Product Data Management

Transcription

1 T ENTERPRISE SYSTEMS ARCHITECTURE: Product Data Management Asko Martio Variantum Oy, File: PDM_ Slide 1

2 Variantum Oy New Finnish company, established 2002, 9 owners Roots in Product Data Management Group (PDMG) of HUT, established in 1992 First big project: EDMS for KONE Oyj, first remarkable document management system in Finland. Today s status: over documents, over 3000 active users. PDM and configurable product related research projects with approx. 20 Finnish companies. Best imaginable technological know-how 2 D.Sc. (Tech), dissertations within configuration domain, 1 Lic. Sc. (Tech), 4 M. Sc. (Tech) approx. 50 man-years of industrial experience in different management positions File: PDM_ Slide 2

3 Variantum products System products VariSelect, Product family selection tool to highlight product properties and their differences VariSales, Sales configurator for sales order definition VariProd, Production configurator that creates Bill of Materials required by the specified product variant (configuration) for the ERP system VariPDM, PDM system for product, document, product model and workflow management Service and support products Expert services for consultation, system training and implementation After sales support services File: PDM_ Slide 3

4 Contents References, terminology Definition of PDM Background, motivation for PDM PDM Functionality Architecture Summary KONE case File: PDM_ Slide 4

5 References Kenneth G. McIntosh ENGINEERING DATA MANAGEMENT A Guide to Successful Implementation, McGraw-Hill Inc. Antti Sääksvuori, Anselmi Immonen Tuotetiedonhallinta PDM, Talentum Media 2002 Hannu Peltonen, Asko Martio, Reijo Sulonen PDM - Tuotetiedon hallinta, IT Press 2002 M. Eigner, R. Stelzer Produktdatenmanagement-Systeme, Springer 2001 I. Crnkovic, U. Asklund, A. P. Dahlqvist Product Data Management and Software Configuration Management, Artech House, Inc John Stark Product Lifecycle Management, Paradigm for 21st century Product realisation, Springer 2004 Rodger Burden PDM: Product Data Management, Resource Pub File: PDM_ Slide 5

6 Terminology: PDM cpdm PAM Document Electronic Technology PDM Product Lifecycle PLM EDM Collaborative Information Data Engineering PDT TIM TDM Management Asset Technical Almost any combination of terms is used, PDM (Product Data Management) and PLM (Product Life-cycle Management) seem to be most common PIM Enterprise Definition File: PDM_ Slide 6

7 Definition: Product Result of industrial activity Product family, brand, model, type, product class, configurable product Product configuration, fixed product Product individual general concept abstract class (cannot be manufactured) concrete class (can be manufactured) physical artifact, service activity File: PDM_ Slide 7

8 Definition: Product Data (CIMdata) All product related information Paper documents Digital files: Document files: specifications, configurations, purchase orders CAD drawings, models, assemblies, parts lists CAE analysis, NC programs and plans Information stored in data bases PDM manages three different product data life-cycles Product type life-cycle: product development approval and change processes beginning and end of production Product individual life-cycle: engineering production, maintenance, recycling Product process life-cycle File: PDM_ Slide 8

9 Definition: PDM ISO Parts Library: A representation of facts, concepts, or instructions about one or more products in a formal manner suitable for communication, interpretation, or processing by human beings or by automatic means. Crnkovic, Asklund, Persson Dahlqvist (2003): PDM is the discipline of controlling the evolution of a product and providing other procedures and tools with the accurate product information at the right time in the right format during the entire Product Life Cycle PDT (Product Data Technology)-advisory group: Product Data Technology includes all aspects of the definition and methods of processing information pertinent to product throughout its development and operational lifecycle. File: PDM_ Slide 9

10 Definition: PLM (CIMdata) What is Product Lifecycle Management (PLM)? A strategic business approach that applies a consistent set of business solutions in support of the collaborative creation, management, dissemination, and use of product definition information across the extended enterprise from concept to end of life integrating people, processes, and information File: PDM_ Slide 10

11 PDM system status today PDM systems coverage is more restricted: Current PDM systems do not include commercial data (stocks, purchase orders, invoices, cost accounting, etc.) of the company. They are managed by Enterprise Resource Planning (ERP) systems. Main interest of PDM lays on product support processes (R&D, etc.) Many PDM systems do not support configurable products and product individual and production process life-cycles PDM system does not create new product data File: PDM_ Slide 11

12 PDM motivation: Changing business environment Increased competition Global markets, aggressive market behaviour Shrinking budgets, lower production costs Products are becoming more complex, exploiting more technologies and built in vast number of variants Quality requirements (ISO 9000 etc) and customer responsiveness are increasing Global manufacturing (expanded teaming) Government and industry standards Less time and money for hassling Requirement for more efficient R&D: Concurrent Engineering File: PDM_ Slide 12

13 PDM motivation: Data integration by system integration Design/Engineering CAD Purchasing & Finance Project Management Manufacturing MRP System Customers File: PDM_ Slide 13 Production Sales/Marketing & Customer Service Process/Plant Suppliers

14 PDM costs and benefits PDM system benefits direct cost savings faster time-to-market benefits change management savings indirect cost savings improved quality other savings PDM system costs hardware, software licences system tailoring, system integration, installation, training system maintenance File: PDM_ Slide 14

15 PDM Benefits, example Metric Standard C.E. Delta (%) Design Hours %/25% Span Time (months) %/42% Tooling Costs $79,461 $49,993 $42,057 47%/16% No. Changes (15 mo.) %/75% No. Changes (30 mo.) %/79% No. Quality Reports %/89% No. Waivers %/95% Mark Knodle, General Dynamics Space Systems Division File: PDM_ Slide 15

16 PDM market forecast File: PDM_ Slide 16

17 PDM biggest vendors File: PDM_ Slide 17

18 PDM end user investment File: PDM_ Slide 18

19 PDM Functions Item and Document Management Product Structure Management Workflow and Process Management SPEC NC ECO ECO 3D Drawings/Documents Classification & Retrieval partno Screw Length axy mm zvy mm dgf mm Program Management Little support + Support utilities As PDM becomes implemented across different industry sectors, functional priorities change. File: PDM_ Slide 19

20 Data vault Central storage for Documents Product configuration data Product model data Product individual data Maintains revision and status data (e.g. electronic approval) Files (drawings, documents, etc.) are managed as objects Check-out and check-in control Query, browsing and reporting Benefits Secure, distributed storage of data Elimination of redundant files Managed data sharing among team members Managed electronic review and approval Management of data relationships Based often on commercial relational data bases File: PDM_ Slide 20

21 Data vault Object: Document Date: 1/1/95 Project: Motor Part #: A Revision: 2.3A Document #: File: A:\PDM\doc\motor\... Application: MS-Word 6.0 Meta-Database data Managed referenced files PDM Server File: PDM_ Slide 21

22 PDM items Item definition Items from the PDM point of view are those product related business objects which are frequently referred in product related processes, e.g. products, materials, documents, resources, activities. Use of standard items makes management and business transactions easier PDM corner stones Item categories Physical items systems, assemblies, parts, components, accessories Document items Product models and software Service items File: PDM_ Slide 22

23 Item views Life-cycle view Item revisions Classification (type) view Classification according to product properties Classification hierarchy Status view Item approval level Item efficiency Language view Structure view Structures dependent on processes Sales (offer, sales order) structure Design structure Manufacturing structure Delivery structure Installation structure Maintenance structure Physical product structure Functional structure Spatial structure File: PDM_ Slide 23

24 Item classification Required to search and browse items efficiently Standards: ISO Part Libraries, IEC electric components classification scheme standard Examples: Specifying code Parametric class hierarchy A Basic mechanical materials and components A2 Non-ferrous metals A20 Sheets and strips Fasteners (Length, diameter) A202 Coated sheets and strips Screws (Length, diameter, thread length) Cross head screws (Length, diameter, thread length, head diameter, standard) File: PDM_ Slide 24

25 Basic item data Identification Generally approx. 8 character code Classifying v. non-classifying Local v. enterprize wide Description Generally approx. 40 characters of cler text Classification Helps to find items Revising Revising method Revision identification Status (recommendation class) Manufacturers, vendors Other data Big systems: approx. 300 fields/item Item is specified to the level that is required by its user Reference documents File: PDM_ Slide 25

26 Item revisions Warning: there is no approved terminology When an item is changed a new version, which is also an item, is created. It is Revision. An item of this type is generated to replace its predecessor immediately or after a transition period. Therefore, the new revision must be compatible (form, fit and function) with its predecessor. Variant. Variant concept is sometimes used for products, parts and items with small differences. An item in this group is related to a higher-level product type. Independent item. An item in this group is neither a variant nor a revision of any other item. The relation to its origin is lost. Example: a new independent product File: PDM_ Slide 26

27 Document management Which document types? Identification method for documents, document revisions and variants Approval of documents Security archives Document tool integration to PDM WWW user interfaces Document structure Document revisions Document variants Equivalence of documents written in different languages Multilingual documents Subdocuments Multipage drawings Figure files 3D models Representations Original,, viewing and printing formats File: PDM_ Slide 27

28 Product structure Bicycle Handlebars Pedal Frame Wheels Saddle Tire Spoke Hub Figure 2.5 Quantified BOM of a bicycle Crnkovic, Asklund, Persson Dahlqvist, Implementing and Integrating Product Data Management and Software Configuration Management File: PDM_ Slide 28

29 Product (breakdown) structure - general All structure items represent elements which can be delivered with the product. They are often physically attached to it. Product requisites like coatings, paints, welding wires, packages, adhesives, lubricants, chemicals are often left out of product structures. All items are identified with a code. A clear text description is required as support information. Physical products include only physical objects as components: non-decomposable (atomic) component, e.g. bolt, integrated circuit, cardboard package box, user manual multipart component File: PDM_ Slide 29 subassembly, e.g. phone receiver kit (group, no assembly process), e.g. installation accessories other material, e.g. 50 m rope, 3 l oil most common views: product (design/manufacturing), location

30 Documents and product structures Documents are linked to products: Product - parts list, assembly drawing Often this link is built into the identification system Product - other manufacturing documents Assembly instructions Test instructions Product specifications etc. Product - deliverable documents deliverable documents are items in product structure File: PDM_ Slide 30

31 References In addition to document links other type of items can be attached to product structures Product - jigs, fixtures Product - tools Product - embedded software Product - NC software File: PDM_ Slide 31

32 Product structure links, revisions 1 Quality 2 Attributes 3 Materials 4 Process Revision A 1 Quality 2 Attributes 3 Materials 4 Process Revision A Revision B Phone Receiver Assembly drawing and BOM Revision A Test Data Revision A Revision A Revision B Revision A Revision A Revision B Analysis Report Revision A Marketing Definition File: PDM_ Slide 32

33 Modelling concepts File: PDM_ Slide 33

34 Workflow management Defined and automated workflow/processes By project, status level, product type,... Sequential, parallel, conditional steps Voting rules and time-outs Folder/package maintenance Notification and distribution Audit processes and actions triggers Process browse/reporting Only for stable processes Change management Document approvals etc File: PDM_ Slide 34 Change process phases Change request (ECR, Engineering Change Request) Internal and external product claims and messages Change proposal (ECP) Consolidation of change requests Evaluation of change effects Change order (ECO) Decided change actions Change follow-up Registration of accomplished actions

35 Utility functions Communications, Data transport Data translation Viewing and annotation Image services Administration System security control System management Password management File: PDM_ Slide 35 Data security services data redundancy, disk mirroring fault tolerant disks, RAIDtechnology (Redundant Array of Inexpensive Disks) automatic back-ups data encryption Authentication services Authorisation services viewing authorisation change authorisation (approvals, document creation and changes, etc.)

36 PDM system architecture Application User CAD/CAM, NC, Purchasing Documentation, Etc. Private Files CAD PDM User Multiple Applications control data Meta-Database data Object: Document Date: 1/1/95 Project: Motor Part #: A Revision: 2.3A Document #: File: A:\PDM\doc\motor\... Application: MS-Word 6.0 data Intranet WEB server Managed Files WEB User PDM Server File: PDM_ Slide 36

37 PDM system selection and implementation Project definition Evaluation of the current status System scope definition Prioritised requirements/ feature summary / configuration plan Short list selection evaluation Request for proposals Demonstration / benchmark requirements File: PDM_ Slide 37 Demonstration / benchmark Evaluation Reference visit agenda Reference visit evaluation Proposal evaluation Pilot project definition Pilot project implementation log Pilot project analysis (vs. benefit targets) Final evaluation summary and report

38 PDM Summary Organisations which do not take PDM seriously will face difficulties The following factors increase PDM importance: organisation size internationality product complexity number of product variants PDM system implementation without management support becomes a failure File: PDM_ Slide 38

39 Case: KONE Corporation World s fourth largest elevator company, onne of the world s leading escalator companies Modernization and maintenance of existing systems account for 2/3 of the revenue Growth from the automatic door service business Present in more than 40 countries with some 800 service centers Strategic alliance with Toshiba of Japan since 1998 Turnover: EUR 2,814 million Personnel: 23,800 employees Sales: 25,000 new elevators and escalators Maintains about 520,000 elevators and escalators and more than 210,000 automatic building doors File: PDM_ Slide 39

40 KONE business environment Distributed Order-Delivery Processes Local front line companies (40 countries) and independent distributors for sales, delivery, installation and maintenance Global order engineering, production and logistics A lot of the production subcontracted to partners Service Business Long life cycles of product individuals File: PDM_ Slide 40 ASEA-Graham Lift no 1: 1898 KONE Lift no 27: 1920 Service and spare parts Information must be available Global, distributed, networked R&D Global products with regional adaptations R&D centers in all continents, complex, mass-customized products A lot of subcontractors and partners involved in the R&D projects

41 Documents at KONE Commercial Documents Invoices, order confirmations, shipping documents etc from ERP Process and Quality Documents: ISO9000 etc. Project Documentation Project Plans, Specifications, Meeting Minutes R&D Projects: Studies, sketches, informal Excel lists of whatever Order Projects: Tendering documents, Order-specific drawings and calculations Training Material, Product, Process and Organisational Training File: PDM_ Slide 41 Product Documentation Marketing Material (brochures etc) Technical Instructions: Drawings Planning (PG) and Sales (DL) instructions Owners/User's manuals Product Descriptions and Ordering instructions (SO) Installation instructions (AM) Service, Maintenance and Spare Parts Instructions (AS,AR) 3D Models, Assembly and Part drawings, Parts lists, Configuration Instructions Testing instructions Software Binary Files Specifications, Certificates Product Change Requests

42 KONE document management systems Variantum EDMS (Engineering Data Management System), ( KONE Global PDM System Product Documentation: Drawings, Instructions, Certificates Parts and Product Structures with documents linked into the structures Engineering Change Management Documentum ( Archiving of ERP data (old invoices etc.) Production of technical instructions (XML-based information management) Management of some business process and quality documentation File: PDM_ Slide 42

43 KONE EDMS Statistics ( ): Number of documents: (New in 09/2004: 25000) Number of parts: (New in 09/2004: 1600) Users: 6396 (New in 09/2004: 96) Document files: 320 GB (New in 09/2004: 12GB) Users in 09/2004: 2950 Amount of data transferred over the WWW interface: 1.5GB / day Software (Server) Variantum EDMS Application Server Database: PostgreSQL Version WWW: CGI scripts written in the TCL language ( Full text indexing: Idzebra ( Linux (Fedora Core 3) Backup: IBM Tivoli TSM Monitoring: Nagios ( File: PDM_ Slide 43

44 KONE EDMS Main screen File: PDM_ Slide 44

45 KONE EDMS- Drawing query File: PDM_ Slide 45

46 KONE EDMS- Query results File: PDM_ Slide 46