K J SOMAIYA COLLEGE OF ENGINEERING, MUMBAI-77

(CONSTITUENT COLLEGE OF SOMAIYA VIDYAVIHAR UNIVERSITY)

Presented by:
Prof. M. A.Palsodkar

9/11/2021 1
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.

PLM system is an information system that facilitates all or some subset of PLM activities.

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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

Students please search for PRP flowchart and share it in chat box.

Some crucial elements of PRP:

- many decisions are made whose rationale must be

remembered

- large amount of data is generated, most is persistent,

should be preserved

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?
Do you know Premier Automobile , Hindustan Motors, Maruti 800

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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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 >150 years ago:
Historical view of Product Lifecycle Management Designer managed product
data (drawings etc.),
Only the designer could
understand this data…

Leonardo Da Vinci’s 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….

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...
~30 years ago The computer: 2D becomes precise and modifications are easy… 2D CAD

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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: > 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

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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
• > 3 million parts, > 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

R=X Y B= Y X = max(5, 0.1L)

D = 0.5H
H

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)

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By convention, derived dimensions are shown in parenthesis by many CAD systems. 24
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 > 10) and (l_length < 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 Young’s modulus of the material]

We must ensure that stress = s = E 3Yh0/2L2 < fracture stress = smax

DESIGN RULE: 3EYh0/2L2 < 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 > 0.5t

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 company’s products all the way across their
lifecycles in the most effective way.

PLM system is [an information system] that facilitates all or some subset of PLM activities.

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Product Lifecycle Management

CAE

Tooling design
CAD

Item management

Product structure
“Item” could be:
centralized DB • CAD document
Security • Text document
[File vault]
• Design spreadsheet
Engineering Changes • Software program
• Process Plan
• SOP
Task management • Customer complaint
• Service records

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Product Lifecycle Management

- product architecture planning

- specification (BOM tree, hierarchical model)
Item management - Instantiation (parametric) from templates

Product structure

centralized DB Security
[File vault]
Engineering Changes

Task management

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Product Lifecycle Management

Item management

- Authority
Product structure
- Views
- Access control (check-in/check-out)
centralized DB
Security
[File vault]

Engineering Changes

Task management

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Product Lifecycle Management

Item management

Product structure
-ECR
centralized DB Security - Design modifications
[File vault] - Confirmation/approval cycle
- ECN
Engineering Changes - Info storage/retrieval

Task management

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• AWS_001
• AWS_001_R1
• R1:- Bearing specification changed from XYZ to ABC
• Bolt M10x40mm long
• Bolt M10x35 mm long

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Product Lifecycle Management

Item management -team specification

(requirement based, resource based)
Product structure - task assignments
- milestones setting, management
centralized DB - critical path
Security - deadline reminders, notifications
[File vault]

Engineering Changes

Task management

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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 US$200 per ECN [total savings: US$ 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.

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.

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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+…

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Summary

PLM: Information system integrating

Product Design + Knowledge-based CAD

Collaboration
Document control
Workflow management
Engineering change management

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 Thank you

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