introduction to pdm and plm plm is the activity of managing a company’s products all the way...
TRANSCRIPT
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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.
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Background: what are lifecycle activities?
- Product Realization: from concept to production
- Production: supply chain coordination
- After-sales: service, maintenance, product updates, obsolescence management…
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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
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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, …
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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?
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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]
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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)
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Historical view of PLM..
~100 years agoThe Drawing Board : Engineers could communicate using a common language, Engineering Drawings
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Historical view of PLM...
~30 years agoThe computer: 2D becomes precise and modifications are easy… 2D CAD
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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
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Historical view of PLM…..
~19853D CAD: allows defining complex parts and assemblies
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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
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Historical view of PLM…….
~19953D CAD: allows analysis
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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
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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”)
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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……….
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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
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Historical view of PLM ………….
~2000: Knowledge-Based CAD to support collaboration:Store the know-how share design rules
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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
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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?
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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
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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
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4x counterbored holes, depth = thickness of flange/3
(5)
Parametric design examples
By convention, derived dimensions are shown in parenthesis by many CAD systems.
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Parametric design examples
Definition of a nut
Length of threads
Length of smooth part =total length – threaded length
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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.
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Parametric design examples..
Exploded view:Yamaha YFM200 MotorcycleAutomatic Clutch
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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
…
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Catalog-based Designs: an example
Catalog of fasteners (screws, nuts, …)
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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
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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
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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
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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
…
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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
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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
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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
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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
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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)
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DMU Examples: Shipman™
Mock up of boat design to test ergonomics of spaces for humans
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DMU Examples
DMU allows for accessibility testing in aircraft design (for repair/maintenance)
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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.
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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.
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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
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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
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Product Lifecycle Management
centralized DB[File vault]
Item management
Product structure
Security
Engineering Changes
Task management
- Authority- Views- Access control (check-in/check-out)
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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
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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
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PLM functionality
PLM supports 3 levels of collaboration
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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
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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 ]
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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)
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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
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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.
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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+…
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PLM: Information system integrating
Product Design + Knowledge-based CADCollaborationDocument controlWorkflow managementEngineering change management
Summary