39
About the Company
ESTABLISHED IN:COMPANY'S HEADQUARTERS, R&D, Foundry, Toolshop:MANUFACTURING:EMPLOYEES:
1991Ivančna Gorica – 140.000 square footČrnomelj - 270.000 square foot970 +
Our Partners
Motorcycle exhaust systems Car exhaust systemsCompositesTitanium and inconel casting parts
Portfolio
5
IT Architecture
ERP SCM CRM PLM
Typical cornerstones of manufacturing enterprise
ERP
SCM CRM
PLM
MW
Goal of the IT strategy in our company is to have clean, flexible, easy to maintain and well-connected IT architecture.
What is PLM?
»In industry, product lifecycle management (PLM) is the process of managing the entire lifecycle of a product
from inception, through engineering design and manufacture, to service and disposal of manufactured
products. PLM integrates people, data, processes and business systems and provides a product information
backbone for companies and their extended enterprise« - Wikipedia
“PLM or Product Life cycle Management is a process or system used to manage the data and design process
associated with the life of a product from its conception and envisioning through its manufacture, to its retirement
and disposal. PLM manages data, people, business processes, manufacturing processes, and anything else
pertaining to a product. A PLM system acts as a central information hub for everyone associated with a given
product” - Aras
In our effort to customize Innovator, PLM definition helps us to stay oriented, where to implement certainfunctionality. Environment is designed to give us a freedom of choice.
Role of a PLM
IDEA PASCalculationSales plan
Project management
Tools Sales
PLM is all about managing people, business processes, manufacturing processes
Inception and envisioning phase
In an Innovator database, wemaintain ideas for possibleproducts. Every product ideayields from a vehicle, and vehiclesare stored in an Innovatordatabase.
We can design several productsfor one vehicle.
Next step in the process is anidea.
We have started our customization efforts on the beginning of the product life cycle, with the inception and envisioning phase.
Idea
• MSRP, • planned quantity, • production cost, • R&D cost, • tool cost • distribution channel.
Calculation estimate based on
Total idea margin is calculated based on all entered products
• economic category, • risk level• product segment• Program
Idea classification is based on
Project category
We have divided project types on a several different categories, with expected phases and expected average duration of each phase.
After we enter the SOP date, APQP G1 date is automatically calculated based on a project classification.
We also enter EOP date here.
Idea is classified with project classification.
Idea approval process
Idea is a subject of a life cycle.
CEO has the final right to promote the idea to therealization phase.
After the idea has been promoted by CEO,promotion automatically generates a business case,business entity required by our controlling.
Business case is a part of a Project approvalprocess, which after its completion, leads to thePAS, project approval sheet.
Project approval phase
Each business case have a pool of products, those are
copied from the idea.
Products are distributed to project charters, based on several
different factors. Business case can yield several projects
We start creating project by creating SAP Work Orders
Work Order creation
After we create the work order in an Innovator, it is created in SAP, by using automatically assigned parameters. SAPautomatically assigns unique ID to the work order, which is passed back to the Innovator.
We keep in Innovator a copy of every SAP Work Order
Products pool
Several ideas can be added to the single business case.
Business case holds a link to the product,as it has been envisioned in the idea phase
Product item is at this stage kept under the G0P sequence prefix.
Product definition
Product classification, SAP related data which is mandatory to
automatically create a material in a SAP, after a promotion in an Innovator,
Links to the other Innovator items, such as business case, Work Order, Project, Idea,
Sales data, detailed calculation and controlling data,
Reference to the product calculation from the idea phase
R&D product costs
Adding the products to the project
After the project charter iscreated, the first step is to addproducts, which are going to berealized as a delivery of theproject.
Only products which are in thepool of related business case,can be selected and assigned tothe project charter.
Project team members
This step has to be done as early as possible, because all employees working on the project are required to report time they consume on the project.
Solution, how to enter theproject team members is based on an Innovator standard team, with some extended properties, such as project team role.We have added more user friendly GUI, roles can be selected with drop down.
Time tracking report
After the team has been assigned to the project charter, team members can add consumed hours on the project.
Team members with managementrole can enter hours in behalf ofother team members.
One person can have several roleson the project.
Time tracking report
To make this process as easy as possible for the team members, we have designed a functionality under the MyInnovator TOC item, where the user can select active project by using drop down box.Only active projects, where the user is a team member, are available for selection.
Next drop down stores manually saved projects.
HR System
In one of our early customization efforts, we have implemented daily synchronization with our HR system. We wanted to have Innovator aware about our organization structure.
We have implemented Employee itemType on the top of the standard Innovator User / Identity itemTypes
Employee data
• job description, • organizational unit, every
employee belongs to • cost center.
For every employee, Innovator is aware about
We keep several employee relateddata in our Innovator HR system,such as training validity periods,assigned assets, active projectswhere they are active members,etc.
Organization group, cost center, Innovator identity
For every organization group, we can see employees belonging to this group, manager of the group and parent group.
Daily synchronization automatically creates Innovator identity group with the same name as organizational units.
Time tracking reports
• job description role, • cost center,• organization unit,• Manager of organization unit
For every team member Innovator knows:
• consumed hours on the project rolebasis,
• consumed hours on the job descriptionbasis,
• many in the cost center basis.
Visualization based on several criteria
Time tracking record detail
Automatically added fields such as Job position, Employee cost center are clearly visible.
Only rows where user isa team member ormanager are shown in agrid. Standard Innovatorfunctionality - teams.
We use actions toapprove or rejectselected time trackingreports.
Only project leader, ororganizational leaderhave a permission to useactions
Time tracking logging
Changes on every time tracking report are logged.
SAP synchronization has failed.
Project charter life cycle
Sales plan, Cost Plan, Cost contribution, Controlling, Approval
Project life cycle is a master life cycle Milestones
In transitions, method controls related item life cycles, to keep them always in sync.
Products and project charters has to be filled with allmandatory data to get final approved status.
Project approval report
Products are automatically opened in SAP and their item_number code is replaced with SAP numbers.
We support several approval cycles, because requirements might change during the project.
Active project
• Project pool management
• Resource planning and management
We can have at any given time between 50 and 100 active projects, our resources are limited.
Our focus is
Innovator standard solution is designed with a single project in mind, so we had to be innovative, how to implement a project pool management support.
We have been looking for the third party universal Gantt component, because Innovator Gantt is not anreusable component.
Gantt component is also needed in case where we would like to replace SharePoint with an Innovator.
Gantt third party component
We have integrated DHTMLX Gantt component it with Innovator.
Tools
• Up to 200 different kind of custom designed tools are needed for the product manufacturing process,
• Tools are smaller, but independent projects on its own,
• They all have to be finished until TF milestone of the master projects,
• Calculation, resource planning,
• Automatic work order and material creation in SAP.
T
Tool status monitoring
SAPAutomated life cycle advancement triggers:
• SAP activity• Delivery attachment• Innovator form entry
Tool resource management
Resource planner can modify start and end dates with a mouse, by repositioning a task bar on the Gantt chart.
With a right click, resource planner gets a context menu with available resources, which could be assigned to the task.
Innovator change procedure – search, open, lock, enter change, unlock & save & close is done in the background
Tool usage meter
• Tools are designed by engineers, to withstand a planned number of the produced parts.
• We need to monitor, how many products were manufactured on every tool.
• Measuring tools or calibers calibration is a subject of a regulation.
• We have connected SAP production orders to the Innovator, enabling Innovator to monitor in the real time, how many product were manufactured on every tool.
SAP INNOVATOR
MES (manufacturing execution)
Sales orders
• Ordered items• Delivery notices• Invoices• Banks• SAP activity log
Integrated with SAP
Customer
CRM migration from Microsoft Dynamics CRM
• Integrated with our B2B andSAP
• In the future, we need toextend the functionality withcustomer claims.
Conclusion and future trend
• Line between ERP and PLM is often blurry
• Well connected ERP and PLM are mandatory
• Innovator, with its proven flexibility and openness for customization is reliable IT cornerstone solution
• We have made all those customizations with internal resources, and with a help of Aras Support team
• IoT trends, with sales data, we can trace real time sensor data for every instance of a product.
• Industry 4.0 trends - Smart Factory, the merging of the virtual and the physical worlds through cyber-physical systems and the resulting fusion of technical processes and business processes.
Future PLM trends
PLM is all about managing people, business processes, manufacturing processes
