From Drawings to Electronic Product Structures

Transcription

1 From Drawings to Electronic Product Structures Chances and Challenges

2 Outline 1. Introduction Bucher Emhart Glass 2. Current PLM challenges 3. Future Concept 4. Implementation experiences & conclusion

3 Forming Process Batch house Furnace Forming Annealing Inspection

4 Bucher Industries A technology group operating in the specialty Engineering and Automotive industries Net Sales: CHF 2691 million (in 2013) employees Divisions Activities Kuhn Group Specialized agricultural machines Bucher Municipal Municipal vehicles Bucher Process Wine and juice processing plants Bucher Hydraulics Gear pumps/hydraulic components Bucher Specials Bucher Vaslin, Bucher Unipektin and Bucher Landtechnik Bucher Emhart Glass Equipment for Glass container industry

5 Bucher Emhart Glass Forming machines for Glass Container production Machine Suppliers Container Glass Producers Fillers (Brands) Retail Examples Emhart Glass Bottero Heye Examples Vetropack St.Gobain(Verallia) Owens-Illinois Examples Coca Cola Heineken ABInbev Examples Coop Migros Wallmart

6 Bucher Emhart Glass Key Figures

7 Worldwide Presence.... headquartered in Switzerland! Sundsvall (S) Örebro (S) Perryburg OH Owensville MO Elmira NY Windsor CT R&D Savona (I) Neuss (D) Cham (CH) Sanjin, Zibo, China Kawasaki (J) St Petersburg FL R&D Inspection Johor, Malaysia Singapore Forming equipment/spare Parts production/assembly Inspection equipment manufacturing Refractory parts Sales/Service offices Shanghai Glass 2014, BEG Presentation

8 Outline 1. Introduction Bucher Emhart Glass 2. Current PLM challenges 3. Future Concept 4. Implementation experiences & conclusion

9 Organically grown product portfolio Characteristics of product portfolio Long History Process invented 100y ago Long Product lifecycles Machine lifetime 10-15y Conservative industry: Established standards, difficult to phase out products Customer specific adaptations Average: 200 engineering hours per machine project > items > 70 years old active drawings > 50% of sales with products that were developed 50 years ago Organically grown product portfolio

10 Modern PDM system, but drawing-centric approach Drawings: Lists to manage variants(example 1) Groups described with notes on drawings Variants arranged in groups BOMs listed on drawing - no electronic BOM available Speaking numbers

11 Modern PDM system, but drawing-centric approach Drawings: Lists to manage variants (example 2) Groups described with notes on drawings Variants arranged in groups BOMs listed on drawing

12 Modern PDM system, but drawing-centric approach Drawings: Assemblies with variants (150% BOM) Groups described with notes on drawings Variants arranged in groups BOMs listed on drawing BOMs on drawing Variants arranged in groups

13 Modern PDM system, but drawing-centric approach Drawings: Unique assemblies (100% BOM) Groups described with notes on drawings BOMs on drawing Variants arranged in groups BOMs listed on drawing BOMs on drawing Variants arranged in groups

14 No clear product lifecycle Lifecycle mainly linked to release state of drawing Soft indication about lifecycle state of item Soft indication A: Active Drawing D: Disactive no longer maintainedby R&D C: Customer Special design Document release state

15 Business Processes relying on many systems with manual interfaces Forecast Sales Forecast L&M Forecast AS CS Forecast Finance RMQ Quote COFS M-BOM stored in CRM D-BOM RMQ Tool Configurator MS Office Manual ERP PTS Manual Manual Manual Manual Semi Manual PDM DW-TIFF Paper Product Structure Options Configuration Pricing

16 In summary: Drawing-centric system leading to inefficient business processes Data consistency along the processes Drawings are not part of an active structure (single objects) Many manual interfaces No source of truth regarding the structure Transparency No possibility to navigate in structures Poor reuse of existing structures No where-used reference Lifecycle Heavy processes in early stage (one process for all lifecycle states) Unstructured phase-in and in phase-out

17 . or in other words Data consistency along the processes Rebuilding the same data and structures based on a drawing Drawings are not part of an active structure (single objects) Many manual interfaces No source of truth regarding the structure Transparency No possibility to navigate in structures Poor reuse of existing structures No where used reference Lifecycle Paper Windchill Heavy processes in early stage (one process for all lifecycle states) Unstructured phase-in and in phase-out

18 Outline 1. Introduction Bucher Emhart Glass 2. Current PLM challenges 3. Future Concept 4. Implementation experiences & conclusion

19 Item-Centric Approach The Item (WT Part in Windchill) is the master object to represent a part, assembly or complete product. The item is described and specified by metadata and a number of documents. This will allow to manage the BOM and variant structures in the system and achieve a consistent change process from CAD into ERP October

20 Overloaded BOM Future Selection chart drawings will be replaced by overloaded BOM in Windchill(configurable module) Side notes will be replaced by options and choices in the BOM The lifecycle of groups (A,D) will be replaced by an item lifecycle Selection drawings are only required if they show a representation of the variants October

21 Product Structure four levels Overloaded BOM 100% BOM Parts level October

22 Future interface to ERP system 150% BOM 100% BOMs PDM ERP Unidirectional link for 100% BOMs R&D fields of item master handed over to ERP PDM as master system PDM Sales configurator Manual link maintained Manual Interface Sales Config. Interface: -Quotations -M-BOMs ERP system October

23 Introduction of Item Lifecycle Obsolete Case B Items only 2 3 G5 4 Released (Commercial) Phase Out 5 Process Depending on Change (Fasttrack, Fulltrack, Fieldtesting) 1 (Phase In) Revise In Change G1 In Work Revise Simple release process, Responsible: Dev, PM, L&M Development Process Comercially Active October

24 Improved documentation of customer specials Attributes in Windchill Customer special flag Customer name, project name, Structure attributes Distinction between two types Items added to product structure (visible when navigating) Items not added to product structure (not visible when navigating) October

25 Outline 1. Introduction Bucher Emhart Glass 2. Current PLM challenges 3. Future Concept 4. Implementation experiences & conclusion

26 Decision to reduce scope in first step Step 1 Windchill out of the box setup (only configured) Implementation of e-boms in Windchill Introduction of lifecycle Maintain numbering system Implementation of step 1 currently ongoing. Target to complete in 2015L Step 2 Implement interface to BPCS

27 Conclusions so far Need a team outside of daily business! Be courageous to maintain focus on main issues! Would earlier decision to consequently use standard tools have helped?

28 Thank you!