pdm and erp and computer

Integrated manufacturing
Larry Whitman
whitman@imfge.twsu.edu
(316) 691-5907
(316) 978-3742

Industrial & Manufacturing Enterprise Department

The Wichita State University
http://www.mrc.twsu.edu/whitman/classes/ie775

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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?

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PDM
PDM is an acronym for Product Data
Management.
Controls the relationships between
elements of engineering information for a
companys products throughout the lifecycle 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)

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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?

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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.

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Design focus

Think
Think
Think
Think

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retrieval of design information

changes
communication
build-to package

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?!)

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Life Cycle (Interfaces)

From An Overview of Product Information Management, by Shoukuo Scott Tsao 1993 Pan Pacific Conference on Information Systems

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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 Shoukuo Scott Tsao 1993 Pan Pacific Conference on Information Systems

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Lifecycle (phases)

From An Overview of Product Information Management, by Shoukuo Scott Tsao 1993 Pan Pacific Conference on Information Systems

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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

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PDM elements

process reengineering,
data vault,
change management,
workflow,
configuration management?

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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

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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.

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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

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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

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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

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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

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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

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PDM summary

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ERP - History
20s and on - Inventory Control
factory)

(inventory in the

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

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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.

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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

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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

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Expectations?

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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.

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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.

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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 companys 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.

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ERP (the big five)

Baan,
PeopleSoft,
SAP,
Oracle and
JD Edwards???

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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

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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

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More buzzwords
Go live - leave legacy systems and use
(trust)ERP system

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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.

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Further reading
Deloitte Touch survey

http://www.dc.com/services/secondwave/wave2.pdf

InfoWorld Article

http://www.informationweek.com/shared/printArticle?
article=infoweek/704/04prerp.htm&pub=iwk

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Next Class
Wonderware in 209!

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