Introduction to PDM and PLM

PLM is the activity of managing a company’s 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]

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

Background: what are lifecycle activities?

- Product Realization: from concept to production

- Production: supply chain coordination

- After-sales: service, maintenance, product updates, obsolescence management…

Background: Product Realization Process

Earlier we saw a PRP flowchart

Some crucial elements of PRP:

- many decisions are made whose rationale must be remembered

- large amount of data is generated, most is persistent

Some questions:

- how can we reduce the effort/time of data creation - how do we manage the project schedule - what is a good way to store the “knowledge learnt”

IC SpecsPin assignmentSoftware, Electronics

testing Specs

IC SpecsPin assignmentSoftware, Electronics

testing Specs

ProductPlanningSchedule

Tooling drawings (plastic, metal): CAD

Hardware InterfacesDevice driversCircuit-board design

Electronics circuits,PCB layout design: CAD

SoftwareSchedule

Software development plan

Tooling quotesSchedule

Selection of tooling vendorSoftware development on PCSimulationIC design

Sample PCB One-time PROMSample Parts

Engineering prototype

Software testingprotocols

Functional testingprotocols

ManufacturabilityProtocols

Design improvements

Engineering Samples

DesignApproved

Pilot RunBOM

Prepare Pilot Run BOM

SOP

Prepare Standard OperationProcedures for Workers

Assembly SequenceAssembly line design

Assembly Planning(Mechanical, PCB)

Electronicstesting SOP

PCB testing jigs design

Orders

Pilot Run Procurement

Factory Workstation Preparations, ToolingIC orders

Software to IC fab

WorkInstructions

MFG prepare QC procedures

Pilot Run

Factory QC

Pilot Sample Testing

Production Planning

A A A A

Exploded viewAssembly views

User manualsService manuals

Packaging design

Packaging, ManualsProduction

Specs for newElectronics Parts

IDD, Specs:New Tooled Parts

ExistingParts

Target SpecsMilestonesProject TeamsCritical Parts: IC’s, Plastic, Metal…

Target SpecsMilestonesProject TeamsCritical Parts: IC’s, Plastic, Metal…

ProductPlanningSchedule

PricesLead times

Detailed Construction ReqtsManufacturability NotesCritical components

Industrial Design Drawing

Product RequirementsCosmetic Requirements

Project conceived

Design House

Industrial DesignControl Drawing

Finalize cosmeticsDummy Mock-up

Design Release Meeting*

Preliminary Cost Analysis

ProjectConfirmed

ConstructionDrawings

Construction Drawings, CADPurchasing & Procurement, ME, ELEC:Categorize critical parts

Contact vendors

Prepare, Approve Schedule (All depts)

Concept Release Meeting

A

Background: Supply Chain Coordination

A fundamental data-set created during the PRP is the Bill of materials (BOM)

- What is the relationship of BOM with MPS ?

PRP involves sourcing/procurement vendor management.

- What are the potential effects of vendor mis-management on the company?

-- different quality specs from different sources -- different prices, lead times, …

Background: After-sales

Service

-- Service manuals are usually created at the end of PRP (often poorly!)

Maintenance, product updates

-- How many Windows™ updates have you received this month ?

Obsolescence management

-- Until what year must a company provide spare parts for a product?

** Will Mazda provide a spare side-mirror for the 1987 RX-7?** Will a Canon EF-S lens work with the next Digital SLR?

Implications of these issues

(1) Large amount of information to manage

A systematic method for information management

A method/strategy that reduces data is better*

A method to reduce effort in information management

Integration of data management

(2) There are a lot of activities, many are concurrent

Mechanism to manage and optimize activities [project management, scheduling for optimal makespan]

Historical view of Product Lifecycle Management

>150 years ago: Designer managed product data (drawings etc.), Only the designer could understand this data…

Leonardo Da Vinci’s Ornithaptor (flying machine)

Historical view of PLM..

~100 years agoThe Drawing Board : Engineers could communicate using a common language, Engineering Drawings

Historical view of PLM...

~30 years agoThe computer: 2D becomes precise and modifications are easy… 2D CAD

Historical view of PLM….

-- 2D does not represent the reality

-- 2D cannot model surfaces & solids

-- 2D is subject to misinterpretation

But… Problems with 2D CAD

Historical view of PLM…..

~19853D CAD: allows defining complex parts and assemblies

Historical view of PLM…...

~1990:3D CAD allows automatic generation of CNC data (to machine the part)

Make 3D model

Define Tool

CNC data

Simulatecutting

Historical view of PLM…….

~19953D CAD: allows analysis

Historical view of PLM……..

(1) Products are assemblies of many parts..

Automobiles: > 10 000 partsShips: > 1 000 000 parts

But here is the difficulty

(2) Assemblies are created by many concurrent designers and enterprises

Need for collaboration, concurrent design in separate locations

Historical view of PLM………

~1995Digital Mockup (DMU) replaces physical prototypes

Boeing 777:• First jetliner to be 100 percent digitally designed using 3D CAD • > 3 million parts, > 900 suppliers from 17 countries• Max alignment error on the first 777 was 0.023” (other planes: ~0.5”)

Digital mock-up is an alternative to constructing physical prototypes

Functions of DMU:

1. Complete 3D visualization of a product

2. Collaboration tool – since all engineers can see (partial) assemblies as the components are designed by different members of the team

3. Assembly analysis- tests if some components are intersecting (design error) on assembly

- allows simulation of the functioning of the product (kinematic)

- allows testing of dynamic stresses (including Finite Element Analysis)

Historical view of PLM……….

Historical view of PLM…………

Upstream

- Design Adherence to Requirements & Regulations- Validation and Certification Process- Optimal Re-Use of Corporate Assets - Impact of Requirements Changes on Project Schedule

~2000Product Lifecycle Management (PLM) extends the scope of DMU

Downstream- Manufacturing- Plant design & simulation

Historical view of PLM ………….

~2000: Knowledge-Based CAD to support collaboration:Store the know-how share design rules

Knowledge-Based CAD

In the beginning: there were 2D blueprints, physical prototypes

Knowledge minds of the engineers/managers/technicians

Levels of KBE:

parametric design

variational design

catalog-based design

rules-governed design

Parametric designs

Traditional design: geometry is dimensioned with constants (e.g. length)

Parametric design: dimensions are in form of variable = expressionsexpression: constant, or an algebraic formula

L

X = max(5, 0.1L)Y B= YR = X

HD = 0.5H

What are the independent variables and the dependent variables?

Parametric designs: an example

sun is bigger

Non-parametric design:Suppose the sun increases in size

Sun gets chopped off at top; book gets cut by the sun

Parametric designs: example..

sun is bigger

LL’

Parametric design:

Geometric relation between center of sun, radius of sun, and top of bookGeometric relation between length of part and size of sun

4x counterbored holes, depth = thickness of flange/3

(5)

Parametric design examples

By convention, derived dimensions are shown in parenthesis by many CAD systems.

Parametric design examples

Definition of a nut

Length of threads

Length of smooth part =total length – threaded length

Parametric design examples

Components that mate with each other (most products are assemblies)

- Dimensions on mating parts are parametrically related.

Advantage:Design modifications in one part will automatically propagate the change in all related parts.

Parametric design examples..

Exploded view:Yamaha YFM200 MotorcycleAutomatic Clutch

Catalog-based Designs

An extended of parametric design:

Base model specifies topology and relations between geometry

The design details are all expressed as parameters

Part design is created by providing a table with parameter values

Al extrusions

Standard sections

…

Catalog-based Designs: an example

Catalog of fasteners (screws, nuts, …)

Catalog design

We shall assume a catalog of parts (though you can have product catalogs)

1. Divide the group of products into categories; each category has the same set of descriptors

2. Each group will form a sub-set of the catalog, called family

e.g. Fastener chapter, Screw family, has attributes: designation, type, dia, length

3. Construct a parametric CAD model of one member of the family

QUESTION: What are the independent variables in this model?

4. Identify the independent variables with names matching attribute names

Catalog design…

4. Identify the independent variables with names matching attribute names

5. Create a table (e.g. a MS Excel table) with attributes and values

6. Use the GUI of the CAD system to link the table, design, family description

Catalog-based Designs

Using catalogs:

Catalogs ≈ a Database table search for a catalog component using a query on its design parameter(s)

ExampleFilter: (l_length > 10) and (l_length < 15)

Alternate method:

Most CAD systems will allow athumbnail preview and select

Rules-governed design

Rules are a mechanism to add design knowledge

Examples of design knowledge:

1. Standard design knowledge

2. Manufacturability knowledge (specific to a company)

3. Design guidelines (specific to a company)

4. Compliance rules

…

Rules-governed design Standard design knowledge

Example: design of a latch in a plastic component

From theoreticalsolid mechanics

Stress = = E [E is Young’s modulus of the material]

We must ensure that stress = = E 3Yh0/2L2 < fracture stress = max

DESIGN RULE: 3EYh0/2L2 < max

Rules-governed design Manufacturability knowledge

Background for this example:Common features in plastics components

These features are constructed using standard operations in CAD systems

Rib operator in CATIA

Rib operator in SolidWorks

Rules-governed design Manufacturability knowledge

Experience from injection molding:

t

rib thickness > 0.5t

Inferred design guidelines:

ACTION: rule is set up in the CAD system; violation triggers a warning

Product instantiation

For a well-defined product architecture, the Product Instance isgenerated by the following steps:

1. Basic assembly model of a template product of the family is retrieved

2. All components that will be used are retained, others are discarded

3. Parameter values for each template part are set

4. New components are designed (using catalogs if possible)

5. Design rules are applied

Digital Mock-Up (DMU)

Constructing a DMU

1. Part designs of all components are stored in a DB

2. Define the product structure as a BOM (BOM can access the DB)

3. The parts are assembled – note that this assembly definition is richer than classical assembly in CAD (it needs to store kinematics)

DMU Examples: Shipman™

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

DMU Examples

DMU allows for accessibility testing in aircraft design (for repair/maintenance)

Collaboration (through DMU)

DMU improves collaborative function because:

1. Parts that are being constructed by different designers get loaded into the DB, and associated with the product structure.

2. Each part that is put into the DMU must be “put-in-place” – namely its spatial relation with other parts already in the system must be defined.

3. It follows that the entire team can see how the product is getting constructed in real-time.

Definitions (re-visit)

PLM is the activity of managing a company’s 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]

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

Product Lifecycle Management

centralized DB[File vault]

Item management

Product structure

Security

Engineering Changes

Task management

“Item” could be:• CAD document• Text document• Design spreadsheet• Software program• Process Plan• SOP• Customer complaint• Service records

CAD

CAE

Tooling design

Product Lifecycle Management

centralized DB[File vault]

Item management

Product structure

Security

Engineering Changes

Task management

- product architecture planning- specification (BOM tree, hierarchical model)- Instantiation (parametric) from templates

Product Lifecycle Management

centralized DB[File vault]

Item management

Product structure

Security

Engineering Changes

Task management

- Authority- Views- Access control (check-in/check-out)

Product Lifecycle Management

centralized DB[File vault]

Item management

Product structure

Security

Engineering Changes

Task management

-ECR- Design modifications- Confirmation/approval cycle- ECN- Info storage/retrieval

Product Lifecycle Management

centralized DB[File vault]

Item management

Product structure

Security

Engineering Changes

Task management

-team specification (requirement based, resource based)- task assignments- milestones setting, management- critical path- deadline reminders, notifications

PLM functionality

PLM supports 3 levels of collaboration

Potential Benefits of Product Lifecycle Management

Reduced Time-to-Market

Improved Design Productivity

Improved Design and Manufacturing Accuracy

Data Integrity Safeguarded

Better Project Planning

Better Management of Engineering Change

Improved Concurrent Engineering

Industry adaptations

Hewlett-Packard Co. uses Windchill™ from PTC:

-- achieved 80% improvement in design and process reuse.-- They reduced time-to-market, product cost, and warranty cost.

NEC computers uses Agile Product Collaboration solution suite:

-- 30% savings in monthly engineering workload;-- 39% reduction in scrap and rework costs.

Rockwell Automation uses Teamcenter from UGS PLM:

-- Manage the engineering change notice system;-- 50% reduction in ECN cycle time-- Save US$200 per ECN [total savings: US$ 400,000 in one business unit ]

Perspectives on adaptation of PLM

NECESSITY- companies that are part of global supply chain or design chain need collaboration tools

MARKETING- companies with short mean-time-between-upgrades, e.g. computer manufacturers

SECURITY- Example 1: eCommerce collaboration between potential client and designer- Example 2: Software/hardware security (e.g. Microsoft windows updates)

Perspectives on adaptation of PLM..

MARKETING- firmware upgrades on digital cameras, mp3 players; where the company captures market by an early release, and later upgrades functionality

PRODUCT STRATEGY- Mass customization and modular product design companies need efficient product architectures to allow part/process reuse over generations

GREEN- companies responsible for recycling of their sold products e.g. printer toner cartridges, aluminum cans, plastic or glass bottles, paper

SERVICE- companies with long-life products, that need continued repair, service etc. e.g. automobiles.

Perspectives on adaptation of PLM…

1. spare parts for older models must be available

2. service manuals

3. testing equipment, e.g. testing onboard computers and microprocessors, must be maintained

4. Management of product recallsFord Explorer, Firestone [2000-2001]: Replaced 13 million tires.Nissan motor [2003]: 2.55 million cars recalled to fix engine defects; Cost: JPY15 billion.

Commercial PLM systems

Parametric Technologies (Pro/Engineer): Windchill

Dassault-IBM (CATIA, Solidworks): SmarTeam

Unigraphics + SDRC (UG, I-DEAS): Teamcenter+Metaphase

Autodesk: Autodesk Vault+Autodesk productstream+…

PLM: Information system integrating

Product Design + Knowledge-based CADCollaborationDocument controlWorkflow managementEngineering change management

Summary