Production Management II (Prof. Schuh)
Lecture 9
Production Management II
- Lecture 9 -
Product Life-Cycle Management II
Contact:
Dipl.-Ing. Wolfgang Boos
w.boos@wzl.rwth-aachen.de
WZL 53B Raum 507
Tel.: 80 - 28 469
© WZL
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
Product Life Cycle Management II
PM II L9 Page 1
Production Management II (Prof. Schuh)
Lecture 9
IT-Systems in the field of Production Management
Market
Engineering
Process
Engineering
Production
Planning
Manufacturing
Assembly
CAD
Distribution
Service
Maintenance
Disassembly
Recycling
CRM
CAM
SCM
CAP
ERP
CAQ
CAE
CAO
PLM-Meta-Data Pool (Links of Product Data)
CAD: Computer Aided Design
CAE: Computer Aided Engineering
CAM: Computer Aided Manufacturing
CAO: Computer Aided Office
CAQ: Computer Aided Quality
CAM: Computer Aided Manufacturing
CRM: Custom Relationship Management
ERP: Enterprise Ressource Planning
PLM: Product Lifecycle Management
SCM: Supply Chain Management
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 2
Production Management II (Prof. Schuh)
Lecture 9
Classification of PLM Definitions
PLM = PDM
PLM 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 the extension of PDM towards a
comprehensive Approach for productrelated
information and knowledge Management
within an enterprise. This includes planning
and controlling of processes, that are
required for managing data, documents and
enterprise resources throughout the entire
product lifecycle. PLM systems
aredistributed Technological information
systems for archieving, administrating and
providing all product or facility related information in required quality and at the right
time and place
IT- oriented approach
Management concept
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.
PLM is the administration and control of all
product data -of 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 beyond the
described systems.
Prof.Dr.Stucky aifb Karlsruhe
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 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
Prof.Dr.M. Abramovici Bochum
source: itm
© WZL
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
Product Life Cycle Management II
PM II L9 Page 3
Production Management II (Prof. Schuh)
Lecture 9
Evolution und Definition of PLM
PLM – horizontal integration
2D-CAD
1960
MRP
1950
Intersection:
• adjustment
of capacities
• configuration
• partsadministration
• BOMadministration
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
Prof.Dr.Stucky aifb Karlsruhe
product life cycle. The range of functions is bigger than the described systems.
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 4
Production Management II (Prof. Schuh)
Lecture 9
Evolution of PDM-Systems
3rd Generation
horizontal integration
PDM
2nd Generation
vertical integration
Life-CycleManagement
ERP
structuremanagement
dokumentenmanagement
1st Generation
isolated EDM/PDM-Systeme
document
management
structuremanagement
CAD-AddOns: drawing administration, bill
of structure characteristics,standard parts,..
2D/3D-CAD-Systems
1980
1985
1990
1992
1995
2000
Source: itm
© WZL
Product Life Cycle Management II
PM II L9 Page 5
Production Management II (Prof. Schuh)
Lecture 9
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
© WZL
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
Product Life Cycle Management II
PM II L9 Page 6
Production Management II (Prof. Schuh)
Lecture 9
Relevance of EDM/PDM-Systemen
3D-CAD
high
EDM/
PDM
VR
Future relevance
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-CADsystems is the highest
of all, but the
importance will
decrease in future
middle
low
2D-CAD
size = grade of control
no
no
low
middle
high
Today´s relevance
Source: WZL-Studie 2003
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 7
Production Management II (Prof. Schuh)
Lecture 9
Structure of Classic PDM-Systems
Applicational Functions
document/
data
management
workflow/
process
management
Utility Functions
communication
notification
product
structure
management
projectmanagement
data
transport
data
transformation
Viewing/
Redlining
classification
system
administration
PDM-Vault
product data
„meta data“(master data, stucture
data, etc,..)
Source: itm
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 8
Production Management II (Prof. Schuh)
Lecture 9
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
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 9
Production Management II (Prof. Schuh)
Lecture 9
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)
Mengenstückliste
Nr.
2457
2458
2549
2550
Bezeichnung
Schraube M6
Schraube M8
Flansch
Mutter M6
Anzahl
36
14
3
20
Baukastenstückliste
1
Nr.
2
3
Strukturstückliste
Bezeichnung
Gehäuse
oberer Deckel
Unterteil
Seitenwand
Boden
6 Bodenblech
7 Füße
8
Schrauben
Artikel-Nr.
1
2
3
4
5
Anzahl
1
1
1
1
1
1
4
8
Erzeugnistyp P
Nr. Gleichteile P1 P2 P3
B1
1
B2
1
E1
1
-1 -1
E2
1
E3
1
E6
1
Gehäuse
Bezeichnung Anzahl
Unterteil
oberer 3
Deckel
1
Nr. Bezeichnung1 Anzahl
Unterteil
4 Seitenwand
1
5 Boden5 Boden
1
6 Schrauben
Nr. Bezeichnung 8 Anzahl
7 Bodenblech
1
8 Füße
4
Erzeugnistyp P
Nr. Gleichteile P1 P2 P3
B1
1
B2
2
B3
1
B4
2
E1
1
-1
E6
1
views of BOM
engineering, manufacturing, dispatching, assembly, etc.
© WZL
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 webbrowser. The graphical display is more used then the text based
illustration.
Product Life Cycle Management II
PM II L9 Page 10
Production Management II (Prof. Schuh)
Lecture 9
Product Structur Management (2/2)
Substantial differences between views of BOM in the field of PDM
criteria
job dependency
stucture difference
engineering BOM
neutral
functional
information
history of origins
revision
manual, by hand
manufacturing BOM
job dependend
manufacturing resp.
assembly oriented
detailed information
about manufacturing
and assembly
systematic revision
administration
© WZL
Product Life Cycle Management II
PM II L9 Page 11
Production Management II (Prof. Schuh)
Lecture 9
Configuration Management (1/2)
product structure
past
A1
= revision proposal
B1
today
A1
C1
D1
B2
future
A2
C1
D2
E1
F1
C1
D2
E1
document structure
ity
ctiv
effe
Source: Eigner 2001
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 12
Production Management II (Prof. Schuh)
Lecture 9
Configuration Management (2/2)
Administration of
product configurations over the whole
life cycle
configurations
Definition und
administration of basic
configurations, ready- future
made parts and
reference
configurations
product
structure
past
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
today
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
t
par
new sion
i
v
re
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
Dies ist
ein den
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
t
cumen
new do
n
revisio
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
ef
fe
ct
iv
ity
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
document
structure
Dies ist
ein
wunder
schöne
s
Dokum
ent und
erfüllt
so voll
und z
den
Source: Eigner 2001
© WZL
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)
Product Life Cycle Management II
PM II L9 Page 13
Production Management II (Prof. Schuh)
Lecture 9
Revisions Management (1/2)
phases of clearance and revision processes
Engineering
Change
Engineering
Request
1
Changes
Request 2
verification and
approval
...
Engineering
Release
Engineering
Request
1
Release
Request 2
Engineering
Change/Release
Order
Implementation
Engineering
Change/Release
Notification
...
Revision proposal
functional improvement
rationalisation of
manufacturing
• customer requirements,
market needs
• removel of errors in the
technical documentation
• eliminate the cause of
producing scrap
• legal requirements
verification and approval
adding of missin data
define department for
revision approval
• departments verificate,
agree or disagree with
statement
• preparation of revision job
engineering change order
stop concering products
revision of documents,
BOM, master data
• updating revision index
• implementation of
collected data in the
revision note
• definition of mailing list
Distribution of Information
clearence of the part
copying of documents
• distribution according to
mailing list
• revision fulfilled
•
•
•
•
•
•
•
•
Source: Eigner 2001
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 14
Production Management II (Prof. Schuh)
Lecture 9
Revision Management (2/2)
Configuration:
mapping of different
authorization in the
revision process
illustration of revision
workflows
Example:
IBM Enovia – revision workflow
Application:
run through the work flow
messages
saving and indexing of
product data
Source: IBM
© WZL
Product Life Cycle Management II
PM II L9 Page 15
Production Management II (Prof. Schuh)
Lecture 9
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
© WZL
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.
.
Product Life Cycle Management II
PM II L9 Page 16
Production Management II (Prof. Schuh)
Lecture 9
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
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 17
Production Management II (Prof. Schuh)
Lecture 9
Potential of PLM
Synergy Factor
€
Trend with PLM
Product volume
Quality factor
Sales factor
Product asset
+
0
Trend without PLM
Clearances
Time-to-market factor
-
Realisation costs
Quality factor,
reuseabilty factor
Product
Product
determination realisation
Launch
Growth
Adolescence
Saturation of
the market
Descent
chronological phases
Source: Betriebshütte
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 18
Production Management II (Prof. Schuh)
Lecture 9
Benefit of PDM during Engineering
100 %
80 %
60 %
40 %
20 %
0%
faster access
to data
less engineering
failures
more consistent
product data
very big
middel
big
small
unnecessary
part redundancies
faster
revision process
no
Source:: Océ 2001/M. W endenburg
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 19
Production Management II (Prof. Schuh)
Lecture 9
Risks during implementation and Use of EDM/PDM
100 %
80 %
60 %
40 %
20 %
0%
system
performance
system
stability
expansion
of systems
user
support
user
acceptance
maintenance/
upgrades
supplier
support
very difficult
normal
very easy
difficult
easy
no response
Source:: Océ 2001/M. W endenburg
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 20
Production Management II (Prof. Schuh)
Lecture 9
Technical Risks during Integration of Systems
Departments and business partners in networks do not
work with the same intergrable CAD/CAM-Systems
AutoCAD
Solid
Works
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
CAD =
PDM
PDM
≠ERP
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
Source:: Océ 2001/M. W endenburg
© WZL
Product Life Cycle Management II
PM II L9 Page 21
Production Management II (Prof. Schuh)
Lecture 9
Criteria of System Choice
100 %
80 %
60 %
40 %
20 %
0%
Functionality
Interfaces
Technology/
Use of Internet
Usability
adaptively/
scalability
very important
important
relatively important
less important
Planning
Investment
Branch
of
secureness Know-how
Implementation
unimportant
Source:: Océ 2001/M. W endenburg
© WZL
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.
Product Life Cycle Management II
PM II L9 Page 22
Production Management II (Prof. Schuh)
Lecture 9
PDM Systems – Branch Distribution (GER)
other 6,6%
Distribution of licenses according to branches
energy supply and
administration 5,6%
pharmaceutics, 0,3%
electronics 8,6%
consumer goods 3,4%
engineering 42,8%
plant construction 11,5%
automobile und
supplier industry 21,2%
Source: EDM-Report, 2/2001
© WZL
Product Life Cycle Management II
PM II L9 Page 23
Production Management II (Prof. Schuh)
Lecture 9
PDM-Systems – Installations (GER)
installation basis
(rates of all PDM-licenses used in Germany)
Other 9%
Helios (ISD), 3%
eMatrix (MatrixOne), 4%
axalant (E+P), 27%
Iman (UGS), 5%
AM WorkFlow
(Cyco), 5%
CIM Database
(Contact), 6%
Compass (AIM), 7%
Gain System (PDS), 9%
Metaphase (SDRC), 15%
Pro*File (Procad), 10%
Source: EDM-Report, 2/2001
© WZL
Product Life Cycle Management II
PM II L9 Page 24