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Product lifecycle management (PLM) is the title commonly applied to a set of application software that enables the New Product Development (NPD) business process. Within PLM there are four primary areas; # Product and Portfolio Management (PPM) # Product Design (CAx) # Manufacturing Planning (MPM) # Product Data Management (PDM) ''Note: While application software is not required for PLM processes, the business complexity and rate of change requires organizations execute as rapidly as possible.'' Product Data Management is focused on capturing and maintaining information on products and/or services through its development and useful life. Typical information managed in the PDM module include
Product and Portfolio Management is focused on managing resource allocation, tracking progress vs. plan for projects in the new product development projects that are in process (or in a holding status). Portfolio management is a tool that assists management in tracking progress on new products and making trade-off decisions when allocating scarce resources. INTRODUCTION TO DEVELOPMENT PROCESS For simplicity the stages described are shown in a traditional sequential engineering workflow.
The major key point events are:
The reality is however more complex, people and departments cannot perform their tasks in isolation and one activity cannot simply finish and the next activity start. Design is an iterative process, often designs need to be modified due to manufacturing constraints or conflicting requirements. Where exactly a customer order fits into the time line depends on the industry type, whether the products are for example Build to Order, Engineer to Order, or Assemble to Order. PHASES OF PRODUCT LIFECYCLE AND CORRESPONDING TECHNOLOGIES Many software solutions have been developed to organize and integrate the different phases of a product’s lifecycle. PLM should not be seen as a single software product but a collection of software tools and working methods integrated together to address either single stages of the lifecycle or connect different tasks or manage the whole process. Some software providers cover the whole PLM range while others a single niche application. Some applications can span many fields of PLM with different modules within the same data model. An overview of the fields within PLM is covered here. It should be noted however that the simple classifications do not always fit exactly, many areas overlap and many software products cover more than one area or do not fit easily into one category. It should also not be forgotten that one of the main goals of PLM is to collect knowledge that can be reused for other projects and to coordinate simultaneous concurrent development of many products. It is about business processes, people and methods as much as software application solutions. Although PLM is mainly associated with Engineering tasks it also involves Marketing activities such as Product Portfolio Management (PPM), particularly with regards to New Product Introduction (NPI). Phase 1: Conceive Imagine, Specify, Plan, Innovate The first stage in the development of a product idea is the definition of its requirements based on customer, company, market and regulatory bodies’ viewpoints. From this a specification of the products major technical parameters can be defined. Although often this task is carried out using standard office software packages there are for the field of Requirements Management a number of specialized software tools available. Parallel to the requirements specification the initial concept design work is carried out defining the visual aesthetics of the product together with its main functional aspects. For the Industrial Design , Styling, work many different medias are used from pencil and paper, clay models to 3D CAID Computer-aided Industrial Design software. Phase 2: Design Describe, Define, Develop, Test, Analyze and Validate This is where the detailed design and development of the product’s form starts, progressing to prototype testing, through pilot release to full product launch. It can also involve redesign and ramp for improvement to existing products as well as Planned Obsolescence . The main tool used for Design and development is CAD Computer-aided Design . This can be simple 2D Drawing / Drafting or 3D Parametric Feature Based Solid/Surface Modelling, Such software includes technology such as Hybrid Modeling, Reverse Engineering , KBE ( Knowledge-Based Engineering ), NDT ( Nondestructive Testing ), Assembly construction. This step covers many engineering disciplines including: Mechanical, Electrical, Electronic, Software (); Kinematics ; Computational Fluid Dynamics (CFD); and mechanical event Simulation (MES). CAQ ( Computer-aided Quality ) is used for tasks such as Dimensional Tolerance (engineering) Analysis. Another task performed at this stage is the sourcing of bought out components, possibly with the aid of Procurement systems. Phase 3: Realize Manufacture, Make, Build, Procure, Produce, Sell and Deliver Once the design of the product’s components is complete the method of Manufacturing is defined. This includes CAD tasks such as tool design; creation of CNC Machining instructions for the product’s parts as well as tools to manufacture those parts, using integrated or separate CAM Computer-aided Manufacturing software. This will also involve analysis tools for process simulation for operations such as casting, molding, and die press forming. Once the manufacturing method has been identified MPM – ( Manufacturing Process Management ) comes into play. This involves CAPE (Computer-aided Production Engineering) or CAP/CAPP – (Production Planning) tools for carrying out Factory, Plant and Facility Layout and Production Simulation. For example: Press-Line Simulation; and Industrial Ergonomics; as well as tool selection management. Once components are manufactured their geometrical form and size can be checked against the original CAD data with the use of Computer Aided Inspection equipment and software. Parallel to the engineering tasks, Sales product configuration and Marketing documentation work will be taking place. This could include transferring engineering data (geometry and part list data) to a web based sales configurator and other Desktop Publishing systems. Phase 4: Service Use, Operate, Maintain, Support, Sustain, Phase-out, Retire, Recycle and Disposal The final phase of the lifecycle involves managing of in service information. Providing customers and service engineers with support information for Repair And Maintenance , as well as Waste Management / Recycling information. This involves using such tools as Maintenance, Repair and Operations Management ( MRO ) software. All phases: product lifecycle Communicate, Manage and Collaborate None of the above phases can be seen in isolation. In reality a project does not run sequentially or in isolation of other product development projects. Information is flowing between different people and systems. A major part of PLM is the co-ordination of and management of product definition data. This includes managing engineering changes and release status of components; configuration product variations; document management; planning project resources and timescale and risk assessment. For these tasks graphical, text and metadata such as product BOMs ( Bill Of Materials ) needs to be managed. At the engineering departments level this is the domain of PDM – ( Product Data Management ) software, at the corporate level EDM (Enterprise Data Management) software, these two definitions tend to blur however but it is typical to see two or more data management systems within an organization. These systems are also linked to other corporate systems such as SCM, CRM, and ERP. Associated with these system are Project Management Systems for Project/Program Planning. This central role is covered by numerous Collaborative Product Development tools which run throughout the whole lifecycle and across organizations. This requires many technology tools in the areas of Conferencing, Data Sharing and Data Translation. The field being Product Visualization which includes technologies such as DMU ( Digital Mock-Up ), Immersive Virtual Digital prototyping ( Virtual Reality ) and Photo realistic Imaging. PRODUCT DEVELOPMENT PROCESSES AND METHODOLOGIES A number of established methodologies have been adopted by PLM and been further advanced. Together with PLM digital engineering techniques, they have been advanced to meet company goals such as reduced time to market and lower production costs. Reducing lead times is a major factor as getting a product to market quicker than the competition will help with higher revenue and profit margins and increase market share. These techniques include:-
Concurrent engineering workflow This is a workflow that instead of working sequentially through the stages a number of tasks is carried out in parallel. For example starting tool design before the detailed design of the product is finished; or the engineer started on detail design solid models before the concept design surfaces models are complete. Although this does not necessarily reduce the amount of manpower required for a project it does drastically reduce lead times and thus time to market. Feature based CAD systems have for many years allowed the simultaneous work on 3D solid model and the 2D drawing by means of 2 separate files with the drawing looking at the data in the model, when the model changes the drawing will associatively update. Some CAD packages also allow associative copying of geometry between files. This allows, for example, the copying of a part design into the files used by the tooling designer. The manufacturing engineer can then start work on tools before the final design freeze, when a design changes size or shape the tool geometry will then update. Concurrent engineering also has the added benefit of providing better and more immediate communication between departments, reducing the chance of costly, late design changes. It adopts a problem prevention method as compared to the problem solving and re-designing method of traditional sequential engineering. Bottom-up design Bottom-up design is where the definition of 3D models of a product starts with the construction of individual components. These are then virtually brought together in sub-assemblies of more than one level until the full product is digitally defined. This is sometimes known as the review structure showing what the product will look like. The BOM contains all of the physical (solid) components; it may (but not also) contain other items required for the final product BOM such as paint, glue, oil and other materials commonly described as 'bulk items'. Bulk items typically have mass and quantities but are not usually modelled with geometry. Top-down design Top-down design follows closer the true design process. This starts with a layout model, often a simple 2D sketch defining basic sizes and some major defining parameters. Industrial Design , brings creative ideas to product development. Geometry from this is associatively copied down to the next level, which represents different sub-systems of the product. The geometry in the sub-systems is then used to define more detail in levels below. Depending on the complexity of the product, a number of levels of this assembly are created until the basic definition of components can be identified, such as position and principal dimensions. This information is then associatively copied to component files. In these files the components are detailed; this is where the classic bottom-up assembly starts. The top down assembly is sometime known as a control structure. If a single file is used to define the layout and parameters for the review structure it is often known as a skeleton file. Defence engineering traditionally develops the product structure from the top down. The system engineering processIncose SYSTEMS ENGINEERING HANDBOOK, A “HOW TO” GUIDE For All Engineers, Version 2.0, July 2000. pg 358 prescribes a functional decomposition of requirements and then physical allocation of product structure to the functions. This top down approach would normally have lower levels of the product structure developed from CAD data as a bottom up structure or design. Front loading design and workflow Front loading is taking top-down design to the next stage. The complete control structure and review structure, as well as downstream data such as drawings, tooling development and CAM models, are constructed before the product has been defined or a project kick-off has been authorized. These assemblies of files constitute a template from which a family of products can be constructed. When the decision has been made to go with a new product, the parameters of the product are entered into the template model and all the associated data is updated. Obviously predefined associative models will not be able to predict all possibilities and will require additional work. The main principle is that a lot of the experimental/investigative work has already been completed. A lot of knowledge is built into these templates to be reused on new products. This does require additional resources “up front” but can drastically reduce the time between project kick-off and launch. Such methods do however require organizational changes, as considerable engineering efforts are moved into “offline” development departments. It can be seen as an analogy to creating a concept car to test new technology for future products, but in this case the work is directly used for the next product generation. Design in context Individual components cannot be constructed in isolation. CAD ; CAiD models of components are designed within the context of part or all of the product being developed. This is achieved using Assembly Modelling techniques. Other components’ geometry can be seen and referenced within the CAD tool being used. The other components within the sub-assembly, may or may not have been constructed in the same system, their geometry being translated from other CPD formats. Some assembly checking such as DMU is also carried out using Product Visualization software. MAJOR COMMERCIAL PLAYERS Total spending on PLM software and services is estimated to be above $15 billion a year but it is difficult to find any two market analysis reports that agree on figures. |
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