Mastering Change and Configuration Management for Business Advantage.

Mastering Change and Configuration Management for Business Advantage

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Agenda

• Understanding Change and Configuration Management (CCM)

• Mastering CCM Through Best Practices

• Recap and Next Steps

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What is Change and Configuration Management?

Product Needs• Opportunities• Enhancements • Problems • Deviations and Waivers

Change & Configuration Management

© 2010 PTC

An orderly process for evolving a product including its data and associated process information from conception to retirement

INPUTS OUTPUTS

Product Data• Parts, Assemblies, Structures• Product Configurations• Product Documentation• Design Data• Product Requirements• Manufacturing Process Plans

Work Instructions, Resources

New Approved Product Data• Parts, Assemblies, Structures• Product Configurations• Product Documentation• Design Data• Product Requirements• Manufacturing Process Plans

Work Instructions, Resources

Change History• Audit & Traceability• Verification

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Multiple Trends Affect Change and Configuration Management

PRESSURES BUSINESS IMPACT

• Demand for more tailored products More product configurations / options to manage, more complicated change impact

• Fierce global competition Shorter development cycles, need to accommodate changes faster

• Growth in global outsourcing Need to effectively coordinate more participants in product development

• Increase in product complexity Multiple authoring tools used, so data must be managed across disparate information systems

• Increase in regulations Need to adapt products for compliance

Takeaway: Take Control of Change to Stay Competitive

© 2010 PTC

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Vertical Market Needs Affect Change and Configuration Management Strategies

Aerospace/ Defense

Automotive High Tech/ Electronics

Industrial Equipment

Consumer Products

Life Sciences

Traceability

Configuration control

High velocity changes

Flexibility

Numerous variants

High velocity changes

Flexibility

Numerous variants

Traceability

Configuration control

Flexibility

Numerous variants

Flexibility

Numerous variants

…Potential benefits are top line, not just cost savings

“An efficient change process can cut up to 33% off of the typical product development cycle time.” (McKinsey & Company)

BUT

“54% of companies lack single repository to review, analyze, approve and track changes across products” (Gartner Group)

© 2010 PTC

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Product Configuration Models Vary Across The Value Chain

• Companies May Use Several Models Common Verticals

Assemble-To-Stock

Configure-To-Order

Engineer-To-Order

Contract

Assemble-To-Order

© 2010 PTC

Consumer Products

High Tech & Electronics

Medical Devices

Industrial

Aerospace & Defense

Automotive

Contract manufacturer

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Structuring a Reliable, Flexible Process

How do I create a reliable,flexible change managementprocess for all users?

Coordinating Changes Across Engineering and Manufacturing

How can I synchronize engineering and manufacturing to be faster, more cost-effective ?

Managing Change Across Disciplines

How do I manage and control change of my product data so it can be leveraged by the entire enterprise?

Common Change and Configuration Management Challenges

Managing the Product’s Configuration

How do I control and deploy the product’s configuration throughout its lifecycle?

© 2010 PTC

Working With Partners

How do I work quickly andefficiently with partners whilemaintaining data security?

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ApproachBest

PracticesChallenge

• For each challenge, identify potential action

• For each action, share ideas on Best Practices*

• Illustrate benefits you can realize with case study examples

Today’s Game Plan

*Practice = proven Process Improvement using PLM technology

© 2010 PTC

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Mastering CCM Challenges

© 2010 PTC

Adopt PLM Technology for Data Replication

Challenge Approach Best Practices

Product Configuration Lifecycle Management

Modular Product Architecture Definition

Generic Product Platform Design

Enable enterprise to create, understand and track product configurations


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Standardized, Automated Change ProcessesImplement a flexible, automated process that always delivers accurate, actionable information


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Integrated Cross-Discipline Change Management

Enable enterprise to link integral product data and configurations so change is synchronized quickly and accurately across disciplines


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Partner Change Integration

Enable external parties to seamlessly interact with product configurations and changes throughout product development

Working with Partners

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Integral Engineering-Manufacturing Change Management

Provide manufacturing with associative views of engineering data to plan, execute closed loop changes quickly

Coordinating Change Across Engineering and Manufacturing

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Provide a single system to accurately create, understand and track product configurations and their change history over time

Benefits

• Quickly retrieve, share accurate information at any time in the product’s history

• Meet diverse configuration requirements across enterprise teams

• Improve design speed and reuse by supporting modular product architectures

• Manage product complexity and simplify variant and option design

• Synchronize fast, accurate change to use-related technical publications

Approach

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Consumer demand drives need for flexible product options

© 2010 PTC

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As products evolve and mature, PTC’s single system provides robust, flexible support for simple or complex levels of configuration management

• Core capabilities (Assemble-to-Stock, Contract Products)

– Versatile BOM creation: in Windchill, from CAD data or Excel

– Easily define, navigate products by Baselines, Release Level, Effectivity

• Configure-to-Order/Engineer-to-Order Products

– Fast, rules-driven variant creation maximizes data reuse

• Assemble-to-Order Products

– Easily create, manage and share option sets for each product

– Integrated navigation, design and visualization of option combinations

…

F1.300.200.G

F3.300.211.B

F3.300.238.F

Best Practice: Product Configuration Lifecycle Management

Easily create product variants for complex configurations

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PTC can provide a proven methodology for defining a modular product architecture

• Capture architecture requirements and variant needs

• Translate requirements into key functions

• Develop module clusters to share work

• Assess & select best modular architecture

• Determine key interfaces

Product X

Comp. 1

Comp. 2

SubComp.2

Module 2a

Product X

Module1

Module 2

Module 3

Complex and uncontrolled dependencies across

the assembly

Defined interfaces and dependencies

between modules

Best Practice: Modular Product Architecture


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Pistons

Block

Crankshaft

Cylinder Head

Engine

Oil System

Cooling System

Cover

Valve Train

Exhaust System

Piston X

Piston Y

Module 1

Module 2Optional Modules

Module 3

Module …

Interface Management

High Level Platform Product Structure

Detailed Platform CAD Structure

Best Practice: Generic Product Platform Design

PTC can provide an infrastructure that efficiently captures and manages the details of a product platform design

• Capture and manage high level platform architecture

• Define module interfaces and control changes

• Manage coordinated development of detailed product structure with CAD designs

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Business Initiative• Increase design reuse, rationalize internal

change process and consolidate engineering data for better collaboration

Solution• Deployed Windchill PDMLink as single data

repository in conjunction with Pro/Engineer

Results• Increased commercial part reuse and design

reuse

• Improved early discovery of design conflicts

• Streamlined internal change process

• Distributed technical information to the shop floor


Case Study: Streamlining The Design Process at Maserati Racing

© 2010 PTC

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“PTC Global Services’ deployment of Windchill PDMLink has improved our internal change process, allowed us to monitor the lifecycles of single serialized objects, and manage various configurations of our racing car.”

– Giorgio Ascanelli, Technical DirectorMaserati Racing

Maserati Racing is a branch of Maserati S.p.A (luxury sports car manufacturer) which has designed and produced the new Maserati MC12.

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Case Study: A Single Repository Simplifies Change and Configurations at SANY


© 2010 PTC

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Business Initiatives• Centralize product data management

• Improve collaboration across subsidiaries

• Improve change management process to ensure BOM consistency and improve configuration management

Solution

• Centralized repository of product information for change/configuration and BOM management

Results

• Improved change management; integrated process management

• Enabled faster BOM configuration and automated release of BOMs to ERP system

• Enabled distributed collaboration

“Our Windchill solution gives us a better way to manage product data and to improve collaborative design capabilities. It is also a better bridge across CAD, CAPP and ERP systems.”

– Liang Bin, Assistant CIO SANY Heavy Industry Ltd. Co.

Leading manufacturer of construction engineering machinery, including excavators, concrete mixers, concrete pumps and motor graders, sold worldwide.

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© 2010 PTC

Case Study: Schneider Electric Make Its World Smaller in One System

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Business Initiative• Consolidate 7 disjointed engineering systems

into one

• Eliminate disconnected methods of information sharing and collaboration

• Ensure secure control and management of design data

Solution• Migrated customized legacy system to a single

PLM solution, ensuring seamless change management and synchronized Production Information Management (PIM)

Results• Reduced engineer-to-order (ETO) process

time by weeks

• System supports 6,000 users to enhance global collaboration

• Multi-million annual savings

“Windchill helps us support our customer growth while providing overwhelming performance improvement.”

– Lionel Aubert Product Data Security Officer

Schneider Electric

One of the world’s largest manufacturers of equipment for electrical power distribution, industrial control and automation

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Implement a standardized, automated process to support rapid and accurate communication of changes and prevent undetected, costly late stage errors and project delays

Benefits

• Accurate, controlled changes in single system connected to product data

• Optimal flexibility to cover full range of changes

• Increased engineering productivity

• Reduced change cycle times, less rework and scrap

• Real time visibility to status across enterprise accelerates change process

• Fully traceable change history

Change process must comprehensively cover upstream and downstream activities

Requirements

Revision

Link changes to product definition

EngineeringBOM Manufacturing

BOM

Revision

© 2010 PTC

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Approach

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PTC provides a flexible, automated, closed loop change process that instantly connects key stakeholders to secure, accurate, actionable information

• Synchronize change with product configuration data in single, integral system

• Provide problem reporting, deviation/waiver requests and change requests, notices, activities

• Apply predefined and configurable change process workflows, activities and process roles

• Automate change routing and task notifications

• Flexible support for simple and complex changes

• Provide enterprise visibility to pending changes throughout the system

Best Practice: Standardized, Automated Change Process

Identify Need

Investigate Need

Change Implementation

Need Approval ?

Approve

Plan Minor ChangePlan Major Change

Release Change

Verify & Validate Process

System DesignConcept DesignDetail DesignVerify & Validate

Product ConfigurationChange History

Clarify

Re-Work

Re-Work

Review / Audit Change

Product Configuration

1.

2.

3.

4.

Physical Implementation

Approve Product ConfigurationChange History

Re-Work

Review / Audit Change

5.

Approve

Verify & ValidateSystem DesignConcept DesignDetail Design

Supplier ManagementDesign OutsourcingMfg Outsourcing

PTC’s Change and Configuration Management process flow


© 2010 PTC

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Case Study: Windchill PDMLink Automates Change Process at Kirloskar Oil Engines Ltd (KOEL)

© 2010 PTC

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Business Initiative• Replace manual change process with online

tracking of engineering changes

• Reduce change cycle time

Solution• Change Management process automation

through Windchill PDMLink

• Separate change management process for Prototype and Production components

Results• Single, automated change management

process for multiple locations

• Easy tracking and monitoring of changes

• Reduced change cycle time

“Windchill PDMLink helped us to automate and smoothen our engineering change process. It helped us to reduce cycle time by 40%. It’s comprehensive reports are helping us as knowledge bank to improve our designs.”

– Mr. R L Harolikar, Sr. GM (CRE)

KOEL is India’s leading manufacturer of diesel engines, engine bearings and generating sets for a broad range of industrial applications.

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California- based Pelco manufactures advanced closed circuit television equipment, camera enclosures, domes, mounts, pan/tilts, multiplexers, and video matrix systems.


Case Study: Windchill PDMLink Automates Change Process at Pelco

© 2010 PTC

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Business Initiative• Pelco needed to improve its customer service

and product quality through paperless automation

Solution• Implemented Windchill PDMLink to support

change management

Results• Automated its change management process

• Moved from a paper-intensive environment to paperless automation

• Improved the impact assessment of proposed changes“Before our PTC solution, getting a status or

an idea about what was holding up a process was virtually impossible. Windchill PDMLink has automated the change management process.”

– Pelco

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Case Study: Improving Global Change Management at Stryker Navigation

© 2010 PTC

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Business Initiative• Implement a global product lifecycle platform

with global change management processes to conform with FDA regulations

Solution• Implemented Windchill PDMLink

Results• Access all product related data electronically in

one platform

• 20% reduction in time taken for change and release process of documents and document search

• Reduce product change process time by 15%“With our Windchill PDMLink process-solution, we will meet our expectations to optimize the product lifecycle process by leveraging our product quality.”

– Klaus Welte, VP R&DStryker Navigation

Stryker Navigation is a worldwide leading innovator of medical products. Stryker focus on orthopedics, instruments, implants, physiotherapy, traumatology, and biotechnology.

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Enable the whole enterprise to work with and view integral product data and configurations so changes can be synchronized quickly and accurately across disciplines.

Benefits

• Reduced errors, rework by leveraging a single source repository for key functions

• More accurate product alignment across disciplines via seamless access to product information

• Improved knowledge of changes to product structure, MCAD/ECAD, software, requirements and documents as product matures

Approach


© 2010 PTC

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Marketing

ManufacturingPlanning

Mechanical

Electrical

Software

Quality

Service

Sourcing

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PTC can implement fast, accurate change across disciplines with a single, integrated process to update the complete product definition

• A Single Source for Product Data– Single global BOM which integrates product

data • Heterogeneous MCAD, ECAD, Software

• Documents

• Requirements

• Visualization

– Robust configuration traceability

• Product data integrally connected to change info through a powerful, flexible toolset

– Global, enterprise visibility

– Formal change impact and root cause analysis

Std Parts

Discloses & Declarations

Analysis

Requirements

CAD Model

Data Sheets

Viewables

Housing

Product

PCA

Schematic

Firmware Assy

Software

Component

ASICs

Mechanical Parts

Software

Battery

Purchased Assy

Approved SuppliersClassified Component

Attributes

AVL

AML / AVL

AML / AVL

PCB

Manual

Best Practice: Integrated, Cross-Discipline Change Management


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Pending Change

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Case Study: Cochlear Standardizes Internal Change Process

© 2010 PTC

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Business Initiatives

• Improve globally visibility of Bill of Information (BOI) for all product development teams

• Improve speed of product design and formal product change

Solution• Implemented Windchill PDMLink to control,

audit the complete BOI; increase speed and efficiency of document reviews and change control using electronic signatures

Results• All product data managed in a single data vault

• Executed design changes centrally and visibly across teams to reduce errors, enforce version control

• Accurate tracking of product configurations across departments

“We needed a data management system that could help our global develop teams accelerate time-to-market by managing our detailed product data better. Windchill stood out as the best solution to provide our engineers online traceability and visibility to product data; not only increasing our ability to collaborate, but also helping us drive quality of product changes through the implementation of clear workflows.”

– Brent Barnes, Manager Documentation SystemsCochlear Limited

Cochlear is the global leader in innovative, implantable hearing solutions


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Enable suppliers, partners and customers to seamlessly interact with product configurations and changes throughout the product development process.

Benefits

• Improve quality, reduce waste by ensuring partners have access to up-to-date, accurate information

• Secure, collaborative environment allows partners to rapidly and directly apply changes, instead of “over-the-wall”

• Eliminate confusion and costly delays by providing traceability as to what partners receive

Approach


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OEM

Tier 1 Design Partner

Tier 2 Design Partner

Component Supplier

Manufacturing Partner

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Best Practice: Partner Change Integration

Requirements

SoftwareCode


© 2010 PTC

Viewable

CAD Model

Data Sheet

Analysis

Test Plan Traceable Data Flow for All Change Sharing Scenarios

C++

“Strategic”

Integral access

“Arm’s length”

Package delivery

Collaborative workspace

PTC can provide a tailored change process integration method appropriate to partner relationship

• Share change and product data information in efficient, controlled manner (multiple approaches)

• Integrate partners into change review, approval and implementation activities

• Exchange design and change information offline

• Use rich visualization to enhance collaboration, design reviews

• Trace history of what was sent and when

Example – change impact analysis

Supplier Collaboration

Example – Request variances

Manufacturing Partner

Example – Submit problem reports, change impact analysis

Strategic Supplier

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© 2010 PTC

Designs, develops, and manufactures on-site electric power generation systems utilizing Proton Exchange Membrane fuel cells for stationary applications

HP Imaging and Printing division spans 23,000 products and tens of thousands of suppliers across 160 countries

World's premier supplier of pumps, systems and services to move and control water and other fluids

Successful Change Management Customers On a Global Scale

• ECN cycle time was cut by 62%

• Variability in the time to complete an ECN was reduced by 76%

• Achieved an 80% improvement in design and process reuse

• Part counts fell 2% to 18%

• Time-to-market, product cost, and warranty cost reduced

• Productivity rose between 20% and 30%

• Implemented global engineering change process with 1 year payback

• Time to implement engineering changes reduced by 50%

• Significant cost reduction for scrap and rework costs

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Tightly align manufacturing process planning to engineering design changes by integrating both groups in the same automated change management process.

Benefits

• Earlier involvement of manufacturing results in:

– faster time to market

– reduced tooling costs

– higher product quality

– reduced inventory

– superior change documentation

• Reduce overall change cycle time with tight coupling of engineering and manufacturing deliverables

Approach

Lower costs, shorter cycles if concurrent engineering and manufacturing processes are integrated early in design process

Coordinating Change Across Engineering, Manufacturing

© 2010 PTC

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Typical engineering change distribution throughout production development

Production

Concept Development

System Design

Detailed Design

Manufacturing Process Management

Concurrent: less costly changes made earlier

Accelerate Production ramp up

Sequential : later, more costly changes delay launch

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f ch

ang

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PTC can involve manufacturing stakeholders earlier by enabling concurrent development of eBOM and mBOM

• Common change process for engineering and manufacturing teams

– Associate manufacturing process data with change records

• Easily synchronize eBOM/mBOM product structure changes

• Manage variance decision

– Incorporate deviations and waivers using same change process for Eng and Mfg

• Provide fully traceable change history

Best Practice: Integral Engineering to Manufacturing Change Management

Changes identified early in design process “ripple” through to improve manufacturing planning

Resources

EngineeringBOM Manufacturing

BOM

Revision

Process Plan

Revision

© 2010 PTC

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Grand River Group (GRG) is China’s largest motorcycle manufacturer with a production capacity of 3 million engines and 3 million motorcycles per year. GRG is also the largest partner of Suzuki Motor Corp. in China.

Case Study: Grand River Unifies Engineering and Manufacturing Change Processes

© 2010 PTC

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Business Initiative• Shorten time to market by accelerating the

engineering to manufacturing change process

• Improve reliability of manufacturing data, process plans and work instructions

Solution• Implemented Windchill PDMLink and MPMLink

to streamline and standardize manufacturing engineering deliverables and implement a closed loop change process

Results• Increased production and manufacturing

engineering efficiency

• Improved product quality and consistency of manufacturing data

• Dramatically reduced the time to propagate a new product derivative to manufacturing

“Our PTC Windchill MPMLink solution is just the thing we need to help us improve our entire manufacturing process.”

– Chen Hai LanGrand River Group


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Agenda




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Key Change and Configuration Management Takeaways

1. Take control of configurations

2. Automate change in single system

3. Unify change across enterprise

4. Enable secure change collaboration with partners

5. Synchronize changes between Engineering and Manufacturing

6. PTC has proven experience enabling best practices with PLM technology

7. PTC can help you plan and execute a strategy for optimal success

© 2010 PTC







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Standardized, Automated Change Processes

Implement a flexible, automated process that always delivers accurate, actionable information


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Next Steps: Explore the Path to Value

Informed by 25 years of experience supporting thousands of customers PTC offers:

• A comprehensive Roadmap containing a structured collection of intellectual property

• A guide to linking Corporate Strategy initiatives to critical business processes and needed technologies

© 2010 PTC

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Next Steps: Three Step Approach

© 2010 PTC

Introductory discussion of PTC’s

Value-based approach to product

development

~10 member * 1-2 hours each,

consultative session, to quantify/rate/prioritize your

unique path to value

Collaborative 30-minute session to

uncover your business’ unique value drivers

PTC Value Roadmap Session

PDS Vision Assessment

Introduce Value

Framework

Mastering Change and Configuration Management for Business Advantage.

Documents

Transcript of Mastering Change and Configuration Management for Business Advantage.