Production Management II. Product Lifecycle Management II

Transcription

1 Production Management II - - Contact: Dipl.-Ing. Wolfgang Boos W.Boos@wzl.rwth-aachen.de WZL 53B Raum 507 Tel.: Seite 0 Objective of the lecture: Overview of ProductData Management systems Evolution of PDM systems Productand process oriented functions of PDM systems Benefit of PDM systems Exercise Case study for a product structure Documents during the product lifecycle PM II L9 Page 0

2 Table of contents : 1. Bibliography Page 3 2. Summary of the lecture Page 4 3. Distinction CAD, PDM and PLM Page 5 4. History of development of PDM systems Page 6 Relevance of PDM-Systems Page 7 5. General function overview of PDM-Systems Page Productoriented functions Product structure management 1/2 Page 9/10 Document management Page 11 Configurationmanagement Page 12 Classification / feature strip Page 13 View management Page Process oriented functions Workflowmanagement Page 15 Revions management Page 16 Access management Page Interfaces and integration of systems Page 18 Technical Risks during introduction/use of PDM-Systems Page Potential of product life cycle managements Page 20 PLM reduces expenditure of engineering time Page 21 PLM lowers qualitycaused production and consequential costs Page 22 PLM raises the levelof carry-over of assembly groups and product periphery Page 23 Usability of all factors effects superproportional growth of market share Page Usability of PLM, SCM and CRM systems Page Conclusion Page Excercise Page PM II L9 Page 1

3 Bibliography lecture 9: Hartmann, G. Technologie, Schmidt, U. Schichtel, M. mysap Product Lifecycle Management Strategie, Implementierung 2., aktualisierte und erweiterte Auflage Galileo Press, Bonn, 2004 Produktdatenmodellierung in der Praxis Carl Hanser Verlag, München, Wien, 2002 Eigner, M. Produktdatenmanagement-Systeme, Stelzer, R. Ein Leitfaden für Product Development und Life Cycle Management Springer Verlag, Berlin, 2001 Schuh, G. Schwenk, U. Produktkomplexität managen - Strategien, Methode, Tools Carl Hanser Verlag, München, Wien, 2001 Eversheim, W. Betriebshütte, Produktion und Management, Schuh, G. Springer-Verlag, 1996 Eversheim, W. Wettbewerbsfaktor Produktionstechnik, König, W. (AWK 1996) Pfeifer, T. VDI Verlag, Düsseldorf 1996 Weck, M. Seite 2 N.N. PDM-Marktstudie 2000 in Deutschland, Beitrag in Zeitschrift edmreport Nr. 2/2001 S. 26 ff., Dressler-Verlag, Heidelberg, 2001 Assmus, D. FE Tomorrow Studie 2003 Pfeifer, T. Unveröffentlichte Studie des Laboratorium für Werkzeugmaschinen und Betriebslehre (WZL) der RWTH Aachen Wendenburg, M. Guten Ideen schneller zum Durchbruch verhelfen Beitrag im CAD/CAM-Report 2001 Heft 11 S Dressler Verlag. Heidelberg, 2001 PM II L9 Page 2

4 Summary of lecture 9: Product Lifecycle Management (PLM) gains more and more importance through the increasing number of different single systems in the economical scenery and the complex requirements on today s products. Therefore PLM gets increasingly into management s focus. After the PLM-introduction and the consideration of CAD within the scope of PLM in Lecture PM II L8 the Product Data Management (PDM) with its different functionalities and potentials will now be described. PDM is an essential basis for today s engineering processes. This technology s propagation increased during the last years and it is used throughout the whole product lifecycle. Requirements on the IT-systems of manufacturing enterprises have increased enormously in quality and quantity. Examples of topics modern IT-strategies have to deal with lean production, business process oriented structures, shorter product lifecycles and times of delivery, decreasing vertical range of manufacture combined with decentralcustomer-supplier cooperation, pressure of costs and quality management. In this environment is where product data management gains an essential role. Through a product data management system information can be recorded or using so called originator systems such as CAD-, CAE-, CAM- and Office Systems adopted automatically, edited individually, retrieved, administrated and forwarded. These systems are adjusted to each particular enterprise s date and process model through flexible customization. Seite 3 PM II L9 Page 3

5 Distinction CAD, PDM und PLM Vertical level of integration Project planning and calculation Collaboration Modification and configuration management Visualisation PDM Production Revision Project Management Structures Collaborative Engineering Configuration management Variant Configuration Modification Service for Production Orders As-built PLM Product structures Documents CAD Document Management Knowledge Management Project Planning Basic Engineering Detail Engineering Job Preparation Production & Mounting Maintenance & Service Legend: PLM=Product Lifecycle Management PDM=Product Data Management Horizontal level of integration CAD=Computer Aided Design Source: Hartmann, Schmidt 2004 Seite 4 Today the lifecycle of a product from the product origin in the development through the procurement and production up to the service is marked by a strong in-plant decomposition and a heterogeneous system scenery. The Product Lifecycle Management (PLM), with the integrating idea in integration depth as well as in integration width, points out to the fact, that focusing on areas and single systems is no more enough for the today's requirements, and offers a comprehensive consideration about the whole lifecycle of the different processes. If one considers PLM as a management concept, PLM encloses the management and control of all product data along the complete lifecycle of the construction and production across the marketing up to service. For this reason the integrated PLM enables access to all product and process data of the whole lifecycle of a product. (Prof. Dr. Stucky, Karlsruhe) Therefore, the drawings and documents which have been provided with CAD are a part of the product data management, that at the same time supplies the PLM systems with the required data. PM II L9 Page 4

6 Evolution of PDM Systems 3 rd Generation Horizontal Integration PDM ERP Lifecycle Management 2 nd Generation Vertical Integration Structure Management Document Management 1 st Generation Isolated PDM Systems Document Management Structure Management 2D/3D-CAD-Systems CAD AddOns: drawing administration, bill of structure characteristics, standard parts, Source: itm Seite 5 At the beginning of the 80's the first product data management systems were characterised by managing technical documents. In the 1st generation of the PDM systems the different individual systems were still isolated, where as during the 2nd generation the vertical integration was in the forefront. At the end of the 90's, PDM systems with existing ERP systems were then further developed into PLM systems in terms of horizontal integration. For the data processing and procurement by different providers, advancements of PDM systems were developed depending upon application extent. PDM² = Product and Process Development Management CPC = Collaborative Product Commerce cpdm = Collaborative Product Data Management VPDM = Virtual Product Definition Management PDC = Product Definition and Commerce PKM = Product Knowledge Management PM II L9 Page 5

7 Relevance of PDM Systems The relevance of 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-CAD systems is the highest of all, but the importance will decrease in future Future relevance no high middle low VR 2D-CAD 3D-CAD EDM/ PDM size= grade of control no low middle high Today s relevance Source: WZL-Study 2003 Seite 6 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. PM II L9 Page 6

8 General Overview of Functions of PDM Systems product oriented functions product structure management document management configuration management classification class lists of characteristics view management revision management file administration storage vaulting process oriented functions lifecycle 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 Seite 7 The functions of PDM-systems can be divided into 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. PM II L9 Page 7

9 Product Structure Management (1/2) Product structure means the structured composition of the product by its components. Assembly groups and single parts lead to structure levels by combining components on a lower level of the product. Bills of material (Data structures of products) are used to transform the product structure into a machinereadable form. Structure level 0 Structure level1 Structure level 2 Productstructure P AG AG AG PP PP AG PP Structure level 3 PP PP Legend: P = Product AG = Assembly Group PP = Purchased Parts Source: Schuh, Schwenk 2001 Seite 8 Products often are very complex objects. To comprehends, modify or design them, a certain transparence is to be created. The illustration of the product complexity takes place in the product structure. PM II L9 Page 8

10 Product Structure Management (2/2) Building up and Administration of: basicbom und part usage quantities BOM structure BOM single-level BOM variant BOM structure variants: variation of BOM at different dates part variants: variants of single parts (e.g. colour) Quantities BOM No. Name Pieces 2457 Screw Screw Flange Screw nut 20 StructureBOM Single-level BOM 1 Body No. Name Pieces 3 Bottom 2part Upper part 1 No. Name 3 Pieces Bottom part 1 4 Side panel 1 5 Bottom 5 Bottom 1 No. Name Pieces 6 Floor panel 1 7 Floor panel 1 8 Foot 4 Manufactured item type P No. Non-variable part P1 P2 P3 B1 1 B2 2 B3 1 B4 2 E1 1-1 E6 1 No. Name Pieces 2457 Screw Screw Flange Screw nut 20 Manufactured item type P No. Non-variable part P1 P2 P3 B1 1 B2 1 E E2 1 E3 1 E6 1 Seite 9 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. The structures are displayed text based or graphically based in a webbrowser. The graphical display is more used then the text based illustration. PM II L9 Page 9

11 Document Management Filing (Check -in) PLM Applikation Server Getting (Check -out) Frontend Computer Document Info Record Document File Frontend Computer System Structure For each document file a seperate document info record is saved The document file contains the document information (e.g. an engineering drawing) The document info record contains metadata of a document (e.g. identification, status, version, author, date, validity) PLM Database Electronic Vault (Safe) Functions Version management Status management Document structure Classification Search of documents Document distribution Web access Source: Hartmann, Schmidt, 2004 Seite 10 The document management serves the administration of all technical documents created during the whole life cycle of a product. Till this day there has been a change-over in the companies from manual editing of documents to the usability of personal computers for editing and exchanging information. Thereby the amount of data has increased considerably and still is rising constantly. For this reason the usability of PDM systems gains more importance, because such systems are adapted to administrate huge amounts of documents and their dedicated describing meta data. Meta data like document number, document description or author describe and identify a document. Reduction of costs and improvement of quality are direct stimulations. Such systems are characterized by following potential benefits: Efficient search and locating of certain documents Quick and direct transmission of information and associated modifications Access to knowledge of existing products and of former projects Encouragement of trans-sectoral collaboration in the engineering PM II L9 Page 10

12 Configuration Management The configuration management applies technical and administrative rules to the product life cycle of a configuration unit from the development across manufacturing till service and support. future today A2 Product structure past A1 B2 A1 C1 B1 D1 E1 F1 C1 D2 E1 C2 D2 E1 Document structure B2 iscompatible to B1 F1 isincompatible to B2 Effectivity Legend: = revision proposal = no modification Source: Eigner, Stelzer 2001 Seite 11 The activities in connection with configuration management are used to inform about a product s construction level (=configuration) at any state of its lifecycle. 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. The following questions are relevant to configuration management: Where and when the part was mounted? Who produced, delivered and mounted the part? Who initialized and effected revisions? Which single parts or assembly groups (versions and mutations) does the part consist of? In which version the part/assembly group is applied? PM II L9 Page 11

13 Classification / Feature Strip Classification Feature Strip Demand of Search A 98 Saved Specification Excisting Objects Result A ~ B A ~ C Seite 12 Classification means the arrangement of similar and standard parts by common attributes to support carry-over. Examples for attributes are descriptions of functions, shape, material, release date, version, editor, project, etc. Classified objects can be identified by a search through attributes or by browsing the classification hierarchy. Examples for classification hierarchies are public (e.g. DIN) standards, factory standards, etc.. Within the scope of classification things and facts are organized by certain considerations. Thereby a classification system describes objects based on properties independent of the product. The feature strip is a principle for direct transformation of characteristic attributes and data into a form able to be machined by search algorithms. The system of feature strips is based on the fact that parts canbe combined in groups of maximum similarity and that the properties are listed as characteristics in a schedular form. Feature strips are used especially for description and classification of geometrically similar components. PM II L9 Page 12

14 View Management Marketing Engineering Process Planning Production Mounting & Assembly Shipping Engineering View Which functions are to be complied? Manufacturing View How to manufacture the single parts? Mounting View In which order the parts are mounted? Distribution View Which sellable units are available? Shipping View Which units are dispatched together? Picture: Gallus Seite 13 During the manufacturing and production process there are different views of the product through the different departments. These perspectives are distinguished in dependence to order, difference in structure, amount of information and modification status. An engineering BOM (bill of material) is not-order-related, composed functionally and modified manually by the designing engineer, if necessary. This perspective informs the designing engineer about the history of development and the required functions of the product. The assembly BOM is linked to a particular customer order and provides detailed manufacturing and assembly orientated information concerning the product structure. Potential revisions are operated systematically by the revision management. PM II L9 Page 13

15 Workflow Management The Workflow Management organizes and controlls the information flow between the involved places and processes of the company. CAD A CAD B Elaboration of single parts create/change of construction BOM CAD drawing BOM Project structure Concerning workflow management the distribution of documents guarantees that at certain moments or milestones the documents are automatically passed to the relevant person. CAD A Tools CAP Check/ release of drawing Createflow chart Flow chart Product structure Concept Environment Workflow Management Document Management Product Data Management Source: PDM -Portal 2005 Seite 14 The procession of business processes are displayed in the workflow management. For all possible results of a process the corresponding successors are defined. PM II L9 Page 14

16 Revisions Management Phases of clearance and revision processes Engineering Change Request Engineering 1 Changes Request 2... Engineering Release Request Engineering 1 Release Request 2... Revision Request Verification and Approval Verification and Approval Engineering Change/Release Order Engineering Change Order Implementation Release Engineering Change/Release Notification Distribution of Information functional improvement rationalisation of manufacturing customer requirements, market needs removel of errorsin the technical documentation eliminate the cause of producing scrap legal requirements adding of missin data define department for revision approval departments verificate, agree ordisagree with statement preparation of revision job stop concering products revision of documents, BOM, masterdata updating revision index implementation of collected data in the revision note definition of mailing list clearence of the part copying of documents distribution according to mailing list revision fulfilled Source: Eigner 2001 Seite 15 The revisions management systemises the revision process to avoid inconsistencies in the product data. A revision request is set, verified and approved by every concerned department. If a request 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 one and is released. With the revision in the PDM-system all departments have the current version and all participants know about the latest revision. PM II L9 Page 15

17 Access Management The access management controls which user can generate, access or change documents or product information at a certain moment. The kind of access to documents is controled by the so called Access Control List. Group 1 Rethberg Brendler Engel Access Control List (ACL) Object Identification User authorization Document 4711 Engel d Document 4711 Rethberg - Document 4711 Schulz w Document 4711 Meier d Legend: - access denied r read access w write access d deleting allowed Documents/ Product informations Meier Schulz Group 2 Müller Source: Eigner, Stelzer 2001 Seite 16 PDM systems allow collective access to stored data for different users. Therefore articles, documents or projects as well as user and their access authorization to objects and functions must be managed. The user administration is in charge of administration of system users, generation of user groups, distribution of rights and data security. So exists an access control to information units as well as the functions of the PDM system. PM II L9 Page 16

18 Data exchange with standard interfaces in the field of CAx CAD Computer Aided Design Legend: IGES: EDIF: IGES, EDIF VDAFS, VDAPS STEP Initial Graphics Exchange Specification Electronic Design Interchange Format VDAFS: Verband der Automobilindustrie Flächenschnittstelle (Association of automotive industry surface interface) VDAPS: Verband der Automobilindustrie STEP: Programmschnittstelle (Association of automotive industry program interface) Standard for the Exchange of Product Data CAD Computer Aided Design IGES, VDAFS, STEP CAP Computer Aided Planning CLDATA, IRDATA, STEP Operating data CLDATA: Cutter Location Data CAM IRDATA: Industrial Robot Data Computer Aided SQL: Structured Query Language Geometry data Manufacturing Operating data STEP SQL ERP Enterprise Resource Planning Operating data CAQ Computer Aided Quality Assurance Application specific linking program Seite 17 For the exchange of data between different divisions of the company some standard interfaces are available whose complexity is not sufficient to transfer all necessary information. Because of using different pre- and post-processors information loss is a result of inexact interface definitions. An example is the exchange of drawing data between two different CAD-systems with the standard interface IGES. PM II L9 Page 17

19 Technical Risks during Integration of Systems Departments and business partners in networks do not work with the same integrable CAD/CAM systems 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 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 CAD = PDM? AutoCAD Solid Works +? PDM ERP Source: Océ 2001/M. Wendenburg Seite 18 PM II L9 Page 18

20 Potential of PLM Synergy Factor Product Sales Quality Factor Sales Factor Trend with PLM Trend without PLM Time-to-market Factor Realisation Costs Product Profit Approval Quality Factor, Reusability Factor Product Determination Product Realisation Launch Growth Adolescence Saturation of the Market Descent Timeline of the phases without PLM Source: Betriebshütte Seite 19 According to the typical volume and profit of every product seven phases of a lifecycle are distinguished. To define each phase the graph of product sales and profit is used. Requirement for a successful product determination is a strong orientation to the market. That means that customer orientation starts with the first phases of the lifecycle and a efficient product engineering process is needed. Each approval of a product realisation is an extensive financial exposure. The product determination has to be executed carefully and adequately ensured. PM II L9 Page 19

21 PLM reduces expenditure of engineering time Functions Product Sales SynergyFactor Sales Factor QualityFactor Product oriented Document management Illustration of product structure Configuration management QualityFactor & ReusabilityFactor Product Product Determination Realisation Market Launch Realisation Costs Growth Time-to-market Factor Adolescence Product Profit Saturation of the Market Chronical Progression of Product Lifecycle Descent t Prozess oriented Workflow Management Sinking Time-to-market Sinking effort of search Less database interfaces Less effort for maintenance Increasing turnover through higher market share (Sales factor) Progression without PLM Progression with PLM Source: PLM -Seminar of WZL 2004 Seite 20 PM II L9 Page 20

22 PLM lowers quality caused production and consequential costs SynergyFactor Sales Factor Functions Product oriented Document management File and storage management Product Sales QualityFactor Realisation Costs Time-to-market Factor Product Profit t Prozess oriented Access management Lifecycle management QualityFactor & ReusabilityFactor Product Product Determination Realisation Market Launch Growth Adolescence Saturation of the Market Chronical Progression of Product Lifecycle Descent Early identification of bugs Less manufacturing errors Less warranty and consequential costs Higher market share through increased quality Progression without PLM Progression with PLM Source: PLM -Seminar of WZL 2004 Seite 21 PM II L9 Page 21

23 PLM raises the level of carry over of assembly groups and product periphery Functions Product Sales SynergyFactor Sales Factor QualityFactor Product oriented Document management Illustration of product structure Configuration management QualityFactor & ReusabilityFactor Product Product Determination Realisation Market Launch Realisation Costs Growth Time-to-market Factor Adolescence Product Profit Saturation of the Market Chronical Progression of Product Lifecycle Descent t Prozess oriented Prozess/operation management Sinking time of creation of parts lists, data sets, drawings etc. Stock reduction of identical data Less effort for maintenance Progression without PLM Progression with PLM Source: PLM -Seminar of WZL 2004 Seite 22 PM II L9 Page 22

24 Usability of all factors effects superproportional growth of market share Functions Product Product Determination Realisation Product Sales QualityFactor & ReusabilityFactor Market Launch SynergyFactor Sales Factor Realisation Costs Growth Adolescence QualityFactor Time-to-market Factor Product Profit Saturation of the Market Chronical Progression of Product Lifecycle Descent t Product oriented Document management File and storage management Prozess oriented Prozess/operation management Revision management Improved support of decisions Less revisions Superproportional growth of market share through concurrent use of Time-to-market factor and quality factor Transparent information and web based cooperation for each participant Progression without PLM Progression with PLM Source: PLM -Seminar of WZL 2004 Seite 23 PM II L9 Page 23

25 Usability of PLM, SCM, and CRM Systems Relevance/ Usability of the Systems Engineering Manufacturing Aftersales, Service CRM SCM PLM Time Product Conception Start of Production End of Production End of Product Lifecycle Legend: PLM=Product Lifecycle Management SCM=Supply Chain Management CRM=Customer Relationship Management Source: CIM Data 2001 Seite 24 PLM, SCM and CRM are the most important systems of supporting operational processes of manufacturing companies. During the lifecycle of a product the different systems have different levels of relevance and usability. During the phase of development/engineering a PLM system is used more frequently than a SCM system, while a SCM system is often used during the phase of manufacturing. PM II L9 Page 24

26 Conclusion The PDM system is a central component of PLM. PLM provides access to all product and prozess data during the whole lifecycle of a product PLM implicates a new operation sequence routine during the whole lifecycle of a product PLM-IT systems represent the functions and processes beeing behind the PLM idea PLM opens up quality, costs, time and synergy potentials PLM is more than an IT system Seite 25 PM II L9 Page 25