PLM- Pros & Cons Final
ABSTRACTToday, organizations want accelerated time to market at the same timeproducts are getting more complex in terms of structure, design ®ulatory compliances and product development occurring in differentdivisions that are geographically spread. Added to this is the complexitythat arises with mergers or acquisitions. All the above results in increasedproduct data and information to be managed and shared in a real-timemannerThis white paper attempts to detail out the how PLM addresses the abovementioned specific pain points while factoring out the drawbacks in PLMsystem which need careful consideration from our PLM implementationand customization experiencePLM Pros & Cons 2007, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.
Table of Content Pros of a PLM system.Page 3,Engineering Data,PLM Solution,Project Collaboration,PLM Solution,Generation of Reports,PLM Solution,Integration to legacy/ERP systems,PLM Solution,Integration to CAD/CAM/CAE (CAx) Tools,PLM Solution Cons of a PLM system.Page 5 HCLT PLM Business Summary . Page 5 2007, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.
PLM Pros & ConsPros of a PLM systemPLM applications track comprehensive product informationand history—including items, bills of material, suppliers,costs, quotes, specs, drawings, files, compliance recordsand much more—in a centralized, version-controlledrepository. Because authorized users have persistentaccess to current product details in context of design andcollaboration history, manufacturers, suppliers, and theiroutsourced partners make better, faster design decisions,develop superior products and more quickly bring them tomarket.It also provides functionality for compliance reporting byutilizing a common framework and centralized informationrepository to support multiple compliance standards.How do PLM systems address the above?Sections below looks at the typical areas whereorganizations face challenges in terms of trying tostreamlines processes, reduce efforts and costs, improvetime to market ,etc,. and how PLM addresses these specificpain pointsEngineering DataEngineering data here refers to the data generated byDesign department like CAD data, Test Plans, etc,. Datagenerated by other departments like marketing, sales,service and production will also need to be referred alongwith the engineering data. Usually this data is managed bypaper or using electronic files (excel files, word files) andstored separately in files servers or managed by the CADsystems themselves.The important categories of data for products are -Figure below depicts a typical Product modelState DataReference DataProcess PlanPart/ProductCAD DataOperationsChange DataComponentsDue multiple product changes, product configurations, datatypes and usages manual/semi-automated method ofmanaging the product information (and sharing) lead toseveral challenges in terms of – Product data not easily traceable Data duplication Loss of data Wrong entries in BOM Difficulty in managing product configuration Sharing data cannot be controlled Tracking and updating product changes Data integrity and availability Part Data re-useProduct Data/Information (Product Model)The data includes part attributes (part number, name,material data, etc,.) relation of a part with other referencedata or data that further defines the part (E.g. CAD file).DefineProduct Configuration dataProduct 2This information pertains to a product assembly information– the parts and sub-assemblies that make up this product,the state of the parts/sub-assemblies (released, WIP, etc,.)configurations and optionsProduct 3Product 1Manage & Share Information Multiple Multiple Multiple MultipleEngineering workflow dataThis data provides information on the status of a product,configuration, users (engineers, reviewers, etc,) who arecurrently working on the product.build - package componentsdata typesusagesdelivery mechanismsSupport transactions acrossmultiple systemsChange ManagementSuppliersWiringThis category of data captures the changes – revisions, thata product has undergone thorough out its life from inceptionto obsolescence. 2007, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.Sheet MetalAssemblyProduce
PLM Pros & ConsThe effects of the above mentioned challenges are –Lower Productivity – As a leading US based toymanufacturer (HCL client) had stated that on an average1000 hours of time is spent in searching per yearDuplication of work - One of HCL clients had stated thatbased on an initial estimate about 40% of parts are recreatedor duplicated due to the inability to search and re-use a part.Higher product costs/Lower Quality – As a leading HiTech company (HCL client) had often faced the issue ofhaving wrong entries in the BOM (old version of parts) whichlead to re-manufacturing the products. About 30% of theproduct cost had to be re-spent.PLM applications capture all the product related informationin a centralized location – Part unique attributes and other attributes BOMs Product configurations Change to parts/productsThey also allow custom search, reports, workflowfunctionalities in addition to provisions for projectmanagement, collaboration, etc.It also provides functionality for compliance reporting byutilizing a common framework and centralized informationrepository to support multiple compliance standards.to collaborate effectively with the right information on a realtime basis becomes important. Collaboration is to – Ability to share right data with appropriate access Ability to read the data appropriately (E.g. see a model in aCAD native file using a generic viewer). All participants ableto view the files simultaneously. Ability to capture the discussion points, action points anddecision and relate it to product.In organizations where the engineering data is not managedcentrally by a dedicated system collaboration can lead tochallenges like – Product data sharing can be difficult Due to multiple file types viewing/reading the files can be anissue Capturing the collaboration artefacts and relating to productPLM SolutionPLM applications, along-with the ability to centrally manageproduct data, have collaboration modules that allows followingfunctions – Ability to set up discussion forums, meeting, project teams,etc,. Ability to share project information (product data) toparticipants Collaborate with product data viewers (similar to webexmeetings) Capture the discussion points and relate to product data Collaboration at specific points in a workflowBenefitsBenefitsShorter development cycle for productsImproved Productivity Increased parts re-use Quick search results for right part information Availability of right data at right time to all stake holders(with right access control) Streamlines processes (workflows) Allow concurrent development of productsImproved quality No room for wrong revisions if parts in BOM No room for un-approved parts to be released Knowledge re-useProject CollaborationIn organizations where different parts are designed byvarious suppliers and divisions of the organization, the need Ideas can be exchanged more easily – Quick designdecisions Allow concurrent design since data sharing is easier andcontrolled Tractability of the development progressGeneration of ReportsReports can be either technical reports (e.g. BOM reports) ormanagement reports (e.g. ECO status reports)In a manual/semi-automated system for managing productinformation, report generation is usually done using exhaustiveprocess of collating the data and preparing the reports. Data isgenerally not available in a central location but is spread acrossdifferent systems.The effects of the above mentioned challenges are –Substantial effort to prepare reports – As a leading Automotive 2007, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.
PLM Pros & Conssupplier in Japan (HCL client) had state that currently 4-5days are spent in preparing a custom BOM comparisonreport.Inability in preparing progress reports – As a leadingApparels manufacturer (HCL client) has stated that currentlydata from a lot of excel documents are to be collated toprepare a work loading chart for the management reviews.Benefits Production has latest and correct BOM Better productivity – Designers spend less time inupdating the ERP BOM Better Quality – PLM systems take care of making thecorrect updates in the ERP BOMIntegrations to CAD/ CAM /CAE (CAx) toolsPLM SolutionPLM applications have OOTB functionality to generateabove such reports and also can be customized to generatespecific reports.Since PLM application centrally manage all the product datathey have access the right information and can be renderedas required.BenefitsQuickly Generate Reports – Custom reports or OOTBreports can be quickly configured and prepared (by click of abutton) since PLM systems provide all the functionality ofreport and also since PLM systems manage and can accessthe part data.Moreover executives and designers who access to PLMsystems can generate the reports from any location (as longas they have access to the PLM system).Integrations to Legacy/ ERP systemsERP systems centrally manage the BOM and product data inan organization. However they do not provide andengineering view of the data and are generally not tightlyintegrated with engineering data authoring tools like CAD,CAM, etc, since ERP systems primarily focus on financials,HR, production, etc.Hence, when engineering data is manually managed thenupdating and synchronizing engineering data with ERPsystems can be challenging and can lead to errors.CAx systems are used to develop product models,assemblies and other information that is related to theproduct. Some CAD systems (e.g. Ideas) provide a limitedfunctionality of managing the data in terms of sharing thedata within a team and providing a simple access control.However to effectively manage information of complex andlarge products in a semi-automated data managementsystems (assemblies and the data related to it, revisions,changes, etc,.) pose several challenges. Even with PLMsystem (but with no CAx integrations) users need tomanually upload the CAx data to the PLM systems. Thechallenges posed due lack of such integrations are – Substantial efforts spent in uploading the CAx data in thedata management system. Changes in CAx will manually have to be updated in thedata management systemPLM SolutionPLM applications come with add-on CAx integrators thatallow the user to perform the following in a CAD-PLMintegrated environment – Create/Update Parts in CAx and publish in PLM system(automatically) Create/Update Product structures in CAx and publish inPLM system (automatically) – BOM is automaticallyupdated in PLM systemBenefitsWrong versions of parts are producedImproved Productivity Designers now need not spend effort in manually updatingthe PLM systems for the data created in CAD systems Data can be automatically opened in the authoring CAxsystem without manually downloading itBOM entries in Engineering department do not synchronizewith BOM entries in production (ERP system). This leads tosubstantial manual effort to update and to ensure both BOMsare identical which can be error prone.Improved Quality With automatic upadation of the PLM system with the data(content and structure information) manual errors areeliminated.PLM SolutionCons of a PLM systemThe effects of not having a integrated environment is asfollows –Most PLM applications have OOTB integrations with ERPsystems to perform the following in an automated manner(either based on user action or an event in either of thesystems) – BOM exchange,To update BOM in ERP system,To update BOM in PLM system Exchange Product data Extract and generate BOM reports containing engineeringdata from PLM and production/finance data from ERPsystemThough a PLM system can bring many benefits to anorganization in terms of improved productivity, quality, timeto market, etc, PLM systems have some drawbacks whichneed careful consideration. Sections below list some of thetypical drawbacks in PLM systems.Implementation challengesPLM implementation needs careful planning and is timeconsuming. Typical challenges that rise due to badimplementation are – 2007, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.
PLM Pros & ConsUser resistance PLM system not used effectively and ends up as a data silo Duplication of data and effort Data in PLM system is incorrect or not sufficient PLM system too slow – no proper planning for the networkbandwidth, server configurations, system configuration,etc.Product limitationsLimitations can be in terms of limited OOTB functionality,ability to be configured for organization’s businessprocesses, ability to be customized, etc.Product performanceApart from bad system planning (e.g. network, servers, etc,.)product themselves many have limitation in terms ofhandling simultaneous users, requests, etc.HCLT PLM Business Summary Test Plans,UT,System Integration Development and Testing User Training & roll-outMigrations and upgrades Version Upgrades Migration to New PDM/PLM Product Data Migrations & Extensions Global roll-outIntegrations and Visualization Integrations with Enterprise SystemsBuild Interfaces to:,CAD/CAEERP,Manufacturing Systems (Shop Floor Control),B-2-B Interfaces,Content Search to ease Document Management,Supply Chain Integrations,Web based collaboration & 3-D view toolsHCL Technologies (HCLT) is one of India’s leading global ITServices companies, employing 36,452 professionals, hadposted revenue (TTM) of US 1.058 billion for the quarterended in September, 2006.HCL Technologies (HCLT) is a subsidiary of HCL Enterprise,which is a leading Global Technology and IT enterpriseencompassing HCLT and HCL Infosystems.Support and Sustenance Based on SLA New Functionality Development Enhancements Bug Fixing & TestingHCL Technologies, leveraging on an extensive globaloffshore infrastructure and its global network of offices in 16countries focuses on select verticals including FinancialServices, Retail & Consumer, Life Sciences Aerospace,Automotive, Semiconductors, Telecom and MPE (MediaPublishing & Entertainment) to deliver solutions.Other Capabilities of HCL-PLM groupCAD Customization Customization of package CAD Applications likeUnigraphics, ProE, Solidworks, AutoCAD, etc Interfaces between CAD/CAM/CAE and PDM packages,Custom CAD Application development Sound knowledge in standard CAD exchangespecifications like DXF, IGES, STEP, etcUnder its Technology Led Services line of business,Engineering Services Group (ESG) having more than 650 qualified engineers and technology professionals areworking on PLM/PDM/CAD/CAM/CAE technologies forvarious verticals like Aero, Auto, Life Sciences, Semi, HiTech.Based out of Bangalore, India, PLM division as part ofEngineering Services Group (ESG) is aimed at providingquality solutions to customers in leading PLM technologieslike Windchill, Teamcenter, eMatrix etc, Focussing on areasincluding Implementation, Customizations, Integrations withERP systems as well as CAD systems and other systems.The various service offerings from HCLT PLM is as follows –New Implementations Requirement Definition, Analysis and Specifications,Business Processes,Software Requirements,Integrations and Data Migrations PLM Solution Architecting,Data Schema Design,GUI Customizations,Integrations and custom functionalities,Development, Testing Plans and Production Roll-OutPlans3D Graphics Solutions Extensive experience in web based graphics like VRML,Open inventor, SVG, etc, Sound knowledge of graphics engines like DirectX,OpenGL, Java3D, etc, Custom 3D graphics application developmentCapability in Geometry, Simulation & ImagingPLM TechnologiesThe various PLM technologies that HCL is involved in are asfollows – Team center Enterprise Team center Community Team center Engineering Windchill Ematrix SmarTeam 2007, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.
PLM Pros & ConsAbout the AuthorHCL Retail & CPG Practice - HighlightsAMR rates HCL a Leader in RetailHCL ranked higher than other Indian offshoringcompanies in Retail capability scope, with leadershipstatus in Supply ChainHCL ranked as a leader across areas like warehousemanagement, product sourcing, ecommerce, advancedretail planning and replenishmentAMR Research10,000 person years of Retail experience DomainExpertiseStrong 2500 resource base – Domainexperts and technical consultantsClearly defined strategy forproducts/frameworksCOEs for JDA, SAP, DemandDriven Supply Chain, DW,POS & RFID"We see HCL as an important Long Term StrategicPartner with whom we can build a relationship to thebenefit of both parties."- Sr. VP/CTO, Jones Apparel GroupDeliveryEfficiencyFocused R&D inNew Technologies& StandardsMature Processes (CMM 5)Integrated Global DeliveryITIL Compliant ProcessesCOPC CSP 2000 Process CertificationMembershipsWorld ClassPartnerships/AlliancesJV with Jones Apparel GroupPrime Implementation Partner of JDAPartnerships with IBM, Microsoft Retail,Infor, Escalate Retail (GERS) & Shipcom 2007, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.
PLM Pros & Cons 2007, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.
Though a PLM system can bring many benefits to an organization in terms of improved productivity, quality, time to market, etc, PLM systems have some drawbacks which need careful consideration. Sections below list some of the typical drawbacks in PLM systems. Implementation challen
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