12+ Jahre PDM: Von der PDM Vision zur Wirklichkeit

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1 12+ Jahre PDM: Von der PDM Vision zur Wirklichkeit Martin Genderka, Alstom Power Swiss PLM-Forum 2011, Rapperswil

2 Agenda Introduction ALSTOM Product Data Management Scope and History ALSTOM Power Component Product Data Management Upcoming Challenges

3 Alstom: a long lasting history A group born Creation of Alsthom through the merger of Thomson-Houston and Société Alsacienne de Constructions Mécaniques (SACM). - The first factory was based in Belfort, France.

4 Alstom Group: Three sectors 93,500 employees in over 100 countries Grid 3.6 bn 17% Power 11.7 bn Grid 19,201 21% Transport 5.6 bn 27% 56% Transport 24,559 27% 52% Power 47,799 Sales by Sector (proforma figures) Employees by Sector Source: Alstom 2010/11 Rail transport infrastructure Power generation infrastructure Power transmission infrastructure Supplier of 1 metro/tram in each 4 Major supplier in 25% of worldwide installed base Leadership in key markets and fast-growing technologies

5 Alstom Power Technologies adapted to all energy sources Gas Hydro Life Cycle Management Coal Nuclear (Conv.Island) Oil Wind Geothermal 12+ Presentation Jahre PDM: Title Von - Presenters der PDM Initials Vision zur - dd Wirklichkeit mmm yyyy - MGE P P 12 Biomass Solar

6 Alstom: a long lasting technology history F.SCHICHAU GmbH (ELBING) STAL Svenska Zamech Ltd Elblag, PL Societe Alsacienne de Construction Mecanique British Thompson- Houston Metropolita n Vickers English Electric

7 Agenda Introduction ALSTOM Product Data Management Scope and History ALSTOM Power Component Product Data Management Upcoming Challenges

8 Power Plant Breakdown Focus on the Product and Components Pre-Tender Tender Clarification Handover Design Order Build & Erect Maintain Project Level Plant Level Plant Contract specific equipment Component Level Product / Component Standardized manufactured parts Cooling System Water Supply Control & Electrical Piping Plant Civil/ Steel Structure Steam Turbine Aux Boiler Aux. Gas Turbine Generator Plant Project Management Overall project tendering and execution Domain Product/Component lifecycle APC-VPDM/APC-RPDM Maritza Bulgaria

9 Objectives of the PDM at the start of the introduction of PDM 1998 Being able to manage systematically the creation and change of a product thus ensuring integrity and traceability over the whole product lifecycle Providing to the right person at the right time and at the right place the correct information about a product during the complete lifecycle from initial design till End of Lifetime of the product. Managing technical information needed for design, ordering, manufacturing and service of ALSTOM Power products Replace the mainframe based system for BOM (AINFO), Configuration (MIA) and Document Management (VTU)(year 2000 Issue and operation cost reduction) Deploy to Gas, Steam Turbines and Generator Right Data Product Right Right Development Place Lifecycle Form Right Time Switch from paper (document) oriented concept to structure base concept Replace the asynchronous document (drawing) distribution by online synchronous document and change management (major change to the factory processes)

10 Product Data Management Vision 1998 to today PDM is about globally managing the engineering processes and data in the Marketing development, design, order, assembly & maintenance (service) phases of the core components of ALSTOM power plants Operation & Maintenance Sales Single Life Cycle Source Management Spec. Sketch Product Assemblies Subassemblies Parts Manual CAD Model FE Analysis Drawing Detail Raster Data Commissioning Development Logistic Product Structure Vision (1998) Seamless traceable of product data from the design to service (O&M) Manufacturing Purchasing

11 General Product Lifecycle in APC-RPDM Sales Customer Product Design Product Ordering Product Manufacturing Product Erection Product Commissioning Product Support Product Service Product Phased Out design engineering order engineering assembly engineering service engineering APC-VPDM CAD Data APC-RPDM Engineering Moduls

12 Vision of ABB Kraftwerke PDM 1998 design engineering order engineering production assembly installation operation maintenance PDM Document Document Management Management Dokumente inkl. Files Anbindung an Erzeugersysteme Konfigurator Konfigurator single source database Basis-PDM Basis-PDM (auftragsneutrale (auftragsneutrale Datenverwaltung) Datenverwaltung) Order-PDM Order-PDM (auftragsspezifische (auftragsspezifische Datenverwaltung) Datenverwaltung) Assembly-PDM Assembly-PDM (Verwaltung der (Verwaltung der 'as built' Daten) 'as built' Daten) Service-PDM Service-PDM (Verwaltung der (Verwaltung der 'as maintained' Daten) 'as maintained' Daten) PPS PPS-Interface PPS-Interface (SAP, (SAP, Triton, Triton,...)...) Deployment Phase 1 Deployment Phase 2 Deployment Assembly & Service PPS-Systeme PPS-Systeme (SAP, (SAP, Triton, Triton,...)...) Auftragsverwaltung, Materialwirtschaft die laufenden Aktivitäten in 1997 / 1998 sind grau hinterlegt

13 History of PDM at Alstom Power A long lasting story of PDM Joint Ventures in the Asia Region PDM Releases Switch off Legacy Systems Merge of Alstom PDMs into ABB KW PDM Upgrade Metaphase 3.1 ABB KW PDM 2.1 initial Deployment (800 User) Germany and Switzerland Start to deploy Service Module Contineous improvement APC-RDPM R10.0 renew complete HW Software Foundation Metaphase TC Enterprise 3.0 TC Enterprise Metaphase 3.2 TC Enterprise 5.0

14 Project Deployment Status APC-RPDM Manufacturing Engineers and Designers APC-RPDM 4600 users 4 Mio Parts 49 location 6 Mio Documents 21 countries Organizations Thermal Power (50%) - Gas Turbines - Steam Turbines - Turbo Generator - Nuclear Steam Turbines - Nuclear Pumps (Bergeron) - Heat Exchanger - Ash Handling Hydro Generator (4%) Thermal Service (45%) Supplier Joint Venture Real Time Collaboration Easy product information sharing Real-time design review Early supplier involvement Enabling collaboration in creating, validating and optimizing manufacturing plans in full alignment with program requirements.

15 Agenda Introduction ALSTOM Product Data Management Scope and History ALSTOM Power Component Product Data Managment Upcoming Challenges

16 P3 (Product) domain Design to Execution process 3D part design Design 3D part concurrent conception design Complete and generic documentation of part PO number Factory No Q-documentation Order Complete documentation of part variant Physical part structure generation Build and Erect Complete documentation of physical part Formal transfer New Equipment Power Service Maintain History management of physical part Outage Management CATIA V5 3D Geometry Analysis calculations 2D Drawing Manufacturing (CAM) APC-VPDM Test plans Material specifications Technical description Multilanguage descriptions (13) Configure specific part variants Generate Purchase Order Manufacturing Opern & Maint information Part serial number Spare part category Recommended quantities Serial Numbers reflow Outage status Impact on physical part and structure History tracking Spare Part Business APC-RPDM Production Planning ERP Inspection Quality documentation reflow TDM / DNC Virtual Part Physical file (drawing,...) Test step for virtual part Test plan for physical part Document reference Test plan for virtual part Physical part Test step for physical part

17 APC-VPDM Functionality coverage Business Business Processes Processes Design Order Build and Erect Maintain 2D / 3D geometry data management - Complete integration with CATIA V5 (APC-VPDM menus in CATIA V5 and vice versa) - 3D model centric - 2D model generation - Stress analysis data management - Approval workflows ensuring consistency before the 2D and the 3D - Revision management - Multi-site collaboration Interface to APC-RPDM to support further business processes - Automatic hand-over of 2D drawings during approval workflow. APC-RPDM becomes then the master of those documents - No automatic hand-over of Bills of Materials (BOMs). BOMs have to be created manually in APC-RPDM 12+ APC-RPDM Jahre PDM: Introduction Von der-pdm Martin Vision Genderka zur Wirklichkeit MGE - P P 12

18 P3 Process Coverage APC-RPDM (1/2) Business Processes Design Product structure centric philosophy Document management with 2D drawings and additional technical documentations, design guidelines, Templates Inspection and test planning Approval process of component structure including associated documentation Variant management Decisions base design know-how Order and Production Configuration of order specific documentation and product configuration from manual to automated configuration procedures Creation of the technical production orders for manufacturing units, external sub suppliers and site activities Order change management Quality documentation Change Management Design Design change, severity management, reporting, and change history recording Change management notification including notification for order engineering Order Build & Construction Maintain. Service

19 P3 Process Coverage APC-RPDM (2/2) Business Processes Construction and Commissioning Receive technical documentation per order Documentation management for site erection and commissioning ( Plant PDM ) Quality documentation of as built status of the product Building the as-built configuration for produced items Maintenance and Service Spare Parts management Event Management (inspections, outages) Creating technical documentation for outages Supporting field service activities (incl. Field Service Instructions) Documenting as maintained status of the product Change Management Design Order Build & Construction Change Management Change management based on Event management Recording of activities planned and executed Recording of physical configurations according change activities Maintain. Service

20 Agenda Introduction ALSTOM Product Data Management Scope and History ALSTOM Power Component Product Data Management Upcoming Challenges

21 New Business Challenges Globalization of the Alstom Power Organization - Major market growth to be expected in Asia/Pacific region - Moving closer to the customers decentralization of the organization - Trend to leverage business by joint ventures and enter into new markets - Protection of the intellectual capital in a globalized world Price per MW decreasing Trend to low cost countries Environmental constrains: Clean Power Power plant fleet age: Potential for optimization and retrofit Plant Optimisation: -5% CO 2 Turbine retrofit: -5% CO 2 Coal: +20 p.p in efficiency saves 40% CO 2 emissions Gas: +20 p.p in efficiency saves 33% CO 2 emissions

22 Upcoming Technical Challenges - Re-shaping the APC-VPDM and APC-RPDM architecture to build one PLM system - Integration to tendering processes - Foundation Software for the PLM Environment incl. CAD to be replaced - Reducing cost of ownership (more than line of customization code) Businesses / PLM integration Today -APC-RPDM -APC-VPDM New Common PLM platform (ATC-PLM) (Alstom Thermal Component-PLM) Midterm (APC-PLM) (Alstom Power Component-PLM) Vision Time

23 Thank you

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