Total Marks-20

Birla Institute of Technology and Science WILP

PPC ASSIGNMENT
NAME - RAVI KUMAR
BITS ID - 201936GE034
COURSE NO. - MTGEZC331
COURSE TITLE – PRODUCTION PLANNING AND CONTROL

MY BITS MAIL ID: - 201936GE034@WILP.BITS-PILANI.AC.IN

Obtained Marks ……………
SUBMITTED BY- SUBMITTED TO-
Ravi Kumar RAVI REOSEKAR
 BITS Pilani
Pilani | Dubai | Goa | Hyderabad

Work Integrated Learning Program

PPC ASSIGNMENT
PRODUCT LIFE CYCLE MANAGEMENT
P R O B L E M S TAT E ME N T

GE LOCOMOTIVE WDG4G (ES43ACMI)

W h a t I s t h e P r o d u c t L i f e C yc l e ?

Product Life Cycle (PLC):-

PLC is an assumption that every product goes through that involves the same
pattern of introduction into the market, growth, maturity, and decline. As the product
spends more time in the market and it makes its way through the cycle, its sales
increase. Each product’s PLC is different in the length of scope and duration, and
each product is at risk of not making it out of the introduction phase. However, the
company strategy should remain consistent throughout each of the phases.

Product lifecycle management (PLM)

Product lifecycle management (PLM) refers to the handling of a good as it moves
through the typical stages of its product life development and introduction, growth,
maturity/stability, and decline.
W h a t I s t h e P r o d u c t L i f e C yc l e ?

• Stage 1: Product Development:

The new product is introduced; this is when all of the research and development
happens.
• Stage 2: Product Growth:
The product is more than an idea or a prototype. At this stage, the product is
manufactured, marketed, and released. Distribution increases, demand increases, and
competition also increases.
• Stage 3: Product Maturity:
During this stage, the product is widely available, and there are many competitors in the
marketplace. You market the product to different segments, but more spending on
advertising will have no impact on its demand.

• Stage 4: Product Decline:

The product is losing market share, or becoming obsolete. It is well past its point of
highest demand, and the demand decreases.
PLC GRAPH
Elements of PLM (Product life cycle management)

This handling involves both the manufacturing of the good and the marketing of it. The
concept of product life cycle helps inform business decision-making, from pricing and
promotion to expansion or cost-cutting.
The three main elements of PLM are:
1)The Information and Communication Technology (ICT) : This is all about the
necessary unified platforms and systems, including the architecture, tools, and
standards.
2)The Processes: This includes all of the people, skills, and organizations involved
3)The Methods: This is the procedures, rules, and practices.
Importance of PLM in GE Locomotive
• In GE Locomotive, PLM is the process of managing the product and the product
data during the entire lifecycle – from the concept, through design and
manufacturing, to service and disposal. PLM integrates people, data, processes
and business systems and provides a product information backbone for
companies and their extended enterprise.

• “Good PLM capabilities are essential to accelerate the maturity growth in

product development projects. This improves product design and cuts lead
time and cost. ... PLM integrates people, data, processes and business systems
and provides a product information backbone for companies and their extended
enterprise.
Importance of PLM in GE Locomotive
If we have made it this far, we hopefully understand the concept of Product Life
Cycle and the characteristics of each of its stages.
We should also understand why it’s important to apply this model to our business.
To eliminate any questions, here are the main advantages and benefits of what
adherence to the Product Life Cycle model can do:
• Allow decision making with better support
• Optimize marketing investments
• Qualify sales efforts
• Offer more control over results
• Give better long term strategic planning
• Offer better organization and process management
• Provide more longevity for products
• Give more appropriate preparation to face competition
PLC management in GE Locomotive
• Life cycle cost analysis is compulsively required for the system operation. System
operation costs are consisted of acquisition, operation, maintenance and so on. In
the beginning of the system planning, we need to take into account of various
costs following the system operating. To implement LCC, we need to analyze
system life cycle to identify all costs during system life.
• The costs can be divided into three parts. The first part is purchasing cost, the
second for operating cost and the last for disposal cost. The second operating cost
can be decomposed of operating cost included labor, energy consumption cost for
system running, maintenance costs to keep systems healthy, delay cost caused
from maintenance and hazard cost, and so on. In this paper, we carried out for
railway locomotives which operate over more 30years and which cost about 10
million USD. We decompose the life cycle of the locomotives and break down the
locomotives into subsystems to require maintenance or not, and subsystems to
need energy or not. We showed how to decide optimal Locomotives through cost
identification and system breakdown.
PLC management in GE Locomotive
PLC management in GE Locomotive
PLC management in GE Locomotive

Locomotive costs

• The essential costs during the locomotive life cycle can be estimated on the basis
of the subsystem analysis. To maintain an operable state of the locomotives
constantly, we have to determine the maintenance levels such as light or heavy
maintenances, and then, we can fix the maintenance shop size and equipment,
and the maintenance staff skill level according the maintenance levels.
Additionally, it has to include the shop operation, training and so on. The life cycle
costs for the locomotives is simply represented in Table 2. As mentioned above,
locomotive operations require a lot of jobs which follow incidental expenses. We
need to assess more exact expenses for the operations. We identify the
expenses items for the subsystems in their life cycles and calculate in point of
view in total amount.
PLC management in GE Locomotive

Locomotive LCC models

• Locomotive LCC is consisted of four part costs which are investment cost ,
maintenance cost , and operating cost , delay cost , and hazard . The investment
costs of the locomotives are composed of equipment and material procurement,
engineering cost for maintenance shop etc. The second term is on the
maintenance and operation costs which contain maintenance expenses,
operating expenses included labor works and energy consumption.
• The delay costs embrace loss during maintenance and repairing caused from
such as accidents. The last term is hazard costs which would provoke expenses
coming after unwanted events during operation, such as contaminations, injuries
and so on.
PLC management in GE Locomotive
CLCC = Cinv + Cman + Cope + Cdel + Chaz
The maintenance and operating, delay, and hazard costs
consists of two parts : the one part forecasts the costs
and the another cannot forecast because of their
randomness. The maintenance activities are divided into
preventive and corrective maintenances. The corrective
maintenance and the delay caused from the
maintenance and accidents take place randomly, on the
contrary, the preventive maintenances and the delay are
scheduled jobs which can be determined. The hazard
cost is similar to the two costs. The operating cost can
exactly be predicted and fixed by the train operation.
The random factors can be determined by failure rate
and accident rate and average costs caused from the
failures and the accidents, which can be fixed on the
basis of past year data.
PLC management in GE Locomotive

The four costs are introduced in this

example. We can consider maintenance
and delay costs are included in the failure
and hazard costs. The costs from failure,
accident and operation have to be
considered uniform periodic payments.
The payments is concerned with
determining the present value or worth
at the end of n interest years of equal
payments made at the end of each
interest year. The presents value is
represented in the equation (2). The
procurement takes place only one time at
the beginning.
PLC management in GE Locomotive
PLC management in GE Locomotive

➢ Management is a broad concept that touches multiple facets. At GE Locomotive,

for example, we mean Project Management. This is often about design, data, how
to deal with milestones and planning projects. In fact, this includes everything
about the development of a product.
➢ Another component that also falls under Management is being able to work
together in a structured way both internally and externally. So, you want to get a
grip on these collaborations and be able to scale them up so far that you can work
together easily, even internationally.
➢ Process Management is about how a product should be developed and what
product information is related to it. For example, certifications, product
documentation, manuals and change processes.
➢ Last, but not least, Change Management tackles the way that changes pass
through an organization. This is best captured in a workflow. This is a great way to
create insights for employees regarding their tasks and responsibilities.
PLC management in GE Locomotive

❖ Innovation & Design

The product lifecycle begins with a basic concept or idea. Here, new product ideas
are explored, and the most promising ones are selected for development.
Innovators design new and improved product solutions, bringing your product to
the level of maturity necessary to begin design development.
❖ Data Management & Simulation
CAD data management enables organizations to
easily access detailed product design information,
making the most of current and historic design
versions.
PLC management in GE Locomotive

❖ Manufacturing & Marketing

After our design is complete, product manufacturing begins. This phase is defined
by the tools and methods used to produce our product. PLM tools such
as Production Planning, enable organizations to develop more agile and efficient
production processes. This phase is key to achieving a faster time-to-market. And to
manufacturing a successful product at launch.

❖ Maintenance & Repurposing

But this is not the end of the story. Our Company continue to collect feedback on
the product in order to maintain and optimize future product versions. This valuable
product data is used to report on real world performance.
What is a PLM Platform in GE Locomotive

Product Lifecycle Management platforms provide solutions for an array of

disciplines – Engineering and Design, Manufacturing, Simulation and more. And,
as each of these areas encompass various specialisms, it makes sense to
provide specialist software tools for them.
So, a PLM platform may connect Computer-Aided Design (CAD) software suites
such as CATIA or SOLIDWORKS with Computer-Aided Manufacturing (CAM)
software suites such as DELMIA. And the PLM platform ecosystem connects all
applications, tools and software available for use in conjunction with your PLM
platform.
This may refer to products developed and managed by the platform provider, or by
developers working alongside them. For example, TECHNIA Software’s
Experience Packaged suite is part of the 3DEXPERIENCE platform ecosystem –
these are tools and applications which complement the 3D EXPERIENCE
platform.
What is a PLM Platform in GE Locomotive

• This means that every speck of data

concerning your product is communicated
live from a single source of truth. Every
team member, wherever they are, has
access to the same data and they’re able
to update, revise and discuss that data in
real time. So, PLM platforms provide a
cohesive ecosystem in which our
organisation, culture and business model
can collaborate efficiently and thrive.
PLM strategies to satisfy requirements

• The main goal of Product Development Leaders to Satisfy Product

Requirements and Meet Delivery Deadlines

A. Ease of use / user interface

B. Configurability / customizability
C. Search
D. System performance and stability
E. Integration with design applications and other enterprise systems
Strategies for improving PLC in GE locomotive
The product life cycle contains four distinct stages: introduction, growth, maturity and
decline. Each stage is associated with changes in the product's marketing position.
You can use various marketing strategies in each stage to try to prolong the life cycle
of your products.
Product introduction strategies
• establish a clear brand identity
• connect with the right partners to promote your product
• set up consumer tests, or provide samples or trials to key target markets
• price the product or service as high as you believe you can sell it, and to reflect the
quality level you are providing
• You could also try to limit the product or service to a specific type of consumer -
being selective can boost demand.
Strategies for improving PLC in GE locomotive
Product growth strategies

• Marketing strategies used in the growth stage mainly aim to increase profits.
Some of the common strategies to try are:
• improving product quality
• adding new product features or support services to grow our market share
• entering new markets segments
• keeping pricing as high as is reasonable to keep demand and profits high
• increasing distribution channels to cope with growing demand
• shifting marketing messages from product awareness to product preference
• skimming product prices if our profits are too low
• The growth stage is when we should see rapidly rising sales, profits and our
market share. Our strategies should seek to maximize these opportunities.
Strategies for improving PLC in GE locomotive

Product maturity strategies

• When we sales peak, our product will enter the maturity stage. This often means
that our market will be saturated and our may find that you need to change our
marketing tactics to prolong the life cycle of our product. Common strategies that
can help during this stage fall under one of two categories:
• market modification - this includes entering new market segments, redefining
target markets, winning over competitor's customers, converting non-users
• product modification - for example, adjusting or improving your product's
features, quality, pricing and differentiating it from other products in the marking
Strategies for improving PLC in GE locomotive

Product decline strategies

• During the end stages of our product, we will see declining sales and profits. This
can be caused by changes in consumer preferences, technological advances and
alternatives on the market. At this stage, we will have to decide what strategies to
take. If we want to save money, we can:
• Reduce our promotional expenditure on the products
• reduce the number of distribution outlets that sell them
• implement price cuts to get the customers to buy the product
• find another use for the product
• maintain the product and wait for competitors to withdraw from the market first
• harvest the product or service before discontinuing it
• sell the brand to another business
• significantly reduce the price to get rid of all the inventory
What Are the Current Trends in PLM in GE LOCO

• “PLM (Product life cycle management) is constantly evolving in all its facets. For
example, the design philosophy, “Cradle-to-Cradle” is increasingly linked to
PLM. This philosophy states that every raw material, and materials used for a
product, must also be reused. The extra dimension of this idea is that the raw
material should not lose value when reused. Recycling and upcycling are
becoming an essential part of the traditional design process.

• Another development is that organizations have increasingly unique

lifecycles. The traditional picture is, of course, when companies do their own
development; have their own production; and also provide services for their
product. But this is not always the case. This means that working together with
different organizations and suppliers plays a big role. This cooperation should be
seamless and have a very low margin of error.
What Are the Current Trends in PLM in GE LOCO

• We are also seeing a shift in business models where PLM can make its
appearance.
• Think of product as a service and lease models. In these cases, the product is
not in possession, but a service is taken to use the product. This gives a
completely different view of product development because it becomes essential
to extend the life of a product. Preventive and predictive maintenance will then
become invaluable.”
P r o d u c t ( D i e s e l L o c o m o t i v e ) l i f e c yc l e i m p r o v e m e n t

By Maintenance :-
Indian Railways (IR) follows the system of preventive maintenance for its Rolling
Stock so as to achieve the maximum possible availability and reliability in service.
The system of preventive maintenance envisages a schedule for maintenance
attention at regular specified intervals including replacement of components.
It aims to replace the components before they actually fail in service due to ageing,
wear and tear, while also endeavoring to obtain maximum life possible for the
components.
The system also aims at synchronization of attention to all related components so
that the manpower and engine days lost on account of the examination is
minimized.
P r o d u c t ( D i e s e l L o c o m o t i v e ) l i f e c yc l e i m p r o v e m e n t

However, IR needs to introduce the concept of predictive maintenance to bring

down both cost and as well as down time for maintenance. To achieve this, it is
necessary to lay down a list of parameters which are required to be monitored
remotely and also during the last shed attention paid to arrive at the decision about
next schedule to be given to the loco. Remote monitoring is an essential
requirement in achieving this objective. It is recommended that, few locos should be
put on trial on the system of predictive maintenance.
The system of preventive maintenance has evolved on one of the following criterion:
i. Time;
ii. KM;
iii. Engine hours
P r o d u c t ( D i e s e l L o c o m o t i v e ) l i f e c yc l e i m p r o v e m e n t

We perform the schedule maintenance, general repair and troubleshooting with in

time slot like as-
Schedule :-
• RM 92
• RM184
• RM 736
Unschedule :-
• General repair
• Failure

So We are increasing PLC of diesel locomotive by providing a excellent

maintenance at Roza shed.