Transcript pdm and erp and computer Integrated manufacturing

pdm and erp and computer Integrated
manufacturing
Larry Whitman
[email protected]
(316) 691-5907
(316) 978-3742
Industrial & Manufacturing Enterprise Department
The Wichita State University
http://www.mrc.twsu.edu/whitman/classes/ie775
cIm -IE775
What is pdm?
 computer Integrated manufacturing is (or at least
starts with) data integration on the shop floor.
 But what about data from engineering (how does it
get organized?)
 How does it get routed?
cIm -IE775
PDM
 PDM is an acronym for Product Data Management.
 Controls the relationships between elements of
engineering information for a company’s products
throughout the life-cycle of those products.
 EDMS - Engineering document management
systems (EDMS)
 can include imaging, capture and output
 Product Information Management (PIM).
(sometimes Plant Information Management)
 Image Management System (IMS)
cIm -IE775
PDM drivers
• ENGINEERING CHANGE (EC/ECN/ECO)
still manual forms?
• Difficulty in finding the appropriate
CAD file and related models and
analysis data?
• Difficulty assessing the impact of a
proposed change on other designs and
on the manufacturing operation
• How are drawing changes completed
and distributed?
cIm -IE775
PDM Characteristics
• Manage relationships between items or objects. Objects
usually include native file formats such as CAD models or word processor
files.
• Manage structures throughout life-cycle (in different
forms or configurations). For example, the configuration of a
complex product may change as it progresses through design review,
manufacture and service.
• Maintain different variants and release levels within a
product range.
• Incorporate or integrate with document management
systems for storage, retrieval and process automation.
cIm -IE775
Design focus




Think retrieval of design information
Think changes
Think communication
Think “build-to” package
cIm -IE775
Package contents (possible)
NC machining instructions,
MRP item master,
process plan,
task within a work schedule,
multiple views (not CAD based) different
disciplines need differing information
 EBOM vs MBOM (single?!)





cIm -IE775
Life Cycle (Interfaces)

From “An Overview of Product Information Management,” by Shou-kuo Scott Tsao
1993 Pan Pacific Conference on Information Systems
cIm -IE775
PDM/PIM Tasks

Release Management - Provides a set of functions similar to a physical drawing vault or library card
catalog: allowing users to register a set of data (files) as a single dataset, enter pertinent administrative
information about the dataset, check it out for modification, prevent other users from checking out the
same dataset, and check it in after the modification is complete; automatically creating a new version of
the dataset after each check-in; allowing certain users to review the dataset for approval before release
according to a pre-defined release procedure.

Change Management - Provides a set of functions to control the change of a registered product dataset:
defining the release procedures for various types of data; allowing users to initiate change requests
against certain datasets, issue change orders in response to certain change requests, and automatically
generate change notices after the change is complete.

Notification/Distribution - Provides a set of functions to send messages and/or datasets to users upon
the occurrence of certain events: creating distribution lists; defining events; automatically acknowledging
to the sender when the messages and/or datasets are received.

Administration - Provides a set of functions similar to the database administration functions provided by
a conventional database management system (DBMS): assigning user access privileges; providing
archive/restore facilities; allowing automatic backup/recovery.

From “An Overview of Product Information Management,” by Shou-kuo Scott Tsao
1993 Pan Pacific Conference on Information Systems
cIm -IE775
Lifecycle (phases)

From “An Overview of Product Information Management,” by Shou-kuo Scott Tsao
1993 Pan Pacific Conference on Information Systems
cIm -IE775
Configuration Management



Product Data Management without Configuration Management is
not complete.
Configuration Management is the "glue" which maintains
synchronization between parts, documentation and change data from
design to manufacture and support.
most manufacturers could cut costs fifty percent if they could get
product configuration information under control. Institute of
Configuration Management

Making information available to the user at the time it is needed does
not guarantee that the information is correct.

From “PDM Industry White Paper: Focus on Configuration
Management: A White Paper” by CMstat
cIm -IE775
PDM elements





process reengineering,
data vault,
change management,
workflow,
configuration management?
cIm -IE775
Applicability to Concurrent
Engineering
 "concurrent engineering is a systematic approach to
integrated, concurrent design of products and their
related processes, including manufacturing and
support. This approach is intended to cause the
developers, from the outset, to consider all elements
of the product life cycle from conceptual design
through disposal, including quality, cost, schedule,
and user requirements.”
 Institute for Defense Analysis
cIm -IE775
Product Development Management II (PDM II)
 PDM II enables companies to achieve quality, time, and cost
benefits by addressing the widely varying requirements for
management of product information throughout the entire product
lifecycle, and across the extended enterprise. (IBM and Dassault)
 PDM II Includes both virtual Product Development Management (VPDM)
and Product Data Management (PDM). VPDM enables new levels of
collaboration during the product development process. It allows ideas to be
shared and discussed by those from both within and outside of the design
community, increasing a company's ability to innovate and increase revenue
from new products.
cIm -IE775
PDMII IBM info

As a product definition matures, PDM ensures that the correct design
information is distributed to and accepted by enterprise organizations
responsible for transforming the design into a finished product. This
reduces development costs and enables products to reach the market
more quickly. PDM helps companies to become more competitive by
increasing profit margins and helping them win in the marketplace.
Combining VPDM and PDM, PDM II enables a smooth transition
from design to manufacturing, despite differing data management
requirements, by integrating data and activities within each domain.
It enables customers to define, configure, manage, and optimize:

product development, which includes product designs,
manufacturing and maintenance processes, and all associated product
information
manufacturing resources definition
plant definition, which includes plant designs, plant manufacturing
and maintenance processes, and all associated plant information


cIm -IE775
ENOVIA Product Development Management II
solutions - (IBM and Dassault)




Product Modeling users are responsible for defining and optimizing the
product, its manufacturing processes and maintenance. They may be engineers
from design, digital mock-up, manufacturing or maintenance departments,
technical publishers, subcontractors or others. ENOVIA solutions are not only
CAD independent, but will actively support major CAD systems.
Product Data Management users control and manage products. They include
program and project managers, configuration engineers, corporate process
managers, product life cycle managers, classification engineers, cost engineers,
purchasing officers and industrial engineers controlling global operations.
ProductManager applications incorporate industry-recognized "best practices"
for such users.
Casual users need to access product information and possibly update product
status. They may include managers, customers, secretaries, and anyone else.
Web-based technologies will provide easy access to product data through a 4D
"virtual reality" window on the Internet.
ERP engineers deal with production operations such as planning and control.
They will be able to access detailed product data through their own "4D
product window" directly from their ERP environment.
http://www.clearlake.ibm.com/MFG/solutions/PDMpaper.html
cIm -IE775
Top 10 Reasons Why Companies Do Not Implement
PDM Well...or At All Presented by: Tom Captain, Deloitte & Touche LLP
at Management Roundtable's PDM Decisions 1996 Conference
 10 Management won't fund it
 9 A better product is coming out next year
 8 Our CAD package does enough PDM for us already
 7 Management doesn't understand the benefits
 6 We're different! No COTS solution will work for us
 5 We're waiting for our IS department to finish the long-range
system plan.
 4 Our corporate re-engineering project needs to finish first,
before we start a PDM project
 3 We'll let other companies fix the bugs and make the mistakes
first, before we jump in
 2 We already bought one but had trouble implementing it and
they fired the leader & promoted the uninvolved
 1 We're spending all of our time and money implementing SAP
cIm -IE775
More PDM info
 PDM overview (required reading)
http://www.pdmic.com/undrstnd.html
 Best of Both Worlds (PDM and MRPII)(read it too!)
http://www.pdmic.com/articles/bestboth.html#what


“SPECIAL SUPPLEMENT - PDM or ERP: Making the Connection,“ Manufacturing
engineering. (1999) VOL 122(5), 125-144 Many articles about ERP and PDM
Integrating PDM and ERP - This special report examines issues related to linking product
data management (PDM) and enterprise resource planning (ERP) JOURNAL NAME:
Computer-aided engineering (1999) Vol. 18(3) (also Volume 17, Number 10)
 Another PDM overview
http://www.pdmic.com/articles/whatspdm.html
 The Integration of Product Data Management and
Enterprise Resource Planning Systems
http://www.pdmic.com/articles/misscrit.html
 Interesting software perspective
http://www.pdmic.com/articles/pdm_rsm.shtml
cIm -IE775
More PDM info (continued)
 Good Q&A for APICS (pdm/mrp/CM)
http://www.pdmic.com/articles/artplct.html
 Metaphase Web Site (leader in PDM)
http://www.metaphasetech.com/
 PDM spec from the OMG
ftp://ftp.omg.org/pub/docs/mfg/98-02-02.pdf
 Configuration Mgmt
http://www.pdmic.com/articles/wppdmfcm.html

International Product Data Management Users Group White Paper
Integrating/Interfacing PDM (Product Data Management)
with MRP II http://www.pdmic.com/IPDMUG/wpipdmug.html
cIm -IE775
PDM summary
cIm -IE775
ERP - History
 20s and on - Inventory Control (inventory in the factory)
 70s MRP (more than inventory)
 80s MRPII (added long range planning and shop floor control
(PAC))
 MRP expanded to beyond the factory
ERP!!!

MRPIII - Money Resource Planning
cIm -IE775
ERP (Enterprise Resource Planning)
 many, many modules to:
 automate business processes (and integrate?)
 share data across enterprise
 access data in real-time
 Enterprise resource planning (ERP) software is a set of
applications that automate finance and human resources
departments and help manufacturers handle jobs such as
order processing and production scheduling. ERP
systems such as SAP AG's R/3 are notoriously complex,
and installing the software often forces users to change
their internal processes.
cIm -IE775
ERP
 software solution that addresses enterprise needs taking
the process view of an organization to meet organizational
goals tightly integrating all functions of the organization
(ERPFANS.com)
 INTEGRATION
cIm -IE775
Is ERP that big of a deal?
 Almost 40% of all companies with more than $1
billion in annual revenue have implemented ERP
systems  Merrill Lynch
 $500 million today, and project
it to grow to $8 billion by 2002.
 Merrill Lynch
 70% of Fortune 1000 firms have
or will soon install ERP systems
cIm -IE775
Expectations?
cIm -IE775
Module: FINANCE
 Modules for bookkeeping and making sure the
bills are paid on time. Examples:

General ledger -- Keeps centralized charts of accounts and
corporate financial balances.

Accounts receivable -- Tracks payments due to a company
from its customers.

Accounts payable -- Schedules bill payments to suppliers
and distributors.

Fixed assets -- Manages depreciation and other costs
associated with tangible assets such as buildings, property
and equipment.

Treasury management -- Monitors and analyzes cash
holdings, financial deals and investment risks.

Cost control -- Analyzes corporate costs related to
overhead, products and manufacturing orders.
cIm -IE775
Module: HUMAN RESOURCES
 Software for handling personnel-related tasks
for corporate managers and individual
employees. Examples:

Human resources administration -- Automates personnel
management processes including recruitment, business travel and
vacation allotments.

Payroll -- Handles accounting and preparation of checks related to
employee salaries, wages and bonuses.

Self-service HR -- Lets workers change their personal information
and benefit allocations online without having to send forms to human
resources.
cIm -IE775
Module: MANUFACTURING AND
LOGISTICS
 A group of applications for planning production,
taking orders and delivering products to the
customer. Examples:

Production planning -- Performs capacity planning and creates a daily production
schedule for a company’s manufacturing plants.

Materials management -- Controls purchasing of raw materials needed to build
products. Manages inventory stocks.

Order entry and processing -- Automates the data entry process of customer
orders and keeps track of the status of orders.

Warehouse management -- Maintains records of warehoused goods and processes
movement of products through warehouses.

Transportation management -- Arranges, schedules and monitors delivery of
products to customers via trucks, trains and other vehicles.

Project management -- Monitors costs and work schedules on a project-by-project
basis.

Plant maintenance -- Sets plans and oversees upkeep of internal facilities.

Customer service management -- Administers installed-base service agreements
and checks contracts and warranties when customers call for help.
cIm -IE775
ERP (the big five)





Baan,
PeopleSoft,
SAP,
Oracle and
JD Edwards???
cIm -IE775
SAP - R/2 Mainframe
 RS Basis System (includes ABAP/4 programming
language)
 RF Financial Accounting
 RA Asset Accounting
 RK Cost Accounting
 RK-P Project Costing
 RM-INST Plant Maintenance
 RM-MAT Materials Management
 RM-PPS Production Planning and Control
 RM-QSS Quality Assurance
 RP Human Resources
 RV Sales and Distribution
cIm -IE775
SAP - R/3 Client/Server













BC Basis (includes ABAP/4 Programming Language)
AM Asset Management
CO Controlling
FI Financial Accounting
HR Human Resources
IS Industry Specific Solutions
PM Plant Maintenance
PP Production Planning
PS Project System
QM Quality Management
SD Sales and Distribution
MM Materials Management
WF Business Work Flow
cIm -IE775
More buzzwords
 Go live - leave legacy systems and use (trust)ERP
system
cIm -IE775
Sample Scenario for ERP
1. Enter order into ERP.
2. ERP checks the BOM module to see what parts are
needed.
3. Inventory-management module automatically
determines if enough material is on hand and sets
up the purchasing procedure is materials are
needed.
4. Other modules determine that machines will be
needed to make the “widgets”.
5. Finally, the shop floor module creates the work
order.
6. Later, the billing module creates an invoice.
cIm -IE775
Further reading
 Deloitte Touch survey
http://www.dc.com/services/secondwave/wave2.pdf
 InfoWorld Article -
http://www.informationweek.com/shared/printArticle?article=info
week/704/04prerp.htm&pub=iwk
cIm -IE775
Next Class
 Wonderware in 209!
cIm -IE775