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PLM - ERP integration

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A presentation on PLM and their link to ERP carried out in parallel of my previous experiences and in order to get feedbacks to complete it

Publicado en: Empresariales, Tecnología

PLM - ERP integration

  1. 1. PLM – ERP Integration Towards Synchronous collaboration*1: Streamlining value added activities from first definition to Steady State*1 SMT Surface Mount Technology – « Collaborate: Design to Manufacture »Based on PTC PLM and SAP ERP
  2. 2. Preliminary WordsExamples worked on this documents are taking reference fromrelevantly chosen fictitious datas. Others were were taken from thewebsite of the providers and reworked towards its adequate use incontext, in my perceptions:In every case, the information included hereby are here to provide anoverview of the world of PLM using 3D as a common media throughoutthe organization. Nothing more, Nothing less. Your input is greatlywelcomed.
  3. 3. Objective  Understand how engineering value chain can enable all actors of the business to focus on value added activities over the development of the NPI*.  Focus on CAD-PLM-ERP IS architecture using full 3D medias during the NPI lifecycle for full enablement of work packages shares*NPI New Product Implementationhttp://www.ptc.com/appserver/wcms/standards/fileothumbredirect.jsp?&im_dbkey=43550&icg_dbkey=841 -3-
  4. 4. Agenda1. Definitions 1.A PDM in PLM 1.B PLM & ERP2. Business Context 2.A PLM-ERP Overall view in NPI 2.B What is an EBOM? What is a MBOM? 2.C Who owns Configuration? 2.D Engineering Change Management - ECM 2.E PLM-ERP interactions over A/C development3. NPI Overview 3.A. Content Management  3.A.1 CAD to Content Management  3.A.2 Content Management 3.B. Product Development  3.B.1 Content Management – Product Development  3.B.2 Product Development 3.C. Process Development  3.C.1 Product Development – Process Development 3.D. Build up to Steady-State Operations  3.D.1 ERP enablement for Steady State Operations4. Example of a unified « PLM-ERP » for NPI development – Siemens5. Summary
  5. 5. 1.A PDM in PLM Product Lifecycle Mngt is based onto a strong Product Data Mngt covering Creation, Management and Release of Products datas. Source : SolidWorks Enterprise PDM
  6. 6. 1.B PLM & ERP PLM IS Solutions meets a business strategy to share digital datas from design to servicing in a constant environment of change, up to maturity in the context of horizontal integration (Extended Enterprises Community) ERP sets up a robust and continuous frame of operations for steady state around the physical product.PLM/ERP needs a clear business vision. • Customization vs Mass-production • Complexity of products • Market Strategies & Customer Profiling
  7. 7. Constraints: Links & 2. Business context Kinematics Volume Definition & location in Reference systems CAD Product Structure Logistic Value Chain Engineering Value ChainEngineeringValue Chain Production Development Process Processes With a clear & consistent business vision, PLM enables to step back from complex engineering structures, and reframe concerns in the whole value chain
  8. 8. 2.A PLM-ERP interactions for NPIs ESI Enterprise Systems Integration WIP Work In Progress CAD Computer Aided Design EBOM Engineering Bill of Materials MBOM Manufacturing Bill of Material -8-
  9. 9. 2.B What is an EBOM? What is a MBOM? EBOM is the engineering bill of material, i.e. all designed components (fasteners, parts, sub-assembly,…) required to create the engineering assembly. MBOM is the manufacturing bill of material, with all parts, and consumables required to effectively build the assembly as per design. • MBOM can differ from EBOM by the division of components (ease of manufacturing) and includes consumables, like packaging materials, tools user manuals, printed guided. The trend, from Airbus A400M program, is to reconciliate both into one BOM: the EBOM. The whole assembly configuration aimed to be fully owned by the design office. What does it mean? -9-
  10. 10. 2.C Who owns the configuration? AS AS AS QUOTED AS COSTED AS DESIGNED AS PLANNED AS BUILT DOCUMENTED MAINTAINED Program Mgt Program Mgt Engineering Matls Mgt Mfg Config Mgt Field Svc Paper Parts WBS Printout or Printout or Printout or Printout or Printout or List Screen Screen Screen Screen Screen File WBS CADCAM Mfg Cabinet database Parts List BOM File File ? ? ? Engineering Change Notice
  11. 11. 2.D Engineering Change Management – ECM& Configuration Status Accounting ECO, ECR, ECN are engineering change orders, requests, notes that request changes on the « As something » product during its development. From initial design, changes can be thought to evolve in a 4F dimensions that defines the possible impacts to the organization (from design to manufacturing & procurement):• Function: What does the change do?• Form: What does it look like?• Fit: How does it interface?• Fee: What do we charge for it? PLM solutions aim to fully integrate, on an unique platform, the various stakeholders of the programme for collaboration during the change process. Once released, the ECN tells us: • What & Why is the product definition changing? • How & when the change will be implemented? • Who have tasks assigned to carry out the change? • Where are the documents for this change? - 11 -
  12. 12. 2.E PLM-ERP uses in A/C deployment Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Serial Design & Concepts Validation Prototype & Industrialization Certification & Serialization Life Critical Major Equip. Proto Serial Start Serial H/C 1st 1st Proto Proto 1st TypeInterfaces Interfaces Interfaces Power Design Final flight H/C Design Release flight Certif. Release Release Release ON Release Assembly Delivery MG MG MG MG MG MG MG MG 3.2 4 5 6.1 7 9 12 13 PDR CDR Content Management Product Development Process Development CAD-PLM ERP
  13. 13. 3. Review of IS interactions over NPI Cycle
  14. 14. 3.A Content Management Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Serial Design & Concepts Validation Prototype & Industrialization Certification & Serialization Life Critical Major Equip. Proto Serial Start Serial H/C 1st 1st Proto Proto 1st TypeInterfaces Interfaces Interfaces Power Design Final flight H/C Design Release flight Certif. Release Release Release ON Release Assembly Delivery MG MG MG MG MG MG MG MG 3.2 4 5 6.1 7 9 12 13 Content Management • Agree with Design Partners interface wing/fuse – wing/engine • Consolidate mature DO product structure • Digital Tests (FEA, Aerodyn.) CI DS1 DS2 R&R P&W CAD to Windchill
  15. 15. 3.A.1 CAD – Content Mngt Tasks Define interfaces and overall geometry Organization Define overall product structure (PLM-wise) Enable DO suppliers to design their equipments (constrained « black box » from design into CAD environment) PLM-ERP interactions Requirement for an integral Visualization of Product & Info Attributes at an early stage to enable feedbacks from lessons learnt from previous NPI now in the ERPDO Design OfficePLM Product Lifecycle ManagementERP Enterprise Ressource Planning - 15 -
  16. 16. 3.A.2 Content Management Tasks Design part contents (sub-assy & assy) in details Review/Accept design from design partners Organization Carry out digital tests analysis (FEA* Stress, tol. ) Manage Maturity of Drawings (« Release» - « WIP ») Set up COS* with suppliers Carry out operations test (Work enveloppe meeting customer specifications) PLM-ERP interactions Translate DO product structure into ERP overall WBS (No drawing, only BOM, identifiers and metadatas) Transfer & Translate into ERP design COSFEA Finite Elements AnalysisCOS Conditions of Supply from partners & Suppliers - 16 -
  17. 17. 3.B Product Development 2011 2012 2013 2014 2015 2016 2017Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Serial Design & Concepts Validation Prototype & Industrialization Certification & Serialization Life Critical Major Equip. Proto Serial Start Serial H/C 1st 1st Proto Proto 1st TypeInterfaces Interfaces Interfaces Power Design Final flight H/C Design Release flight Certif. Release Release Release ON Release Assembly Delivery MG MG MG MG MG MG MG MG 3.2 4 5 6.1 7 9 12 13 Content Management Product Development • Agree with Design Partners • Engineering Change (Digital, interface wing/fuse – Physical & Software) wing/engine • Update of interface with • Design to release mature design partners DO product structure • Definition of Tools & • Digital Tests (FEA, Assembly Sequences Aerodyn.) • Detailed specs of long lead times items CI DS1 ASO 1 ASO 2 DS2 +Tools +Metrology R&R +Quality P&W +BOM CAD to Windchill Windchill to SAP
  18. 18. 3.B.1 Content Management – Product Devt Tasks Incorporate change requests from downstreams feedbacks (Manufacturing, Jigs&Tools, Procurement Org.) in design Organization CAD Certify designed parts for prototypes, to assess physical specs, & ensure virtual product meets customers requirements Define parts required for product assembly (J&T), SOW to tooling providers PLM-ERP interactions DO product structure translated into workable WBS structure in ERP As there is a transfer of info between 2 IS systems, requirement for an additional check to ensure consistency btw PLM and ERP WBS architecture - 18 -
  19. 19. 3.B.2 Product Development Tasks Define & Update WBS details, with ressources required, on ERP (Ressources like Manning, Tools, Time, Budget Code) Agreement on SOW & Bidding specs to Organization procure physical parts Handle maturity of Design Solutions after DFMRP Tools Reception & Certification PLM-ERP interactions ERPPLM: -MM Materials Creation & Updates (Suppliers Code/ Cat. Of materials) -CO Definition & Update of controls accounts – PP Transfer (EBOM) to SAP (MBOM) for long lead times items PLMERP: -Transfer of parts costing info. From ERP to PLM -ERP-PLM info consolidation - 19 -
  20. 20. 3.C Process Development Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Serial Design & Concepts Validation Prototype & Industrialization Certification & Serialization Life Critical Major Equip. Proto Serial Start Serial H/C 1st 1st Proto Proto 1st TypeInterfaces Interfaces Interfaces Power Design Final flight H/C Design Release flight Certif. Release Release Release ON Release Assembly Delivery MG MG MG MG MG MG MG MG 3.2 4 5 6.1 7 9 12 13 Content Management Product Development Process Development • Agree with Design Partners • Engineering Change (Digital, • Build up on ERP all Assembly Stage interface wing/fuse – Physical & Software) Operations in Manufacturing WBS wing/engine • Update of interface with • Release ASO to PO for production • Design to release mature design partners • Certification of Tooling DO product structure • Definition of Tools & • Change enablement with production • Digital Tests (FEA, Assembly Sequences • Training of Operators Aerodyn.) • Detailed specs of long lead • Certification of « as built » wing to « As times items designed » Specs CI DS1 ASO 1 ASO 2 DS2 +Tools +Metrology R&R +Quality P&W +BOM CAD to Windchill Windchill to SAP SAP to Production
  21. 21. 3.C.1 Product Development – ProcessDevelopment Tasks Suppliers & Internal Manuf. Quality (Metrology..) Organization Update process with mods from change Produce prototypes components for test Certification of Tools & Training of Production Workforce Include COS into ERP procurement process Agree CDS with internal Business partners PLM-ERP interactions PLMERP Update & Refine WBS activities with ressources on ERP (Manning, Tools, Time, Budget Code) PP: MBOM updates, Compile ASO content from drawings notes, tools & eBOM. PO: release PO from ASO for 1st production ASO Assembly Stage Operation ERPPLM PO Production Order - 21 - CDS Component Delivery Specification Status of operations/Process
  22. 22. 3.D. Steady State Operations The NPI project now has fully mature products and processes for production:  NPI enabled for high volumes production of physical products  Customization enabled to customers requirements  Integrate support of live product (Servicing – Maintenance)  Handles large quantities of specific transaction (ERP mode)  Financials (Consolidation & Budget Review)  Procurement  Logistics  Quality  Refurbishing Operations from flight tests
  23. 23. 3.D.1 ERP enablement to Steady-StateOperations Tasks Organization Mature Logistics Flo Maintenance of Tools Certification of Wing with external regulations (Static, Fatigue Specimens + Flying Prototype) Refurbish Parts missing certification gate PLM-ERP interactions Certification that the latest PLM info are enabled in production via the ERP Validation of Refurbishing and Mods enabled in production on real products - 23 -
  24. 24. 4. Example of an unified PLM architecture - Siemens Modular Segments - Storage of info. cPDM*1 - Extended Ent. Collab - Future IS extension - Knowledge mngt modules PIM*2 Mngt*1 – cPDM: Collaborative Product Data/Definition Management Layers to*2 - PIM: Product & Information ManagementSource: A CIMdata White Paper – Teamcenter « unified » - Siemens access information - 24 -
  25. 25. 5. Summary - IPLM are enabling to streamline value added activities during the development of a new product throughcollaboration of the business ressources around adequate & updated information.The engineering value addedchain has critical impacts for highly- customized/complex design products.PLM-ERP integration is a long term strategic vision that can increase values of products contents andprocesses for the business overall, if an overall business IS roadmap & business strategy*1 are well defined: • set up Clear positionning on Master Data Management, where does it lie? • To understand & share Business and Process Workflow in very transverse org. • Fit within the business • Handle Chance consistently & efficiently • Extended Enterprises Collaboration & Harmonization – Intellectual Property • Architecture of the IS solutions (modular?) & ScalabilityIS Business solutions of best in class businesses start from PLM-ERP integration before integration with otherbusiness processes*2 (SCM, CRM,…). *Source: 1.Ten Questions to ask PLM solutions suppliers – A CIMData White Paper – August 2010 2. Integrating PLM & ERP Research Brief – Aberdeen Group – June 2008
  26. 26. 5. Summary - IIAs complexity of design is stream-lined through collaboration with all the business, Budget andCosting can enable Product Cost Management metrics to effectively control the development.Developments on PLM are now carried out to link cost management over product development: ERP covers historical costs and transactions of existing product PLM covers new product introduction, with possibly new parts that have no cost est..How to account for cost via Activity Based Budgeting and Costing at all stages of the productlifecycle is the next PLM challenge, i.e. to enable Cost Management Collaboration, fromengineering costs to manufacturing costs.Example: From most CAD softwares, geometric cost drivers & cost controls points, aPrioridevelops product cost management systems from design to manufacturing. - 26 -

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