCAQ: Computer Aided QualityCAM: Computer Aided Manufacturing

CAQ

CRM: Custom Relationship ManagementERP: Enterprise Ressource PlanningPLM: Product Lifecycle Management

SCM: Supply Chain Management

ERP

The PLM-Meta-Data Pool ist the integration platform of all product data. Meta-Data are datums to identify data material (e.g. date of revision of a drawing). The pool is integrated by links and references to data of CAD, CAE, etc.



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Classification of PLM Definitions

source: itm

Management conceptIT- oriented approachPLM = PDMPLM is not a new class of systems and not a new kind of PDM-Systems, but the consequent implementation,based on web-technolgies, of enterprise and location spanned use of PDM-core competencies.Data management, process management and system integration in all fields and phases of the industrial value added.

www.pdm-infoshop.de/Schoettner Professor of Chinese Academy of Sciences

PLM is a PDM-System driven by engineering. PLM aides all employees during the complete product-life-cycle by administration of all associated data and processes.

Ohnemus, T.; in eDM-REPORT Nr.3 2000

Product Data Management (PDM) describes the management and classification of design data and Specifications for an engineered product, and the management of change to this information. PDM is supported by various Product Data Technologies, such as STEP. Product Life-cycle Management (PLM) describes the management and control of all product-related information over the entire product and asset life cycle

Pdteurope/ Prof.Dr.Anderl TU Darmstadt

PLM is the extension of PDM towards a comprehensive Approach for productrelatedinformation and knowledge Management within an enterprise. This includes planningand controlling of processes, that arerequired for managing data, documents and enterprise resources throughout the entireproduct lifecycle. PLM systemsaredistributed Technological informationsystems for archieving, administrating and providing all product or facility related infor-mation in required quality and at the right time and place

Prof.Dr.M. Abramovici Bochum

PLM is a strategic business approach that applies a consistent set of business solutions in support of the collaborative creation, management, dissemination, and use of product definition information across the extended enterprise from concept to end of life – integrating people, processes, and information--

www.cimdata.com

PLM is the administration and control of all product data -of the complete life-cyclealong the extended logistic chain -starting with engineering and manufacturing, over distribution and ending with maintenance. The integrated PLM has access to all product and process data ofthe whole product life cycle. The range of functions is beyond the described systems.

Prof.Dr.Stucky aifb Karlsruhe

The term of product-life-cycle is used in the literature and by system suppliers in different ways.

Three different kinds have to be distinguished:

•PLM as a synonym for product data management

•PLM as an a integrating platform of different IT-systems

•PLM as integrated management concept of data administration and allocation of information



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2D-CAD1960

MRP1950

PLM – horizontal integration

Intersection:• adjustment

of capacities• configuration• parts-

administration• BOM-

administration

Evolution und Definition of PLM

PLM is the administration and control of all product data -during the complete life-cycle along the extended logistic chain - starting with engineering and manufacturing, over distribution and ending with maintenance. The integrated PLM has access to all product and process data of the whole product life cycle. The range of functions is bigger than the described systems. Prof.Dr.Stucky aifb Karlsruhe

In the beginning application software was used to aid isolated activities in the organisation. Examples are 2D-CAD-Systems and MRP (Material Requirement Planning).

In the course of integration of activities and the growth of performance of IT-systems additional functions were integrated.

The system suppliers have driven the progress further by mergers and strategic collaboration, finally it results in an overlapping of CAD-Systems and ERP-Systems.



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Evolution of PDM-Systems

1980 1985 1990 1992 1995 2000

2D/3D-CAD-Systems

CAD-AddOns: drawing administration, bill of structure characteristics,standard parts,..

1st Generationisolated EDM/PDM-Systeme

documentmanagement

structure-management

2nd Generationvertical integration

structure-managementdokumenten-management

3rd Generationhorizontal integration

PDM ERPLife-Cycle-

Management

Source: itm



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Terms of Advanced PDM Developments

� PDM2 = Product and Process Development Management� CPC = Collaborative Product Commerce� PLM = Product Life Cycle Management� cPDM = collaborative Product Data Management� VPDM = Virtual Product Definition Management� e-PLM = electronic Product Life Cycle Management� PDC = Product Definition and Commerce� PKM = Product Knowledge Management� …

Source: itm

The kind of information handling and acquisition that is more sophisticated than today´s functionality of PDM-systems are named differently in the Literature.

Examples are:

cPDM of CIMdata

vPDM of Gartner Group

e-PLM of AMR



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Relevance of EDM/PDM-Systemen

� The relevance of EDM/PDM-systems is growing, but there is a lack of control of the systems

� VR-systems will get more important in the future, but the control of these systems is very low

� the control of 2D-CAD-systems is the highest of all, but the importance will decrease in future no low middle high

no

low

middle

high

Today´s relevance

Futu

re re

leva

nce

VR

3D-CAD

2D-CAD

size = grade of control

EDM/PDM

Source: WZL-Studie 2003

A study, performed by the WZL, asked 32 different companies about today's and future importance of IT-systems in the field of product engineering. Additional the grade of control of these IT-systems was analysed.



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Structure of Classic PDM-Systems

Applicational Functions Utility Functions

PDM-Vault

document/data

management

workflow/process

management

productstructure

management

classificationproject-management

communicationnotification

datatransport

datatransformation

systemadministration

Viewing/Redlining

product data„meta data“(master data, stucturedata, etc,..)

Source: itm

PDM-systems have applicational functions, utility functions and the so called PDM-vault. The applicational functions aid directly the activities of user interaction. Utility functions are tasks that are running in in the background layer without any user interaction. The master data is supplied by the PDM-vault. The applications functions refer to product data, the utility functions refer to meta data.



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General Overview of Functions of EDM/PDM-Systems

product oriented

� product structure management� document management� configuration management� classification� class lists of characteristics

� view management� revision management� file administration� storage� vaulting

process orientiert

� life-cycle-management� process/activity management� workflow management� project management� status management� interface management� viewing und redlining

� clearence sequences� revision management� access authorisation

administration� auditing� communication management� history

The functions of EDM/PDM-systems can be divided in two main categories. These are the product oriented and process oriented group of functions. The product oriented functions are used for generation of product data and the administration of product data. The use of process oriented functions is focused on collaboration in- and outside of the enterprise.



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Product Structure Management (1/2)

Building up and Administration of:� basic BOM und part usage

� quantities BOM� single-level BOM� structure BOM

� variant BOM� structure variants:

variation of BOM at different datums� part variants:

variants of single parts (e.g. colour)

� views of BOM� engineering, manufacturing, dispatching, assembly, etc.

Nr. Bezeichnung Anzahl2457 Schraube M6 362458 Schraube M8 142549 Flansch 32550 Mutter M6 20

Bezeichnung Anzahl1 Gehäuse 1

2 oberer Deckel 13 Unterteil 1

4 Seitenwand 15 Boden 1

6 Bodenblech 17 Füße 4

8 Schrauben 8

Artikel-Nr.

1Nr. Bezeichnung Anzahl

2 oberer Deckel 13 Unterteil 1

Gehäuse


4 Seitenwand 15 Boden 16 Schrauben 8

Unterteil


7 Bodenblech 18 Füße 4

Boden

Mengenstückliste

Baukastenstückliste

Strukturstückliste

Nr. Gleichteile P1 P2 P3B1 1B2 2B3 1B4 2E1 1 -1E6 1

Erzeugnistyp P

Nr. Gleichteile P1 P2 P3B1 1B2 1E1 1 -1 -1E2 1E3 1E6 1

Erzeugnistyp P

Product structures are often called bills of materials (BOM), they describe the assignments of product components (material, semi-finished products, parts, assembly groups, products) to each other.

The assignment is based on the use of components (“belongs to”) and the breaking up into components (“is made of”). The relation has information about quantity, assembly location, etc. The building up of several different structures is leading to different views.

Typical views are the functional view of the engineer, manufacturing and assembly oriented view of the process engineer or the distribution oriented view of the marketing department.

The structures are displayed text based or graphically based in a web-browser. The graphical display is more used then the text based illustration.



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Product Structur Management (2/2)

Substantial differences between views of BOM in the field of PDM

engineering BOM� neutral� functional

� history of origins

� manual, by hand

manufacturing BOM� job dependend� manufacturing resp.

assembly oriented� detailed information

about manufacturing and assembly

� systematic revision administration

criteriajob dependencystucture difference

information

revision



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Configuration Management (1/2)

Source: Eigner 2001

pastA1

C1 D1

B1todayA1

C1 D2 E1

B2futureA2

C1 D2 E1

F1

product structure

document structure

effectivity

= revision proposal

The activities in connection with configuration management are used to inform about a product´s construction-level(=configuration) at any state of it´s life-cycle. In addition there is information about the measures that leaded to the current construction-level. This verification management is very important in the course of product liability.

Changes of customer requirements are leading to configurations. These configurations have two different variants. The compatible configuration changes one part only, the incompatible configuration changes connecting parts either, because of different connection dimensions.

Past: All ever constructed parts and/or their state of manufacturing

Today: Current manufactured version

Future: Product and document structures that are in state of revision.



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Configuration Management (2/2)

� Administration of product configu-rations over the whole life cycle

� Definition und administration of basic configurations, ready-made parts and reference configurations

Dies ist ein wunderschönes Dokument und erfüllt so voll und z den













documentstructure

productstructure

effec

tivity

configurations

future

past

today

new document

revision

new part

revision

Source: Eigner 2001

Configuration Management (CM) is a systematic method to administrate the configuration model over the complete life-cycle. The guideline to CM is the ISO 10007. According to this standard CM is the management discipline, which is used over the whole product life-cycle, to secure the transparency and control over the functional and physical characteristics of a product.

To identify a construction-level the term “effectivity” is used. Effectivity is determined depending to the use-case by:

• Date or revision index (mostly mass products or consumer products)

• Serial number (mostly for investment goods in a limited-lot production in security relevant fields like aerospace, transportation and defence)



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Revisions Management (1/2)

phases of clearance and revision processes

EngineeringChangesRequest 2

EngineeringChange Request 1

EngineeringRelease Request 2

...

...

EngineeringRelease Request 1

Implementation EngineeringChange/ReleaseNotification

Revision proposal

• functional improvement• rationalisation of manufacturing

• customer requirements, market needs

• removel of errors in thetechnical documentation

• eliminate the cause of producing scrap

• legal requirements

engineering change order

• stop concering products• revision of documents, BOM, master data

• updating revision index• implementation of collected data in therevision note

• definition of mailing list

verification and approval

• adding of missin data• define department forrevision approval

• departments verificate, agree or disagree withstatement

• preparation of revision job

Distribution of Information

• clearence of the part• copying of documents• distribution according to mailing list

• revision fulfilled

EngineeringChange/ReleaseOrder

verification and approval

Source: Eigner 2001

The revisions management systemises the revision process to avoid inconsistencies in the product data. A revision proposal is set and is verified and approved by every concerned department. If a proposal is declined a statement is needed to justify the refusal.

If all departments agreed the revision proposal the old version is locked by the change order. The new version is elaborated and the new one replaces the old and is cleared. With the revision in the PDM-system all departments have the current version and all participants know about the latest revision.



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Revision Management (2/2)

Configuration:� mapping of different

authorization in the revision process

� illustration of revision workflows

Application:� run through the work flow� messages� saving and indexing of

product data

Example:IBM Enovia – revision workflow

Source: IBM



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Product Configuration (1/2)

� web-based configuration of products

� reuse of existing solutions

� illustration of available variants

� publishing functions for catalogue compilation

Beispiel:PTC Windchill Dynamic Design Link –user view (specification)

Source: PTC

Product Configurators are used to illustrate the product construction kit.

Products can be selected customer specific by vendor- or customer interaction. Exemplary the Car-Configurator by BMW it is given.

Product Configurators are often implemented in PDM-Systems, if a special solution would be to expensive,

The illustration shows a solution for a configuration of car trailers by PTC..



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Product Configuration (2/2)

� basis:generic product structure

� pre-configuration of parameter types and und fields of choice

� illustration of allowed and prohibited combinations

Beispiel:PTC Windchill Dynamic Design Link –Illustration of configuration

Source: PTC

Requirement for a product configurator is the mapping of the product structure with allowed and prohibited configurations in the PDM-system.

On a basis of parametric product data the customer is able to configure the product on his own.

The use of a product configurator should always be analysed very cautious. The effective work-flow of an order goes together with complex implementation of the configurator.



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Potential of PLM

Source: Betriebshütte

Clearances

Productdetermination

Productrealisation Launch Growth Adolescence Saturation of

the market Descent

€

0

Realisation costs

Product asset

Product volume

+

-

Quality factor,reuseabilty factor

Time-to-market factor

Quality factor

Synergy Factor

Sales factor

chronological phases

Trend without PLM

Trend with PLM

According to the typical volume and asset of every product seven phases of a life-cycle are differed. To define each phase the graph of product volume and asset is used. Requirement for a successful product determination is a strong orientation to the market. That means that customer orientation start with the first phases of the life-cycle and a efficient product engineering process is needed. Each clearance of a product realisation is an extensive financial exposure. The product determination has to be executed carefully and adequate ensured.



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Benefit of PDM during Engineering

0 %

20 %

40 %

60 %

80 %

100 %

very big

big

middel

small

no

faster accessto data

less engineeringfailures

unnecessarypart redundancies

fasterrevision process

more consistentproduct data

Source:: Océ 2001/M. Wendenburg

The use of a PDM-system is difficult to quantify. The saving of time or the consistent data pool is hard to be determined in costs or savings. But the advantages are clear. The engineer has not to search for drawings in old archives anymore, additionally he do not know if this is the current revision of the drawing. PDM-systems make this much more easier. The engineer has wide overview upon all engineering solutions and saves a lot of time.



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Risks during implementation and Use of EDM/PDM

0 %

20 %

40 %

60 %

80 %

100 %

very easy

no response

very difficult

difficult

normal

easy

systemperformance

systemstability

usersupport

useracceptance

suppliersupport

maintenance/upgrades

expansionof systems


A big problem during the implementation of a PDM-system is the migration of old data. Old data has to be reconfigured and reworked to avoid migration of inconsistencies in the new PDM-System.



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Technical Risks during Integration of Systems

� Departments and business partners in networks do not work with the same intergrable CAD/CAM-Systems

� system providers do not open their systems� interface and standards implementation is difficult

� same provider of CAD- and PDM-Systems � shifting the problem to PDM/ERP integration

� quality of the interface depends on transfer and administration of non-geometric data

� PDM/PPS-connection problem of software und organisation (e.g. which BOM will be maintained with which system, etc.)

� different CAD-systems depend on different structure information

� process flows are difficult to map � implementation is very difficult

AutoCADSolid

Works

?+ ?

CAD =

PDM

�

PDM≠ERP




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Criteria of System Choice

Functionality Interfaces Technology/Use of Internet

Usability adaptively/scalability

Planning of

Implementation

Investmentsecureness

BranchKnow-how

0 %

20 %

40 %

60 %

80 %

100 %

very important

relatively important

important

less important

unimportant


The difficulty is to define requirements, e.g the implementation of global goals within technical criteria. The selection of requirements is crucial for a successful implementation of PDM-systems. The cost calculations should span over five years at minimum because of the long life character of PDM-systems. The definition of requirements should take place on corporate workshops.



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PDM Systems – Branch Distribution (GER)

engineering 42,8%

automobile und supplier industry 21,2%

plant construction 11,5%

consumer goods 3,4%

electronics 8,6%

pharmaceutics, 0,3%

energy supply and administration 5,6%

other 6,6% Distribution of licenses according to branches

Source: EDM-Report, 2/2001



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PDM-Systems – Installations (GER)

axalant (E+P), 27%

Metaphase (SDRC), 15%

Pro*File (Procad), 10%Gain System (PDS), 9%

Compass (AIM), 7%

CIM Database (Contact), 6%

AM WorkFlow(Cyco), 5%

Iman (UGS), 5%

eMatrix (MatrixOne), 4%

Helios (ISD), 3%

Other 9%

installation basis(rates of all PDM-licenses used in Germany)

Source: EDM-Report, 2/2001

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Product Life-Cycle Management II - RWTH Aachen … Management II (Prof. Schuh) Product Life Cycle Management II Lecture 9 PM II L9 Page 2 ©WZL IT-Systems in the field of Production