Introduction to PDM and PLM

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Introduction to PDM and PLM
PDM is the management and classification of
design data and specifications for an engineered
product, and the management of change to this
information.
PLM is the activity of managing a companys
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
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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
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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
gt150 years ago Designer managed product data
(drawings etc.), Only the designer could
understand this data
Leonardo Da Vincis Ornithaptor (flying machine)
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Historical view of PLM..
100 years ago The Drawing Board Engineers
could communicate using a common language,
Engineering Drawings
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Historical view of PLM...
30 years ago The computer 2D becomes precise
and modifications are easy 2D CAD
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Historical view of PLM.
But Problems with 2D CAD
-- 2D does not represent the reality -- 2D cannot
model surfaces solids -- 2D is subject to
misinterpretation
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Historical view of PLM..
1985 3D 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)
Define Tool
CNC data
Make 3D model
Simulate cutting
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Historical view of PLM.
1995 3D CAD allows analysis
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Historical view of PLM..
But here is the difficulty
(1) Products are assemblies of many
parts.. Automobiles gt 10 000 parts Ships
gt 1 000 000 parts
(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
1995 Digital Mockup (DMU) replaces physical
prototypes

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

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Historical view of PLM.
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)
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Historical view of PLM
2000 Product Lifecycle Management (PLM) extends
the scope of DMU
Upstream - Design Adherence to Requirements
Regulations - Validation and Certification
Process - Optimal Re-Use of Corporate Assets -
Impact of Requirements Changes on Project
Schedule
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
expressions expression constant, or an
algebraic formula
X max(5, 0.1L)
B Y
Y
R X
D 0.5H
H
L
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
L
L
Parametric design Geometric relation between
center of sun, radius of sun, and top of
book Geometric relation between length of part
and size of sun
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Parametric design examples
4x counterbored holes, depth thickness of
flange/3
(5)
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 Motorcycle Automatic
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
Standard sections
Al extrusions

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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) Example Filter (l_length gt 10) and
(l_length lt 15)
Alternate method Most CAD systems will allow
a thumbnail 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 theoretical solid mechanics
Stress s E e E is Youngs modulus of the
material
We must ensure that stress s E 3Yh0/2L2 lt
fracture stress smax
DESIGN RULE 3EYh0/2L2 lt smax
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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
rib thickness gt 0.5t
t
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 is generated 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)
PDM is the management and classification of
design data and specifications for an engineered
product, and the management of change to this
information.
PLM is the activity of managing a companys
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
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Product Lifecycle Management
CAE
Tooling design
CAD
centralized DB File vault
Item management
Product structure

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

Security
Engineering Changes
Task management
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Product Lifecycle Management
centralized DB File vault
Item management
- product architecture planning - specification
(BOM tree, hierarchical model) - Instantiation
(parametric) from templates
Product structure
Security
Engineering Changes
Task management
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Product Lifecycle Management
centralized DB File vault
Item management
Product structure
- Authority - Views - Access control
(check-in/check-out)
Security
Engineering Changes
Task management
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Product Lifecycle Management
centralized DB File vault
Item management
Product structure
-ECR - Design modifications - Confirmation/approva
l cycle - ECN - Info storage/retrieval
Security
Engineering Changes
Task management
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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 Concurrent Engineering
Improved Design and Manufacturing Accuracy
Data Integrity Safeguarded
Better Project Planning
Better Management of Engineering Change
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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 US200 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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Perspectives on adaptation of PLM
SERVICE - companies with long-life products,
that need continued repair, service etc. e.g.
automobiles.

• spare parts for older models must be available
• service manuals
• testing equipment, e.g. testing onboard computers
  and microprocessors, must be maintained
• Management of product recalls
• Ford 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)
TeamcenterMetaphase Autodesk Autodesk
VaultAutodesk productstream
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Summary
PLM Information system integrating Product
Design Knowledge-based CAD Collaboration Docum
ent control Workflow management Engineering
change management