Transcript Document

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 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]
Background: what are lifecycle activities?
- Product Realization: from concept to production
- Production: supply chain coordination
- After-sales: service, maintenance, product updates, obsolescence management…
Project conceived
Product Requirements
Cosmetic Requirements
Design House
Industrial Design Drawing
Background: Product Realization Process
Dummy Mock-up
Finalize cosmetics
Industrial Design
Control Drawing
Design Release Meeting*
Detailed Construction Reqts
Manufacturability Notes
Critical components
Preliminary Cost Analysis
Project
Confirmed
Purchasing & Procurement, ME, ELEC:
Categorize critical parts
Earlier we saw a PRP flowchart
Specs for new
Electronics Parts
Construction Drawings, CAD
Construction
Drawings
IDD, Specs:
New Tooled Parts
Existing
Parts
Contact vendors
Prices
Lead times
Prepare, Approve Schedule (All depts)
Product
Planning
Schedule
Concept Release Meeting
Target Specs
Milestones
Project Teams
Critical Parts: IC’s, Plastic, Metal…
A
Some crucial elements of PRP:
A
A
A
Tooling drawings (plastic, metal): CAD
Product
Planning
Schedule
A
Electronics circuits,
PCB layout design: CAD
Hardware Interfaces
Device drivers
Circuit-board design
Software development plan
Software
Schedule
Selection of tooling vendor
Software development on PC
Simulation
IC design
Tooling quotes
Schedule
IC Specs
Pin assignment
Software, Electronics
testing Specs
Sample Parts
Sample PCB
One-time PROM
Engineering prototype
- many decisions are made whose rationale must be remembered
Exploded view
Assembly views
User manuals
Service manuals
Software testing
protocols
Functional testing
protocols
Design improvements
Packaging design
Manufacturability
Protocols
Engineering Samples
Packaging, Manuals
Production
Design
Approved
Prepare Standard Operation
Procedures for Workers
Prepare Pilot Run BOM
Pilot Run
BOM
- large amount of data is generated, most is persistent
Assembly Planning
(Mechanical, PCB)
Assembly Sequence
Assembly line design
SOP
Factory Workstation Preparations, Tooling
Orders
Pilot Run
MFG prepare QC procedures
Work
Instructions
Factory QC
Pilot Sample Testing
Production Planning
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”
PCB testing jigs design
Electronics
testing SOP
Software to IC fab
Pilot Run Procurement
IC orders
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, …
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?
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]
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)
Historical view of PLM..
~100 years ago
The Drawing Board : Engineers could communicate using a common
language, Engineering Drawings
Historical view of PLM...
~30 years ago
The computer: 2D becomes precise and modifications are easy… 2D CAD
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
Historical view of PLM…..
~1985
3D CAD: allows defining complex parts and assemblies
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
Historical view of PLM…….
~1995
3D CAD: allows analysis
Historical view of PLM……..
But here is the difficulty
(1) Products are assemblies of many parts..
Automobiles: > 10 000 parts
Ships:
> 1 000 000 parts
(2) Assemblies are created by many concurrent designers and enterprises
 Need for collaboration, concurrent design in separate locations
Historical view of PLM………
~1995
Digital 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”)
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)
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
Historical view of PLM ………….
~2000: Knowledge-Based CAD to support collaboration:
Store the know-how  share design rules
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
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
R=X
B= Y
Y
X = max(5, 0.1L)
D = 0.5H
H
L
What are the independent variables and the dependent variables?
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
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
Parametric design examples
4x counterbored holes, depth = thickness of flange/3
(5)
By convention, derived dimensions are shown in parenthesis by many CAD systems.
Parametric design examples
Definition of a nut
Length of threads
Length of smooth part =
total length – threaded length
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.
Parametric design examples..
Exploded view:
Yamaha YFM200 Motorcycle
Automatic Clutch
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
…
Catalog-based Designs: an example
Catalog of fasteners (screws, nuts, …)
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
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
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 > 10) and (l_length < 15)
Alternate method:
Most CAD systems will allow a
thumbnail preview and select
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
…
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 Young’s modulus of the material]
We must ensure that stress = s = E 3Yh0/2L2 < fracture stress = smax
DESIGN RULE:
3EYh0/2L2 < smax
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
Rules-governed design
Manufacturability knowledge
Experience from injection molding:
rib thickness > 0.5t
t
Inferred design guidelines:
ACTION: rule is set up in the CAD system; violation triggers a warning
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
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)
DMU Examples: Shipman™
Mock up of boat design to test ergonomics of spaces for humans
DMU Examples
DMU allows for accessibility testing in aircraft design (for repair/maintenance)
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.
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 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]
Product Lifecycle Management
CAE
Tooling design
CAD
Item management
Product structure
centralized DB
[File vault]
Security
Engineering Changes
Task management
“Item” could be:
• CAD document
• Text document
• Design spreadsheet
• Software program
• Process Plan
• SOP
• Customer complaint
• Service records
Product Lifecycle Management
Item management
- product architecture planning
Product structure - specification (BOM tree, hierarchical model)
- Instantiation (parametric) from templates
centralized DB
[File vault]
Security
Engineering Changes
Task management
Product Lifecycle Management
Item management
Product structure
centralized DB
[File vault]
Security
Engineering Changes
Task management
- Authority
- Views
- Access control (check-in/check-out)
Product Lifecycle Management
Item management
Product structure
centralized DB
[File vault]
Security
Engineering Changes
Task management
-ECR
- Design modifications
- Confirmation/approval cycle
- ECN
- Info storage/retrieval
Product Lifecycle Management
Item management
Product structure
centralized DB
[File vault]
Security
Engineering Changes
Task management
-team specification (requirement based, resource based)
- task assignments
- milestones setting, management
- critical path
- deadline reminders, notifications
PLM functionality
PLM supports 3 levels of collaboration
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
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 ]
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)
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
Perspectives on adaptation of PLM…
SERVICE
- companies with long-life products, that need continued repair, service etc.
e.g. automobiles.
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 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.
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+…
Summary
PLM: Information system integrating
Product Design + Knowledge-based CAD
Collaboration
Document control
Workflow management
Engineering change management