Introduction to PDM and PLM

PDM is the management and classification of design data and specifications for an engineered product and the management of change to this information.

PLM is the activity of managing a companys products all the way across their lifecycles in the most effective way. [Stark]

PLM system is [an information system] that facilitates all or some subset of PLM activities. [Stark]

Background: what are lifecycle activities?

! Product "eali#ation$ from concept to production ! Production$ supply chain coordination ! %fter!sales$ service maintenance product updates obsolescence management&

Pro*ect conceived Product "e(uirements .osmetic "e(uirements

2esign 3ouse

Background: Product Realization Process

'arlier we saw a P"P flowchart
Specs for new 'lectronics Parts ':isting Parts

-ndustrial 2esign 2rawing

2ummy Mock!up

6inali#e cosmetics -ndustrial 2esign .ontrol 2rawing

2esign "elease M eeting= 2etailed .onstruction "e(ts Manufacturability <otes .ritical components

Preliminary .ost %nalysis

Pro*ect .onfirmed

Purchasing > Procurement M' 'L'.$ .ategori#e critical parts -22 Specs$ <ew /ooled Parts

.onstruction 2rawings .%2 .onstruction 2rawings

.ontact vendors Prices Lead times

Prepare %pprove Schedule 0%ll depts1 Product Planning Schedule

.oncept "elease Meeting /arget Specs Milestones Pro*ect /eams .ritical Parts$ -.s Plastic Metal&

Some crucial elements of P"P$ ! many decisions are made whose rationale must be remembered ! large amount of data is generated most is persistent

/ooling drawings 0plastic metal1$ .%2 Product Planning Schedule

'lectronics circuits P.4 layout design$ .%2 3ardware -nterfaces 2evice drivers .ircuit!board design

Software development plan Software Schedule

Selection of tooling vendor /ooling (uotes Schedule Software development on P. Simulation -. design -. Specs Pin assignment Software 'lectronics testing Specs Sample Parts Sample P.4

5ne!time P"5M

'ngineering prototype ':ploded view %ssembly views ;ser manuals Service manuals Packaging design Software testing protocols 6unctional testing protocols Manufacturability Protocols 'ngineering Samples Packaging Manuals Production 2esign %pproved 2esign improvements

Prepare Pilot "un 45M Pilot "un 45M

Prepare Standard 5peration Procedures for 7orkers S5P

%ssembly Planning 0Mechanical P.41 %ssembly Se(uence %ssembly line design

P.4 testing *igs design 'lectronics testing S5P

Pilot "un Procurement 5rders 6actory 7orkstation Preparations /ooling

Software to -. fab -. orders

Pilot "un M68 prepare 9. procedures 7ork -nstructions 6actory 9.

Pilot Sample /esting

Production Planning

Some (uestions$ ! how can we reduce the effort)time of data creation ! how do we manage the pro*ect schedule ! what is a good way to store the +knowledge learnt,

Background: u!!ly "hain "oordination

% fundamental data!set created during the P"P is the 4ill of materials 045M1 ! 7hat is the relationship of 45M with MPS ?

P"P involves sourcing)procurement vendor management. ! 7hat are the potential effects of vendor mis!management on the company? !! different (uality specs from different sources !! different prices lead times &

Background: #fter$sales
Service !! Service manuals are usually created at the end of P"P 0often poorly@1 Maintenance product updates !! 3ow many 7indowsA updates have you received this month ? 5bsolescence management !! ;ntil what year must a company provide spare parts for a product? == 7ill Ma#da provide a spare side!mirror for the BCDE "F!E? == 7ill a .anon '6!S lens work with the ne:t 2igital SL"?

Im!lications of these issues

0B1 Large amount of information to manage % systematic method for information management % method)strategy that reduces data is better= % method to reduce effort in information management -ntegration of data management 0G1 /here are a lot of activities many are concurrent Mechanism to manage and optimi#e activities [pro*ect management scheduling for optimal makespan]

%istorical view of Product Lifecycle Management

HBIJ years ago$ 2esigner managed product data 0drawings etc.1 5nly the designer could understand this data&

Leonardo 2a Kincis 5rnithaptor 0flying machine1

%istorical view of PLM&&

LBJJ years ago /he 2rawing 4oard $ 'ngineers could communicate using a common language Engineering Drawings

%istorical view of PLM&&&

LMJ years ago 'he com!uter$ G2 becomes precise and modifications are easy& (D "#D

%istorical view of PLM)& 4ut& Problems with G2 .%2

!! G2 does not represent the reality !! G2 cannot model surfaces > solids !! G2 is sub*ect to misinterpretation

%istorical view of PLM)&&

LBCDI *D "#D$ allows defining comple: parts and assemblies

%istorical view of PLM)&&&

LBCCJ$ *D "#D allows automatic generation of .<. data 0to machine the part1
2efine /ool

.<. data Make M2 model Simulate cutting

%istorical view of PLM))&

LBCCI *D "#D$ allows analysis

%istorical view of PLM))&&

But here is the difficulty

0B1 Products are assemblies of many parts.. %utomobiles$ H BJ JJJ parts Ships$ H B JJJ JJJ parts

0G1 %ssemblies are created by many concurrent designers and enterprises

+eed for colla,oration- concurrent design in se!arate locations

%istorical view of PLM)))

LBCCI Digital Mocku! .DM/0 replaces physical prototypes

Boeing 777$ N 6irst *etliner to be BJJ percent digitally designed using M2 .%2 N H M million parts H CJJ suppliers from BE countries N Ma: alignment error on the first EEE was J.JGM, 0other planes$ LJ.I,1

%istorical view of PLM)))&

2igital mock!up is an alternative to constructing physical prototypes 6unctions of 2M;$ B. .omplete M2 visuali#ation of a product G. .ollaboration tool O since all engineers can see 0partial1 assemblies as the components are designed by different members of the team M. %ssembly analysis ! tests if some components are intersecting 0design error1 on assembly ! allows simulation of the functioning of the product 0kinematic1 ! allows testing of dynamic stresses 0including 6inite 'lement %nalysis1

%istorical view of PLM))))

LGJJJ Product Lifecycle Management 0PLM1 e:tends the scope of 2M; ;pstream ! 2esign %dherence to "e(uirements > "egulations ! Kalidation and .ertification Process ! 5ptimal "e!;se of .orporate %ssets ! -mpact of "e(uirements .hanges on Pro*ect Schedule 2ownstream ! Manufacturing ! Plant design > simulation

%istorical view of PLM ))))&

LGJJJ$ Pnowledge!4ased .%2 to support collaboration$ Store the know-how share design rules

1nowledge$Based "#D
-n the beginning$ there were G2 blueprints physical prototypes Pnowledge minds of the engineers)managers)technicians

Levels of P4'$ parametric design variational design catalog!based design rules!governed design

Parametric designs
/raditional design$ geometry is dimensioned with constants 0e.g. length1 Parametric design$ dimensions are in form of variable = expressions e:pression$ constant or an algebraic formula

%=X &

$= #

X = max(5, 0 !L" ' = 0 5&

7hat are the independent variables and the dependent variables?

Parametric designs: an e2am!le

sun is bigger

<on!parametric design$ Suppose the sun increases in si#e Sun gets chopped off at topQ book gets cut by the sun

Parametric designs: e2am!le&&

sun is bigger L L(

)arametric design* +eometric relation between center o, sun, radius o, sun, and top o, book +eometric relation between length o, part and si-e o, sun

Parametric design e2am!les

R: counterbored holes depth S thickness of flange)M

(5)

$. convention, derived dimensions are shown in parenthesis b. man. /0' s.stems

Parametric design e2am!les

2efinition of a nut Length of threads

Length of smooth part S total length O threaded length

Parametric design e2am!les

.omponents that mate with each other 0most products are assemblies1 ! 2imensions on mating parts are parametrically related.

%dvantage$ 2esign modifications in one part will automatically propagate the change in all related parts.

Parametric design e2am!les&&

':ploded view$ Tamaha T6MGJJ Motorcycle %utomatic .lutch

"atalog$,ased Designs
%n e:tended of parametric design$ 4ase model specifies topology and relations between geometry /he design details are all e:pressed as parameters Part design is created by providing a table with parameter values Standard sections

%l e:trusions

&

"atalog$,ased Designs: an e2am!le

.atalog of fasteners 0screws nuts &1

"atalog design
7e shall assume a catalog of parts 0though you can have product catalogs1 B. 2ivide the group of products into categoriesQ each category has the same set of descriptors G. 'ach group will form a sub!set of the catalog called family
e.g. 6astener chapter Screw family has attributes$ designation type dia length

M. .onstruct a parametric .%2 model of one member of the family

9;'S/-5<$ 7hat are the independent variables in this model?

R. -dentify the independent variables with names matching attribute names

"atalog design)
R. -dentify the independent variables with names matching attribute names I. .reate a table 0e.g. a MS ':cel table1 with attributes and values

U. ;se the 8;- of the .%2 system to link the table design family description

"atalog$,ased Designs
;sing catalogs$ .atalogs V a Database table search for a catalog component using a (uery on its design parameter0s1 ':ample 6ilter$ 0lWlength H BJ1 and 0lWlength X BI1

%lternate method$ Most .%2 systems will allow a thumbnail preview and select

Rules$governed design "ules are a mechanism to add design knowledge ':amples of design knowledge$ B. Standard design knowledge G. Manufacturability knowledge 0specific to a company1 M. 2esign guidelines 0specific to a company1 R. .ompliance rules &

Rules$governed design

Standard design knowledge

':ample$ design of a latch in a plastic component

6rom theoretical solid mechanics

Stress S S ' [' is Toungs modulus of the material] 7e must ensure that stress S S ' MThJ)GLG X fracture stress S ma: 2'S-8< ";L'$ M'ThJ)GLG X ma:

Rules$governed design
4ackground for this e:ample$ .ommon features in plastics components

Manufacturability knowledge

/hese features are constructed using standard operations in .%2 systems

"ib operator in .%/-% "ib operator in Solid7orks

Rules$governed design
':perience from in*ection molding$

Manufacturability knowledge

rib thickness H J.It

-nferred design guidelines$

%./-5<$ rule is set up in the .%2 systemQ violation triggers a warning

Product instantiation
6or a well!defined product architecture the Product -nstance is generated by the following steps$ B. 4asic assembly model of a template product of the family is retrieved G. %ll components that will be used are retained others are discarded M. Parameter values for each template part are set R. <ew components are designed 0using catalogs if possible1 I. 2esign rules are applied

Digital Mock$/! .DM/0

.onstructing a 2M; B. Part designs of all components are stored in a 24 G. 2efine the product structure as a 45M 045M can access the 241 M. /he parts are assembled O note that this assembly definition is richer than classical assembly in .%2 0it needs to store kinematics1

DM/ 32am!les: hi!man4

Mock up of boat design to test ergonomics of spaces for humans

DM/ 32am!les
2M; allows for accessibility testing in aircraft design 0for repair)maintenance1

"olla,oration .through DM/0

2M; improves collaborative function because$ B. Parts that are being constructed by different designers get loaded into the 24 and associated with the product structure. G. 'ach part that is put into the 2M; must be +put!in!place, O namely its spatial relation with other parts already in the system must be defined. M. -t follows that the entire team can see how the product is getting constructed in real!time.

Definitions .re$visit0

PDM is the management and classification of design data and specifications for an engineered product and the management of change to this information.

PLM is the activity of managing a companys products all the way across their lifecycles in the most effective way. [Stark]

PLM system is [an information system] that facilitates all or some subset of PLM activities. [Stark]

Product Lifecycle Management

"#3 'ooling design "#D Item management Product structure centralized DB 56ile vault7 ecurity 3ngineering "hanges 'ask management

+-tem, could be$ N .%2 document N /e:t document N 2esign spreadsheet N Software program N Process Plan N S5P N .ustomer complaint N Service records

Product Lifecycle Management

Item management

! product architecture planning Product structure ! specification 045M tree hierarchical model1 ! -nstantiation 0parametric1 from templates
centralized DB 56ile vault7 ecurity 3ngineering "hanges 'ask management

Product Lifecycle Management

Item management Product structure centralized DB 56ile vault7 ecurity 3ngineering "hanges 'ask management

! %uthority ! Kiews ! %ccess control 0check!in)check!out1

Product Lifecycle Management

Item management Product structure centralized DB 56ile vault7 ecurity 3ngineering "hanges 'ask management

!'." ! 2esign modifications ! .onfirmation)approval cycle ! '.< ! -nfo storage)retrieval

Product Lifecycle Management

Item management Product structure centralized DB 56ile vault7 ecurity 3ngineering "hanges 'ask management

!team specification 0re(uirement based resource based1 ! task assignments ! milestones setting management ! critical path ! deadline reminders notifications

PLM functionality
PLM supports M levels of collaboration

Potential Benefits of Product Lifecycle Management

"educed /ime!to!Market -mproved 2esign Productivity -mproved .oncurrent 'ngineering -mproved 2esign and Manufacturing %ccuracy 2ata -ntegrity Safeguarded 4etter Pro*ect Planning 4etter Management of 'ngineering .hange

Industry ada!tations
3ewlett!Packard .o. uses 7indchillA from P/.$ !! achieved DJY improvement in design and process reuse. !! /hey reduced time!to!market product cost and warranty cost. <'. computers uses %gile Product .ollaboration solution suite$ !! MJY savings in monthly engineering workloadQ !! MCY reduction in scrap and rework costs. "ockwell %utomation uses /eamcenter from ;8S PLM$ !! Manage the engineering change notice systemQ !! IJY reduction in '.< cycle time !! Save ;SZGJJ per '.< [total savings$ ;SZ RJJ JJJ in one business unit ]

Pers!ectives on ada!tation of PLM

<'.'SS-/T ! companies that are part of global supply chain or design chain need collaboration tools

M%"P'/-<8 ! companies with short mean!time!between!upgrades e.g. computer manufacturers

S'.;"-/T ! ':ample B$ e.ommerce collaboration between potential client and designer ! ':ample G$ Software)hardware security 0e.g. Microsoft windows updates1

Pers!ectives on ada!tation of PLM&&

M%"P'/-<8 ! firmware upgrades on digital cameras mpM playersQ where the company captures market by an early release and later upgrades functionality

P"52;./ S/"%/'8T ! Mass customi#ation and modular product design companies need efficient product architectures to allow part)process reuse over generations

8"''< ! companies responsible for recycling of their sold products e.g. printer toner cartridges aluminum cans plastic or glass bottles paper

Pers!ectives on ada!tation of PLM)

S'"K-.' ! companies with long!life products that need continued repair service etc. e.g. automobiles. B. G. M. R. spare parts for older models must be available service manuals testing e(uipment e.g. testing onboard computers and microprocessors must be maintained Management of product recalls 6ord ':plorer 6irestone [GJJJ!GJJB]$ "eplaced BM million tires. <issan motor [GJJM]$ G.II million cars recalled to fi: engine defectsQ .ost$ [PTBI billion.

"ommercial PLM systems

Parametric /echnologies 0Pro)'ngineer1$ 7indchill 2assault!-4M 0.%/-% Solidworks1$ Smar/eam ;nigraphics \ S2". 0;8 -!2'%S1$ /eamcenter\Metaphase %utodesk$ %utodesk Kault\%utodesk productstream\&

ummary

PLM$ -nformation system integrating Product 2esign \ Pnowledge!based .%2 .ollaboration 2ocument control 7orkflow management 'ngineering change management