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Enterprise software implementations are usually not a simple task. Compared to selection of your next mobile device and RSS reader, it is an organizational effort. Enterprise software gets really complicated when it comes to the point implementation requires involvement of people. Product lifecycle management (PLM) is one of these systems. Implementation of PLM is  deeply connected to product development and manufacturing processes. Success or failure of PLM implementation is directly impacted by how people are involved in PLM system adoption and use.

Companies are taking different approaches in implementing PLM. However, fundamentally, I can see two different ways in implementation. First is holistic approach usually called “business transformation”. It implies significant process changes as a result of PLM system implementation. Companies are analyzing their existing processes, optimize and restructuring the way they do business. Second approach is focusing on a specific process or problem solving. It is usually come as an improvement of a specific activity and/or process.

There are lots of debates about PLM implementations these days. The value of PLM system implementations becomes clear to organizations on different levels. At the same time, it is obviously not easy to people to understand how to start using a PLM system that will have such a significant impact of everything they do.

I was reading an Minerva blog post – Should we pull PLM deployment? A new lean deployment strategy by Yoann Maingon. In this article Yoann shares his view on different approaches to implement PLM. The idea of lean and “pulling data” resonated. Here is an interesting passage:

The lean concept is highly based on a pull flow. Most of the arguments I’ve had were about the fact that the main data is created in Engineering so we should start deployment in engineering. Well, what if you should provide a system to the first person who enter the system. The one who will pull the flow, the customer? the marketing? assistance & support?

It made me think about how to maximize the value of PLM implementation withing short period of time. Here is the idea. Every company is manufacturing products for customers in some ways. The biggest process loop in every manufacturing company starts from requirements and ends with “release” of product to customer. To control the loop between requirements and results can be an interesting problem to handle first.

The idea of “pull” will be related to pulling of product requirements and documents representing released products and combined them together in a single system. In my view, it can provide an interesting insight on company operation. It is also very useful information source that every company can “re-use” for different purposes – new projects, customer support, etc.

What is the conclusion? It all starts from ROI. How to make it faster… This is a challenge most of PLM implementations are facing these days. For most of the implementations the process of getting to results can be slow. To provide system that can capture requirements to release control can be an interesting option. Lots of valuable information is hidden in this relationships of requirements-result. It also can drive management attention and focus in a company. Just my thoughts…

Best, Oleg

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After 20+ years of CAD and PDM development, the issue of versioning is not solved. How about that? I hope, I’ve got your attention :) . Versions, revisions, changes, CAD models, drawings, parts… My experience is that as soon as it comes to engineers, revisions are getting messy. I touched it in my previous posts few times. If you want to refresh your memories navigate to Revisions in CAD, PLM, ERP: old problems or new challenges? A bit old (from 2010), but still very relevant post – Future CAD-PLM and Assembly Version Management. As a confirmation that topic is alive and not solved, I just read Minerva blog – Versioning, different meaning from one activity to another by Yoann Maingon. It is short a sweet, so take few minutes and have a read. Yoann is speaking about “difference in intentions”. Here is the main point of the writeup:

…it is sometimes hard for people to have a common way to think about versioning. For the software development oriented person, versionning means saving or tagging. It means that the actual work has to be saved because we want to keep a state of the actual work. “I want to keep a state, I make a version, this version is stored”. In my view, related to main PLM concepts, versioning is creating something new. “I want to start a new work or I want to change a document, I version it. my new version is my working copy”.

If I speak about CAD/PLM software, here is the root of the problem. PDM systems create too many options in the mechanism of versions by implying “creation of something new” in place where it is absolutely unnecessarily. It was done by so many PDM systems in so many different ways with one common mistake – try to capture the intent of change and related dependent changes. The right answer to me is different. Versioning (and PDM is not different from software development and just Microsoft Word) is only about making “change” in the content (3D model, drawing, source code, assembly, configuration, etc). The role of PDM software is to capture the change and make it available for history tracking. You can ask me what about Parts, Revisions and other configuration management aspects? In my view, the answer on this question in the context of PDM/PLM is straightforward – use Parts, Part Numbers and Part Revisions (if needed).

What is my conclusion? Versioning is a mechanism that helps people to capture a change. Not the intent of change, but the change. It must be flexible and configurable, but at the end of the days, simple and reliable. I don’t want to miss my changes and I don’t want to run as a dog in order to find a right change.  Most of PDM/PLM software created a complicated versioning systems. I don’t see much difference between PDM and software. With the amount of software code we have in products, these two options will come together sooner than later. Just my thoughts…

Best, Oleg

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I want to get back to my BOM 101. In my view, Bill of Material management is one of the fundamental processes in PDM/PLM and requires lots of attention. I want to take the feedback made by Jos Voskuil and turn the conversation to be more business oriented. One of the trends in manufacturing today is customization. And this is a big challenge for manufacturing companies. Life was good in mass-production world, when the goal was to provide large series of items with predefined configurations. Not anymore… Today, clients are interested to how customize everything. Companies dealing with ETO type of business are facing similar challenges.

Efficient Bill of Materials management system can solve this problem. If you have flexible BOM management system allowing you to manipulate BOM structures and integrated with you ERP environment, you are half way done. However, technology out of the box won’t help you. It requires to apply some best practices too. One of the practices I want to discuss is “modular Bill of Materials”. Wikipedia provide a very short article about that, but I liked the definition.

Modular BOMs define the component materials, documents, parts and engineering drawings needed to complete a sub-assembly. While the terms BOM and modular BOM are most commonly used in association with physical products, the concept can be used in a variety of industries (e.g. software, medical records). Modular BOMs are used by modern information systems to serve a variety of purposes, such as defining the components needed to produce a sub-assembly, and providing cost information for each component and “rolled-up” cost information for the overall sub-assembly.

The core idea of modularization is to create a set of “modules” (aka sub-assemblies) that you can manipulate in order to create a final product. The product development process will be divided into two essential steps: create your modular bills and create a planning bill for a specific product. The last one will allow you to roll out cost and delivery time for a specific product order. Below I put five steps to follow in order to modularize the process of Bill of Material management in your company.

1. Identify family groups. This work can take time, but will allow you to make some steps to improve you product portfolio. Most probably you already have some portfolio management tools in house. Engineering has a tendency to complicate everything. So, you may find an overwhelming number of product families in your company. So, you must take some time and optimize that.

2. Identify options. These are elements of products and bill of materials that can be added to multiple product families. Usually represents additional features that can be added and can be replaced. The typical example of options is different configuration of car in-dash navigation and entertainment system. What is also important at this stage is to identify constraints between options (conflicts, incompatibilities, etc.)

3. Create Master Bill of Materials. This is a very important step. Master Bill of Materials represents all families and all options. This is “THE” bill of materials of all your products, which allows you to plan and to manufacture any product and configurations. In most of BOM management system you operate with ‘phantom’ feature to create an efficient master bill of materials. The reliability of BOM management system is very important at this stage.

4. Create planning BOM. Planning bill of materials represents a specific product, configuration, order, etc. You generate “planning BOM” out of your master BOM in order to create a specific delivery task for your manufacturing system. You practically derive your planning BOM out of Master BOM. Tools that allows you to copy/compare structures and BOM levels are absolute must to make it work.

5. End item bill. This is a final stage. End item bill represent the customer world and the way to translate planning bill of materials into the delivery. There are multiple ways to create end item bills – create bill for every SKU#, manually configure options or implement automatic rule based configurations. In my view, the last one is the most promising alternative. However, it requires additional efforts to implement. So, don’t be surprise many of customers are manually configuring end item bills.

What is my conclusion? Modern manufacturing practices require good technologies and best practices applied together. To me, BOM modularization is one of best examples. You need to have an efficient BOM management system with technologies and user experience allowing you to work collaboratively on BOM in a very granular way. At the same time, you need to apply some planning steps to rationalize and optimize the way you work with configurations, custom orders and product customizations. The cost is a fundamental driver in a modern manufacturing world. An efficient BOM modularization will allow you to follow demands of customers for customization and keep product cost down. Just my thoughts…

Best, Oleg

Image courtesy of [Salvatore Vuono] / FreeDigitalPhotos.net

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BOM 101: Preliminary Product Structures and Part Numbers

February 1, 2013

I want to continue my BOM 101 thoughts and speak about working with Bill of Materials during early stages of product development. Engineers are using multiple sources of information to create an initial Bill of Materials. The initial BOM structure can come from CAD system, other BOMs developed earlier and also created from scratch. One [...]

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BOM 101: How Many Levels Do You Need in BOM?

January 30, 2013

I’m continue my BOM 101 series of posts. When working on bill of materials, you can often hear about the ability of BOM management software to support so-called “multi-level” BOM. You can search for the definition of multi-level BOM using Google and find many results. I found the following definition of multi-level BOM on Arena [...]

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BOM 101: 5 “Don’ts” for Bill of Materials Management

January 21, 2013

BOM is fascinating. After posting 3 Modern BOM Management Challenges a week ago, I keep getting back to Bill of Materials management topic.  If you missed my previous BOM 101 posts, here are links to get up to speed: BOM 101- The four pillars of every BOM management solution, BOM 101- How to optimize Bil [...]

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BOM 101: The four pillars of every BOM management solution

January 17, 2013

I suggest you an experiment. Invite two engineers and ask them to provide a definition for some of PDM/PLM related terms. I’d not be surprised if you will get more than two definitions. It is not unusual to spend lots of time during PLM software implementation meetings to define terms, language and meaning of things. [...]

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Single Bill of Materials in 6 Steps

January 16, 2013

Last week I started the discussion about about modern BOM challenges. That discussion made me think more about the idea of unified and consistent Bill of Materials that can be shared across the company (single BOM). In my view, this is a clear paradigm shift from what we know today as “multiple BOMs”. How to [...]

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BOM 101: How to optimize Bill of Materials

January 14, 2013

Last week, I started the conversation about Bill of Materials and modern challenges. BOM is a heavy topic. Previous blog made me think about few additional things related to BOM management and I decided to share it with you too. One of the concepts I see as important in modern PLM and other enterprise systems [...]

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3 Modern BOM Management Challenges

January 11, 2013

Bill of Materials. Probably the key element in product development and manufacturing. Surprisingly enough, many companies are still struggling with this topic. Bill of Materials drives lots of controversy and discussions. Why it is so important? On a surface you may think BOM is a really simple thing. Just a list of components. However, if [...]

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