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An Airbus A380 readies for takeoff. Airbus recently signed a deal with Aras for the aircraft builder to use the Aras Innovator PLM
platform for up to 30,000 users for enterprise-wide engineering business processes.
September 2015 | AdvancedManufacturing.org 117
PLM SOftware
Redefining PLM
Patrick WaurzyniakSenior Editor
PLM software developers face many new
challenges, including the impact of Big
Data and the Internet of Things (IoT) on
the manufacturing industryT
o keep pace with the breakneck speed of
product developments, manufacturers demand
the utmost performance from product lifecycle
management (PLM) software. With the latest
advances in PLM’s core technologies, manufacturers
can trim costs, improve product designs, and speed
time-to-market on new product developments.
Enterprise software that makes up PLM consists
of a wide range of systems, from product data man-
agement (PDM) to CAD, CAM and CAE engineering
applications. In addition, PLM includes the critical
digital manufacturing tools that allow manufacturers to
quickly and easily lay out plant-floor equipment and test
factory-floor processes prior to finalizing plant designs.
The PLM market has flourished in recent years,
particularly in the area of advanced 3D visualization tools
and CAE multiphysics simulation software, and the PLM
market’s growth in 2014 increased by 6.8% over 2013
Photo courtesy Aras
to reach a total of $37.2 billion, according to recently released
statistics from market researcher CIMdata Inc. (Ann Arbor,
MI). “Calendar year 2014 was a solid year for PLM,” said
Stan Przybylinski, CIMdata’s vice president of Research. “The
result was total revenues above our forecast.” Companies
continued investing in PLM to achieve short-term benefits as
well as long-term strategic value across the product lifecycle
and across their extended enterprises. “There was growth in
all segments,” said Przybylinski, “and simulation and analysis
continued its strong showing of the last few years.”
Morphing PLM Into Something New
In order to fully realize digital manufacturing’s potential,
PLM developers and users need to rethink PLM, finding new
ways to employ these key tools for manufacturing, noted
CIMdata President Peter Bilello at last year’s CIMdata PLM
Road Map 2014 in Plymouth, MI. “We must rethink PLM,”
said Bilello. “The way we do PLM today really isn’t cutting it.
What should PLM be? The product lifecycle is changing.”
In its “Aerospace and Defense Industry PLM Value Gap Sur-
vey,” CIMdata concluded there is a significant gap between the
vision for PLM tools—CAD, CAM, CAE and digital manufactur-
ing factory-layout software—and the reality of what most com-
panies can actually accomplish with their PLM systems. This
2013 survey concluded that only a few aerospace and defense
builders come close to fully realizing the vision for PLM, and it’s
a similar story for many automotive OEMs and suppliers.
Today’s PLM developers are trying to balance a blend of
their traditional PDM and CAD/CAM/CAE tools with newer
technologies including analytics for dealing with Big Data’s
huge volumes of information, as well as for the “smart
products” that incorporate Internet of Things (IoT) functional-
ity, with sensors and software that can communicate with
enterprise software systems via the Web.
“The industry trends to develop ‘smart’ products, IoT, mass
customization, etc., are creating a compelling requirement for
PLM systems to expand beyond the traditional 3D CAD file
management role, and begin to manage the complete product
PLM SOftware
including embedded software, electronics and services,” said
Peter Schroer, CEO and founder of Aras Corp. (Andover, MA),
developer of the Aras Innovator PLM software. “For most
manufacturing companies, this is a significant change in how
product compliance, configuration manage-
ment and design validation is achieved.”
One of the major trends in PLM, Schroer
said, is the expansion of configuration manage-
ment and product structure control mechanisms
to handle the complete product definition includ-
ing the embedded software content. “Of the
intriguing changes driven by increase in software
content is a new understanding of where the
‘factory’ ends and where maintenance begins,”
Schroer noted. “With software, we are seeing
an almost continuous upgrade process, on the
factory floor, in the supply chain and even during
end-user operation of products.”
PLM systems traditionally have man-
aged product information only through design phases of
the lifecycle, he added. “In the last 5-10 years we’ve seen
increased requirements for PLM to manage product con-
figuration through the manufacturing phase as well,” Schroer
The Aras Innovator PLM includes 3D visualization tools for easy global
collaboration on product development designs.
Imag
e co
urte
sy A
ras
120 AdvancedManufacturing.org | September 2015
said. “Now, PLM will need to handle the entire product life
span, because we are continuously engineering products to
improve performance, and updates are being pushed out to
operating units in the field in real-time. Brave new world.”
An IoT Explosion
Though a relative newcomer, IoT is expected to take off
big-time, as market researcher IDC (Framingham, MA) re-
cently released a forecast showing the worldwide IoT market
is expected to grow dramatically, at a
16.9% compound annual growth rate
(CAGR), from $655.8 billion in 2014
to $1.7 trillion in 2020. Several PLM
developers have made significant IoT
investments, including the December
2013 purchase of ThingWorx by PLM
developer PTC (Needham, MA) for
$112 million, and in May, PTC made
a $105 million acquisition of predictive
data analytics developer Coldlight.
Smart, connected products are
driving manufacturers and, subse-
quently, PLM vendors, said Kevin
Wrenn, PTC’s divisional vice president
and general manager, Product Life-
cycle Management. “Once composed
solely of mechanical and electrical
parts, products have become complex
systems that combine hardware, sen-
sors, data storage, microprocessors,
software, and connectivity in myriad
ways,” Wrenn said. “These ‘smart, con-
nected products’—made possible by
vast improvements in processing power
and device miniaturization and by the
network benefits of ubiquitous wireless
connectivity—have unleashed a new era
of competition.”
Such smart, connected products
are transforming industries, customer
relationships, and the nature of com-
petition, said Wrenn. “With the right
strategy, manufacturers can capitalize on
these new opportunities to unleash real
economic value,” Wrenn said. Examples
could be farming equipment controlled
by GPS that plants seeds and fertilizer
in the same place, reducing waste, he
said. Products designed with applica-
tions controlled through easily configu-
rable, cheaper electronic interfaces can
PLM SOftware
See us at WESTEC Booth #2315
122 AdvancedManufacturing.org | September 2015
reduce the number of physical components that
need to be developed and manufactured, such as a
Tesla car with all-electronic controls, Wrenn noted.
“SCPs [smart, connected products] require
manufacturers to evaluate their current PLM strate-
gies so they manage the full definition of smart
products—mechanical, electrical, software. Plan-
ning, production and quality must follow suit and
account for testing and manufacturing of products
that require coordination across these disciplines,”
Wrenn said. “PLM software must include traceability
from early requirements, through the systems engi-
neering, design, production, and out to testing and
validation for complex, smart connected products.”
In July, PTC introduced its new IoT offering, the
Integrity product family of software and systems
engineering solutions. Wrenn said that Integrity is
a key part of PTC’s solution suite for managing the require-
ments, system modeling, testing, and validating that are
required for smart, connected products and their systems-
of-systems. “For companies designing new generations of
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PLM SOftware
With Internet of Things (IoT) sensor data, a manufacturer tracks its assets in
the field with real-time data tracked in PTC’s PLM systems.
Imag
e co
urte
sy P
TC
September 2015 | AdvancedManufacturing.org 123
IoT products, they need a clear definition of requirements
linked to a full system model,” he said. “System models
ensure mechanical, electrical and software definitions work
together. Manufacturers can no longer wait and simply test a
physical prototype without some early validating of the entire
smart design. PTC’s Integrity manages requirements, system
definitions, as well as systems-of-systems, and the software
development need for next-generation products. Integrity is
also able to deliver quality with traceability from requirement
definition out to testing and validation.”
Big Data, IoT and additive manufacturing “absolutely will
have an impact on PLM’s roles in the enterprise, and the road-
map of most of the PLM vendors,” said Aras’ Schroer. “For
example, the rapid growth of additive manufacturing is driving
a growing concern over IP protection, compliance, and design
validation. When end users at the edges or fringes of the
design value chain are able to ‘print’ products, rapidly, from
raw digital information, how do we know if those designs have
been validated for the intended end-user application, do they
meet FDA requirements, FAA? How do we know the ‘printer’
has the correct version of the CAD file? As the rate of data
flow increases and the simplicity of translating digital ideas to
hardware becomes almost frictionless, this makes PLM an
increasingly strategic solution for managing risk.”
The interest in IoT is also driving electronics and software
content into products that have been traditionally 100% me-
chanical, he added. “PLM systems now need to manage the
complete configuration of product data, including the soft-
ware, and for many legacy PDMs this is just not possible.”
“Drivers like the IoT with machine-to-machine communi-
cations, Big Data, the cloud, 3D printing and advanced ro-
bots are creating valuable new possibilities for smart, flexible
production systems that combined with PLM will create new
opportunities for manufacturers,” said Aaron Frankel, director
of product marketing, Siemens PLM Software (Plano, TX).
Some key capabilities from PLM developers, Frankel noted,
include intelligent models—a full digital product model that
contains a rich set of intelligence and can be used directly in
manufacturing; Digital Twin—fully digital product and produc-
tion definition that accurately simulates reality; and optimized,
distributed production systems that operate by themselves,
make their own decisions and learn from the past.
As for “rethinking” PLM, Frankel said that companies are
going beyond simply digitizing for the benefit of automation
to digitalizing how they run their businesses. “Digitalization
fundamentally changes the process to create new value,” he
See us at WESTEC Booth #427
124 AdvancedManufacturing.org | September 2015
said. “More companies are now using virtual commissioning
to reduce risks and save time. We’re seeing an increased
use of vision systems attached to robots to increase flexibility
and drive even higher quality results.” Manufacturers also are
starting to use data from production systems to feed digital
models of production systems, Frankel noted, in order to
analyze the impact and need for process changes, and de-
termine system parameters based on production forecasts.
Simulating the Factory with Realism
Highly accurate 3D visualizations of
the factory floor, equipment, and work-
ers have become critical for users of
PLM systems in recent years, enabling
great improvements in compress-
ing product development times and
reduction of physical prototypes while
boosting overall product quality. Today’s
PLM systems employ high-fidelity simu-
lations for 3D factory-floor planning and
layout, and 3D ergonomic simulations
and immersive virtual reality for more re-
alistic views of factory-floor processes.
“Simulation, immersive experiences,
augmented reality and mobility tools give
engineers the means to gain a better
understanding of how the manufactur-
ing system works and what can be
improved,” said Frankel. “One trend is
using point clouds created by scanning
the actual factory floor in manufacturing
planning applications. Point clouds help
to plan in the context of the scanned
factory, visualize the planned assembly
processes and verify the ‘as-built’ plant
to 3D CAD layout.”
Simulations also can help compa-
nies reduce energy utilization and CO2
emissions of manufacturing processes,
Frankel said. “Digital models can help
analyze various energy-saving sce-
narios without disrupting production,”
he noted. “Lastly, companies are con-
necting PLM and MES to merge the as-
planned and as-built worlds of manu-
facturing. With a digitalized definition
of the process and production system,
companies can directly connect to their
manufacturing ecosystem and establish
feedback loops.”
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PLM SOftware
September 2015 | AdvancedManufacturing.org 125
“The world is a visual place and we will continue to see a
proliferation of advanced visualization technologies and ca-
pabilities,” said Garrett Miller, vice president, SAP (Newtown
Square, PA). “Engineers will be able to continue honing and
refining design techniques. However,
I believe much of the advancements
with visualization will be realized
beyond the R&D/engineering depart-
ments and labs.
“As visualization becomes more
accessible to the rest of the enterprise,
improvements will be realized in most
areas,” Miller said. “We already see that
happening with our customers as they
adopt our technologies for visualized
hand-over to manufacturing, visual
work instructions and the benefits as-
sociated with visual navigation for asset
management and maintenance.”
Great progress has been made in
managing 3D product content over the
last decade, said Aras’ Schroer. “We
are especially proud of our Visual Col-
laboration solution which leverages the
standard PDF format to simplify com-
munication of critical product informa-
tion,” Schroer said. “While we applaud
the progress made in 3D and mechani-
cal CAE, we caution customers that
having a too narrow focus on the 3D
mechanical content in their products is
a recipe for risk and disaster.
“Leading companies with some of
the best simulation and design valida-
tion practices in the world do not have
a complete picture of the mechani-
cal with the electronics, software and
firmware that truly represent the Digital
Twin to the physical world,” Schroer
added. “We believe this narrow focus
on only the 3D experience really is not
in the best interest of most companies.”
Broadening PLM’s Reach
Strengthening PLM’s links with the
shop floor is key to developers deliver-
ing what manufacturing users need to compete effectively.
“We see PLM as what we’ve done in the past, plus adding
capabilities for handling Big Data analytics into our 3DExperi-
ence platform,” said Patrick Michel, Dassault Systèmes vice
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president. Dassault last updated its 3DExperience platform in
January and now offers users 12 distinct industry experiences.
“We’re true to our roots, and we’re working on delivering 3D
instructions to the shop floor,” Michel said. “In the last release,
for the first time you can run anything in what we call ‘near real
time’ and anyone in engineering can see it. The manufacturing
KPIs are no longer top secret, and it’s simple and powerful.
Sometimes it’s the simple visibility that goes a long way.”
Dassault is also working to expand
into the areas generally considered out-
side of the PLM aerospace and defense
or automotive strongholds. “We’ve
defined 12 industries, and while they’re
not all the size of the biggest ones, every
customer, whatever they do, has some
level of PLM,” Michel noted.
Last year, Dassault introduced its
latest brand, Biovia, created from the
company’s earlier acquisitions of Ac-
celrys and BioPLM. The Biovia solution
focuses on biological, chemical and
materials modeling and simulation,
research and open collaborative dis-
covery, enterprise laboratory and quality
management, and process manufactur-
ing intelligence.
“One of our visions is that the devel-
opment of new drugs should have the
same tools that we have for developing
airplanes,” Michel stated. “We have an
aggressive vision for this, and we like
to say that we have a couple of Nobel
Prize winners using our tools.”
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