PLM-ERP Integration
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The document discusses the integration of SolidWorks Enterprise PDM with ERP systems, emphasizing the roles of Product Data Management (PDM) and Enterprise Resource Planning (ERP) in the product lifecycle. It highlights the necessity for integration between the two systems to ensure efficient bidirectional data flow, improving product reusability and reducing time-to-market. Case studies showcase successful integrations with Infor XA and SAP, demonstrating the benefits of streamlined operations and reduced errors through effective data management.
PLM-ERP Integration
- 1. SolidWorks Enterprise PDM Integration with ERP Praveen Rudraradhya, Director – Enterprise Consulting Barry-Wehmiller International Resources, Chennai, India
- 2. What’s Inside? • Role of PDM & ERP in Product Lifecycle • Need for integration between PDM and ERP • Industry-specific demands • SolidWorks Enterprise PDM and ERP integration • Case Study 1 : SolidWorks EPDM – Infor XA Integration • Case Study 2 : SolidWorks EPDM – SAP Integration • Conclusion
- 3. Role of PDM & ERP in Product Lifecycle
- 4. Role of PDM & ERP in Product Lifecycle PDM is responsible for the intellectual assets in a product lifecycle, whereas ERP looks at a product from a transactional point of view Innovation • Definition lifecycle Service / maintenance • Context-oriented content • Intellectual assets Concepts System Design Portfolio / requirements designs engineering Require- management ments New Digital products manufacturing Logistics and Ideas Design chain Disciplined maintenance collaboration creativity Intellec- tual Supplier Property Disciplined Order / service Product collabo- relationship knowledge ration forecasting Costs Production Accounting planning Supply chain logistics Sourcing logistics Demand Execution Invoices • Deliverable assets • Transaction- Supply Orders oriented • Production lifecycle
- 5. Role of PDM & ERP in Product Lifecycle The boundary between design (PDM) and manufacturing (ERP) is logical due to differing formats and type of information generated in these stages PDM ERP Key facts on differences Innovation focused Transaction focused • Many products are never released to Manages and promotes change Steady state manufacturing, but saving product failures Product lifecycles Order lifecycles capture valuable information Disciplined, but flexible design process Controlled business processes • Number of design iterations required before a Complex design relationships BOM aware manufacturability item is released is high Product iterations and decision history Final revisions Design aware Item aware • Very small portion of unstructured data Central theme of speed Central theme of control produced in design are used in manufacturing Enterprise and cross-enterprise focused Enterprise focused • Unstructured information could potentially Project / program focused Order focused cause performance problems in the ERP Ensure base cost is optimal Manage cost performance / variances systems Flexible data structure Rigid data model Documents, unstructured information Structured data • Structured promotion process and hand-off Dynamically related data Simple data relationships points need to defined for data flow from design to manufacturing and vice-versa Knowledge search and retrieval Data mining Objective: Reusability and more Objective: Balancing demand and supply profitable products One system cannot be selected over the other as they solve different problems.
- 6. 6 Role of PDM & ERP in Product Lifecycle In PDM, the product structure focuses on the “Functional” composition, whereas in ERP it focuses on the “manufacturing process and costing” PDM Database ERP Database • Functional structuring of a product • “Transactional” structuring of a product • Focused on Cost and planning, logistics, and • Focused on design and components routing • Item creation: Item Number, description, and • Costs: Item cost, inventory costs, and purchase level costs • Item specifications • Planning: Stocking type, item category, catalog, and availability • Unit of measurement • Make/ Buy decision • Quantity • Packaging: Serial no. required?, Bulk/ Packaged, • Material: Components, variants, and Lot status code, type, and size alternates • Sourcing: Lead time, order mode and quantity, • Assembly: Relationship between components, inventory level, reorder level, scrap off (%), BoP, routing producing and receiving locations • Attachments: Documents and drawings • Pricing: Sales price and pricing method • Release: Processes, targets, and dates • Sales: Forecasting, backorders allowed?
- 7. Need for integration between PDM and ERP
- 8. Need for Integration between PDM and ERP PDM ERP • PDM is Context Oriented • ERP is Transaction Oriented • PDM is about Intellectual Assets • ERP is about Deliverable Assets Project Costing’s Status CAD Change Change Resource Viewables Documents Records Records Planning Concept / Raw BOM BOM Inventory Proto Designs Materials Mfg.PDM – ERP CAD Design Shipped Process Supplier Info Supplier Info OVERLAP Models Validations Goods Planning Item – Doc Item – Doc Test Results Routings Items Relationship Relationship Marketing Product Ware house Lifecycle Info Lifecycle Info Specs Specification Goods Assembly Project Status Fixtures
- 9. Need for Integration between PDM and ERP Though the structures differ significantly, bidirectional information flow between PDM and ERP is critical for both database users PDM Database ERP Database • Multi-level structuring: An Item is assembled of • Single-level structuring: The process and raw materials, components, which in turn are assembled of other and assembly are important for manufacturing components/ raw materials About the bike “End of assembly” view of the bike • Requires costing and inventory details to proactively design • Requires product design and release details for with low-cost, available components manufacturing • Requires feedback for engineering changes • Requires latest information from engineering changes • Requires feedback from the external world on regulatory • Requires “maturity status of design” to plan for sourcing implications, sourcing considerations, and customer requirements
- 10. Need for Integration between PDM and ERP PDM-ERP synergy enables reduced time-to-market and increased product reusability, thereby achieving individual “design” and “planning” KPIs PDM Database ERP Database • Time to market • Level of Inventory • New product success rate • Inventory accuracy • Percent of revenue from new products • Manufacturing schedule compliance • Process cost reduction • On time shipments • Total material cost reduction • Complete shipments • Number of new products per year • Visibility of all standardized business processes supporting the • Defect rates quote to cash cycle • Lead time for custom orders • Reaction to exceptions in real time • Frequency of engineering changes • Proactive decision making • Number of new patents • Ability to standardize business processes and ERP • Percent parts reuse implementation • Time to volume production • Collaboration across departments and line of business ownership • Engineering change cycle time • Knowledge management • Warranty claim rate • Advanced technology adoption rate • Frequency of regulatory or non-compliance events • Number of physical prototypes required Post-integration synergies • Reduction in Item & BOM error cost as BOMs are created once and then managed consistently in both PDM and ERP • Reduction in the time, cost, and errors associated with re-keying data entry from one system to the other • Reduction in inventory costs as the result of designers and engineers knowing what parts are already on hand and incorporating them into new versions or products – improved part reuse • Reduction in scrap of materials that cannot be used in production and which were either already in inventory or ordered before procurement was aware of pending changes
- 11. Need for Integration between PDM and ERP Information shared between PDM and ERP systems Most of the organization wants the following information to be transferred between PDM & ERP bi-directionally Item Document BOM Change Record Vendor Info Lifecycle Info Item – Document Document –Change Record Relationship Relationship
- 12. Need for Integration between PDM and ERP A good Integration between PDM and ERP system should • Offer PDM users an effective and intuitive integration with their ERP System. • Be easy to use and Robust in performance • Provide the ability for bi-directional exchange of information, documents, files, BOMs and change records • Integrate data as well as structures of both PDM and ERP and provide connectivity with multiple data sources • Have good customization capabilities yielding lower support and maintenance costs. • Have an extensible architecture which allows to provide additional Connectors • Use standards and state-of-the-art APIs of the ERP systems wherever Possible • Have all integration activities via user interaction or automatically triggered by the process events (Ex: check-in, check-out, change state etc…)
- 14. Industry-specific demands Target Markets Industrial Manufacturing Automotive Aerospace PDM - ERP Hi-Tech Defense & Research Electronics
- 15. Industry-specific demands Industrial Industry A&D Automotive Electronics Hi-Tech Manufacturing • Geometry • Geometry • Configuration • Configuration • Formulas • Engineering • Manufacturing Control • Service Parts • Service • Latest Trends Essential • Compliance Management Requirements • Manufacturing Control Product • Manufacturing • Change Information Control Management • Manufacturing Pace • PDM needs to handle • Feature level • Need powerful • Good configuration • Specification complex product engineering control is configuration login for rule set for selling management has structure relationship needed because of guided selling as well and making to order emerged as key between parts and high cost and lead time as extraordinary part as well as product application, bringing assemblies for associated with information access information which together business case effectivity production tooling enables services for using buying power management • Long historical reach like instant-level to use savings on raw • Need for a new and maintenance of software version materials with better What is control, diagnostic design access to important? • Compliance requires manufacturing process service records rigorous revision to translate from the against the unit-level data and contractual reusable product management and digital design to metal BOM terms information to speed process with precision enough time to market documentation to produce large • Deals with BOM and support volumes how it can be quickly transferred through the supply chain to consumers
- 16. SolidWorks EPDM and ERP integration
- 17. SolidWorks EPDM and ERP integration SolidWorks Enterprise PDM is capable of integrating with many ERP tools. Some of the successful interfaces are done with SAP, Infor XA, Microsoft Dynamics. SolidWorks Enterprise PDM can associate with ERP tools using following methods shown below • Integration using Dispatch (From EPDM Version 2010 SP0) • Integration using Data Import / Export • Integration using Customization • Combination of All the above © Third Party Trademarks: - XA, SAP, Microsoft ERP logos
- 18. SolidWorks EPDM and ERP integration Key Benefits Access to right designImprove Data andmanufacturing and Supply chain data Support effective and efficient engineering processes data and related Process Quality DEFECT By integrating these two applications,both the systems, henceminimizedtangible, Beyond just PDM, companies have started torepetitive small projects with ofto larger Synchronization of data takes place in the invest in work is chances extent high value returns as opposedorganizationimplementation projects with vague mis-matches / errors are less in to major level. No longer Result of Collaboration, the Drive Increasedcurrentapartis achieved using returns. Retrieval and Sharing of Information between both the systems Easy a can designers and engineers work on the Innovation from the rest of As This incremental approach is based separate and economic conditions the enterprise, hence the complexity in handling data is reduced investments. By interface. as well as the increasing frustration with low ROI software Integrating ERP – PDM, the profit margin is increased significantly
- 19. Case Study 1
- 20. Case Study 1 SolidWorks Enterprise PDM Integration with Infor XA ERP SolidWorks Enterprise PDM INTEGRATION Client : PCMC - Paper Converting Machine Company Location : Green Bay, WI, USA Software : PDMWorks Enterprise 2008 SP 4.0 Course : EPDM – Infor XA Integration Method : Customization © Third Party Trademarks: - Infor XA logo
- 21. Case Study 1 Integration with XA – New Item Create • This customized program helps create a new item in XA right from PDMWE explorer interface. • Items are created during document creation process • Item numbers are created in PDMWE using a set logic for serial numbers. This number is then used to create a new item in ERP. • Avoids user intervention in manually creating item numbers and hence Reduces errors. 2. New Item Create form in XA is displayed. 1. User clicks “Create Item in XA” button on file data card in PDMWE. 4. Item is created in XA. 3. Item number is added to file data card in PDMWE.
- 22. Case Study 1 Integration with XA – Build Item-Document Relationship • This customized common web-Interface helps to build relationship Between items in XA ERP and Document in PDMWE .
- 23. Case Study 1 Infor XA – EPDM (PDMWE) Integration Architecture © Third Party Trademarks: - Infor XA logo
- 24. Case Study 1 EPDM – Infor XA Integration features • Connect (log-inlog-out) to Infor XA from EPDM interface • Document & Item number creation in EPDM & XA from EPDM interface • Bi-Directional Meta data transfer - EPDM to Infor XA & vice versa • Data Validation before pushing Information from EPDM to Infor XA &vice versa • Ability to View the XA items, EPDM Documents and their relationships in a single web based interface. • Ability to Plot the documents in centralised plotter
- 25. Case Study 1 Benefits of EPDM – XA Integration SolidWorks Enterprise PDM • Item is created in Infor XA • Document is created in SolidWorks EPDM • Relationship is created between XA Item and EPDM Document as per business logics using EPDM – XA interface • Both the item and documents can be queried through a web based Content Manager • The Output can be either be viewed or printed using a centralised plotter. © Third Party Trademarks: - Infor XA logo
- 26. Case Study 1 EPDM Integration with XA - Statistics Case study : The interface tool developed by BWIR is a single interface for referring both Item number Information and document Information with the batch print, and view capabilities. Engineers and Non-Engineers saved lot and lot of time in Searching for items and documents and plotting the same. Direct Benefits InDirect Benefits Huge Time Saving Effective Search Engine
- 27. Case Study 2
- 28. Case Study 2 SolidWorks Enterprise PDM Integration with SAP SolidWorks Enterprise PDM INTEGRATION Client : PCMC - Paper Converting Machine Company Location : Green Bay, WI, USA Software : PDMWorks Enterprise 2008 SP 4.0 Course : EPDM – SAP integration Method : Customisation © Third Party Trademarks: - SAP logo
- 29. Case Study 2 EPDM – SAP Integration features • Connect (log-inlog-out) to SAP from EPDM interface • Document (Document Information Record) number creation in SAP • Uni-Directional Meta data transfer from EPDM to SAP • Data Validation before pushing Information from EPDM to SAP • Tested but not implemented in production system Material Master creation from EPDM to SAP Building Document number to Material Master relationship from EPDM to SAP Document lifecycle status & revision status updates from EPDM to SAP Pulling Meta data from SAP to EPDM systems
- 30. Case Study 2 EPDM – SAP Integration Approach SolidWorks Enterprise PDM SolidWorks Enterprise PDM • Document created in EPDM with Meta data • Document number attached to document • User checks-in the document to the vault • Data Validation Check in EPDM • Document Information registers in SAP ERP • Document Meta data gets transferred from EPDM to SAP ERP • Returns “SuccessFailure” events to the user in EPDM Interface © Third Party Trademarks: - SAP logo
- 31. Case Study 2 EPDM Integration with SAP – Document Creation Functionality: A DIR (Document Information Record) number will be created in SAP, when a new file (SolidWorks model, drawing, CADRA document, AutoCAD drawing) is added to the vault. The DIR number will be based off of the PDMWE serial number generated for the document. Significance: User need not open a session of SAP to create a DIR. Validation: To validate, create a new model in the vault (in the explorer). Wait till you get a confirmation about DIR Number created in SAP. Cross check by logging into SAP and finding the document details using “Find Document”.
- 32. Case Study 2 EPDM Integration with SAP – Meta Data Transfer Functionality: Meta data (custom properties) like document number, description, material, document type, document version, rev level will be transferred from EPDM system to SAP automatically whenever the document is first checked-in to EPDM vault . Significance: User need not open a session of SAP to create a DIR. Validation: To validate, create a new model in the vault (in the explorer). Wait till you get a confirmation about DIR Number created in SAP. Cross check by logging into SAP and finding the document details using “Find Document” and search for relevant document classification Information for meta data.
- 33. Case Study 2 EPDM Integration with SAP – Methodology VB.NET function calls SolidWorks Enterprise PDM XXXXX ****** XXXXX ****** SAP - BAPI calls © Third Party Trademarks: - SAP logo
- 34. Case Study 2 EPDM Integration with SAP - Statistics Case study : Engineers need to spent ~3 minutes per document for creating same Information in PDM & ERP system as well. For an project with 32,000 partsdocuments engineers needs to spent 1600 extra hours per project for data re-entry in both the systems Direct Benefits InDirect Benefits High Reduction in Time Saved ERROR Errors / Mismatches 1600 Hours / Project.
- 35. Case Study 2 Other Possibilities With „SAP – BAPI‟ function calls from „VB.NET‟ • BOM ExportImport from EPDM to SAP ERP • Engineering Change Process Management with EPDM-SAP integration (Change Masters creation, updates and approvals) • Bi-Directional Meta data transfer from one system to another • Any other customer specific requests * BAPI - Business Application Programming Interface
- 36. Conclusion
- 37. Conclusion Our customers experienced the following benefits by integrating SolidWorks Enterprise PDM with ERP • Provide single-integrated user interface allowing engineers to easily create and maintain document Information in EPDM & ERP system at the same time • Integrating SolidWorks EPDM with ERP is simple because of its excellent integration capabilities, it also provides Bi-Directional Approach • Reduce time, cost, and errors associated with re-keying data entry from one system to the other. • Reduce overall product development efforts (ex: time spent by an engineer in Information search) that require high manual interaction to exchange data between EPDM-ERP systems • Ensures consistency and use of product/plant related Information by personnel in organizations throughout the enterprise
- 38. Conclusion Organizations should make use of the integration opportunity to focus on process improvements and align with industry standards to succeed Revisit the fundamental business imperatives • Understand the enterprise integration • Reduce no. of engineering changes standards and tools • Initiate & complete engineering change earlier in • Construct the architecture to support the the design cycle use of industry standards • Reduce overall design cycle time • Differences in PDM and ERP need to be accounted for in an integration • Encourage component & design reuse • Changes to core PDM or ERP capabilities • Streamline non / low value add work Program require additional configuration and activities (faxes, emails, hard copy & Technology customisation filing) strategy • Leverage technology to prevent redundant data entry and maximise productivity and process improvements Technical Guiding principles • Establish discipline & rigor around configure or • Engineering Change Management: customise decisions Define an integrated engineering Process & Implemen- change management process and workflow tation • BOMs are a critical part of the integration: design functionality in accordance – Business processes related to BOM need to be clearly defined • The important processes are as follows – Differences in attributes need to be – Data management accounted for – Release management – Need to be designed to avoid – Change management redundant data entry – Data reconciliation
- 39. Questionnaire
- 40. THANK YOU