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T-86.5141ENTERPRISE SYSTEMS ARCHITECTURE:

Product Data Management

Asko MartioVariantum Oy, www.variantum.com

19.9.2006


Variantum Oy

� New Finnish company, established 2002, 9 owners� Roots in Product Data Management Group (PDMG) of HUT,

established in 1992� First big project: EDMS for KONE Oyj, first remarkable document

management system in Finland. Today’s status: over 1 000 000 documents, over 3000 active users. PDM and configurable product related research projects with approx. 20 Finnish companies.

� Best imaginable technological know-how� 2 D.Sc. (Tech), dissertations within configuration domain, 1 Lic. Sc.

(Tech), 4 M. Sc. (Tech)� approx. 50 man-years of industrial experience in different management

positions


Variantum products

System products� VariSelect, Product family selection tool to highlight product

properties and their differences � VariSales, Sales configurator for sales order definition� VariProd, Production configurator that creates Bill of Materials

required by the specified product variant (configuration) for the ERP system

� VariPDM, PDM system for product, document, product model and workflow management

Service and support products� Expert services for consultation, system training and implementation� After sales support services


Contents

� References, terminology� Definition of PDM� Background, motivation for PDM� PDM Functionality� Architecture� Summary� KONE case


References

� Kenneth G. McIntoshENGINEERING DATA MANAGEMENTA Guide to Successful Implementation, McGraw-Hill Inc.

� Antti Sääksvuori, Anselmi ImmonenTuotetiedonhallinta PDM,Talentum Media 2002

� Hannu Peltonen, Asko Martio, ReijoSulonenPDM - Tuotetiedon hallinta,IT Press 2002

� M. Eigner, R. StelzerProduktdatenmanagement-Systeme, Springer 2001

� I. Crnkovic, U. Asklund, A. P. DahlqvistProduct Data Management and Software Configuration Management, Artech House, Inc. 2003

� John StarkProduct Lifecycle Management, Paradigm for 21st century Product realisation, Springer 2004

� Rodger BurdenPDM: Product Data Management,Resource Pub 2003

� www.cimdata.com

� www.pdmic.com


Terminology: PDM

Almost any combination of terms is used, PDM (Product Data Management) and PLM (Product Life-cycle Management) seem to be most common

PDM

PIM

EDM

TDM

TIMProduct

Data

Management

Information

Engineering

Technical

DocumentEnterprise

PDT

Technology

Electronic

cPDm

Collaborative

Asset

DefinitionLifecycle

PLMPAM


Definition: Product

� Result of industrial activity general concept� Product family, brand, model, abstract class (cannot

type, product class, be manufactured) configurable product

� Product configuration, concrete class fixed product (can be manufactured)

� Product individual physical artifact, service activity


Definition: Product Data (CIMdata)

� All product related information � Paper documents� Digital files:

� Document files: specifications, configurations, purchase orders

� CAD drawings, models, assemblies, parts lists

� CAE analysis, NC programs and plans

� Information stored in data bases

� PDM manages three different product data life-cycles� Product type life-cycle:

� product development� approval and change processes� beginning and end of production

� Product individual life-cycle:� engineering� production, maintenance, recycling

� Product process life-cycle


Definition: PDM

� ISO 13584-10 Parts Library:A representation of facts, concepts, or instructions about one or more products in a formal manner suitable for communication, interpretation, or processing by human beings or by automatic means.

� Crnkovic, Asklund, Persson Dahlqvist (2003):PDM is the discipline of controlling the evolution of a product and providing other procedures and tools with the accurate product information at the right time in the right format during the entire Product Life Cycle

� PDT (Product Data Technology)-advisory group:Product Data Technology includes all aspects of the definition and methods of processing information pertinent to product throughout its development and operational lifecycle.


Definition: PLM (CIMdata)

What is Product Lifecycle Management (PLM)?A strategic business approach that applies a consistent set of business solutions in support of the collaborative creation, management, dissemination, and use of product definition information across the extended enterprise from concept to end of life –– integrating people, processes, and information


PDM system status today

� PDM systems coverage is more restricted:� Current PDM systems do not include commercial data (stocks,

purchase orders, invoices, cost accounting, etc.) of the company. They are managed by Enterprise Resource Planning (ERP) systems.

� Main interest of PDM lays on product support processes (R&D, etc.)

� Many PDM systems do not support configurable products and product individual and production process life-cycles

� PDM system does not create new product data


� Increased competition� Global markets, aggressive market behaviour� Shrinking budgets, lower production costs� Products are becoming more complex, exploiting more

technologies and built in vast number of variants� Quality requirements (ISO 9000 etc) and customer responsiveness

are increasing� Global manufacturing (expanded teaming)� Government and industry standards� Less time and money for hassling� Requirement for more efficient R&D: Concurrent Engineering

PDM motivation:Changing business environment


PDM motivation:Data integration by system integration

CAD

Design/Engineering Purchasing & Finance

Production Process/Plant

MRP System

Customers Suppliers

Project Management

Manufacturing

Sales/Marketing& Customer Service


� PDM system benefits� direct cost savings� faster time-to-market benefits� change management savings� indirect cost savings

� improved quality

� other savings� PDM system costs

� hardware, software licences� system tailoring, system integration, installation, training� system maintenance

PDM costs and benefits


PDM Benefits, example

��

Metric Standard C.E. Delta (%)

Design Hours 5337 5929 4460 16%/25%

Span Time (months) 21 19 11 48%/42%

Tooling Costs $79,461 $49,993 $42,057 47%/16%

No. Changes (15 mo.) 16 24 6 63%/75%

No. Changes (30 mo.) 22 28 6 73%/79%

No. Quality Reports 23 37 4 83%/89%

No. Waivers 36 40 2 94%/95%Mark Knodle, General DynamicsSpace Systems Division


PDM market forecast


PDM biggest vendors


PDM end user investment


PDM Functions

As PDM becomes implemented across

different industry sectors, functional priorities change.

Littlesupport

ProgramManagement

Product StructureManagement

Classification& Retrieval

partno Length

Screw

axy1234 10 mm

zvy3245 20 mm

dgf2345 30 mm

Workflow and ProcessManagement

ECOECO

Item and DocumentManagement

Drawings/Documents

NC

3D

SPEC

+ Support utilities


Data vault

� Central storage for� Documents� Product configuration data� Product model data� Product individual data

� Maintains revision and status data (e.g. electronic approval)

� Files (drawings, documents, etc.) are managed as “objects”

� Check-out and check-in control� Query, browsing and reporting

� Benefits� Secure, distributed storage of

data� Elimination of redundant files� Managed data sharing among

team members� Managed electronic review and

approval� Management of data

relationships

� Based often on commercial relational data bases


Data vault

PDM Server

Meta-Database

data

Managed referenced files

Object: DocumentDate: 1/1/95Project: MotorPart #: 8893-0ARevision: 2.3ADocument #: 4569-29File: A:\PDM\doc\motor\...Application: MS-Word 6.0


� Item definition� Items from the PDM point of

view are those product related business objects which are frequently referred in product related processes, e.g. products, materials, documents, resources, activities. Use of standard items makes management and business transactions easier

PDM items

� PDM corner stones� Item categories

� Physical items� systems, assemblies, parts,

components, accessories

� Document items� Product models and

software� Service items


Item views

� Life-cycle view� Item revisions

� Classification (type) view� Classification according to

product properties� Classification hierarchy

� Status view� Item approval level� Item efficiency

� Language view

� Structure view� Structures dependent on

processes� Sales (offer, sales order)

structure� Design structure� Manufacturing structure� Delivery structure� Installation structure� Maintenance structure

� Physical product structure � Functional structure� Spatial structure


� Specifying code

� Parametric class hierarchy

A Basic mechanical materials and components

A2 Non-ferrous metals− A20 Sheets and strips

• A202 Coated sheets and strips

Fasteners (Length, diameter)

Screws (Length, diameter, thread length)

− Cross head screws (Length, diameter, thread length, head diameter, standard)

� Required to search and browse items efficiently� Standards: ISO 13584 Part Libraries, IEC 61360 electric

components classification scheme standard� Examples:

Item classification


Basic item data

� Identification� Generally approx. 8 character

code� Classifying v. non-classifying� Local v. enterprize wide

� Description� Generally approx. 40

characters of cler text

� Classification� Helps to find items

� Revising� Revising method� Revision identification

� Status (recommendation class)

� Manufacturers, vendors� Other data

� Big systems: approx. 300 fields/item

� Item is specified to the level that is required by its user

� Reference documents


Item revisions

� Warning: there is no approved terminology� When an item is changed a new version, which is also an item,

is created. It is� Revision. An item of this type is generated to replace its predecessor

immediately or after a transition period. Therefore, the new revision must be compatible (form, fit and function) with its predecessor.

� Variant. Variant concept is sometimes used for products, parts and items with small differences. An item in this group is related to a higher-level product type.

� Independent item. An item in this group is neither a variant nor a revision of any other item. The relation to its origin is lost. Example: a new independent product


Document management

� Which document types?� Identification method for

documents, document revisions and variants

� Approval of documents� Security archives� Document tool integration to

PDM� WWW user interfaces

� Document structure� Document revisions� Document variants

� Equivalence of documents written in different languages

� Multilingual documents

� Subdocuments� Multipage drawings� Figure files� 3D models

� Representations� Original,, viewing and printing

formats


© 2003 Crnkovic, Asklund, Persson Dahlqvist, ”Implementing and Integrating Product Data Management and Software Configuration Management”

Figure 2.5 Quantified BOM of a bicycle.

Tire HubSpoke

1 32 1

Saddle

Bicycle

Pedal WheelsHandlebars Frame

1 2 1 2 1

Product structure


Product (breakdown) structure -general

� All structure items represent elements which can be delivered with the product. They are often physically attached to it. Product requisites like coatings, paints, welding wires, packages, adhesives, lubricants, chemicals are often left out of product structures.

� All items are identified with a code. A clear text description is required as support information.

� Physical products include only physical objects as components:� non-decomposable (atomic) component, e.g. bolt, integrated

circuit, cardboard package box, user manual� multipart component

� subassembly, e.g. phone receiver� kit (group, no assembly process), e.g. installation accessories

� other material, e.g. 50 m rope, 3 l oil� most common views: product (design/manufacturing), location


Documents are linked to products:� Product - parts list, assembly drawing

� Often this link is built into the identification system

� Product - other manufacturing documents� Assembly instructions� Test instructions� Product specifications� etc.

� Product - deliverable documents� deliverable documents are items in product structure

Documents and product structures


In addition to document links other type of items can be attached to product structures�Product - jigs, fixtures�Product - tools�Product - embedded software�Product - NC software

References


1 Quality2 Attributes3 Materials4 Process

1 Quality2 Attributes3 Materials4 Process

Assembly drawing and BOM

Test Data

Analysis Report

Marketing Definition

Phone Receiver

Revision A

Revision B

Revision A

Revision B

Revision A

Revision B

Revision A

Revision ARevision A

Revision A

Revision A

Product structure links, revisions


Modelling concepts

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Workflow management

� Defined and automated workflow/processes� By project, status level, product type, ...� Sequential, parallel, conditional steps� Voting rules and time-outs� Folder/package maintenance� Notification and distribution� Audit processes and actions “triggers”

� Process browse/reporting� Only for stable processes

� Change management� Document approvals� etc

� Change process phases� Change request (ECR,

Engineering Change Request)� Internal and external product

claims and messages

� Change proposal (ECP)� Consolidation of change

requests� Evaluation of change effects

� Change order (ECO)� Decided change actions

� Change follow-up� Registration of accomplished

actions


� Communications, E-mail � Data transport� Data translation� Viewing and annotation� Image services� Administration

� System security control� System management� Password management

Utility functions

� Data security services� data redundancy, disk

mirroring� fault tolerant disks, RAID-

technology (Redundant Array of Inexpensive Disks)

� automatic back-ups� data encryption

� Authentication services� Authorisation services

� viewing authorisation� change authorisation

(approvals, document creation and changes, etc.)


PDM system architecture

Application UserCAD/CAM, NC, Purchasing

Documentation, Etc.

CADPrivate Files

Managed Files

PDM Server

Meta-Database

data

PDM UserMultiple Applications

datadata

control

WEB server

WEBUser

IntranetObject: DocumentDate: 1/1/95Project: MotorPart #: 8893-0ARevision: 2.3ADocument #: 4569-29File: A:\PDM\doc\motor\...Application: MS-Word 6.0


PDM system selection andimplementation

� Project definition� Evaluation of the current

status� System scope definition� Prioritised requirements/

feature summary / configuration plan

� Short list selection evaluation� Request for proposals� Demonstration / benchmark

requirements

� Demonstration / benchmark Evaluation

� Reference visit agenda� Reference visit evaluation� Proposal evaluation� Pilot project definition� Pilot project implementation

log� Pilot project analysis (vs.

benefit targets)� Final evaluation summary and

report


PDM Summary

� Organisations which do not take PDM seriously will face difficulties

� The following factors increase PDM importance:� organisation size� internationality� product complexity� number of product variants

� PDM system implementation without management support becomes a failure


Case: KONE Corporation

� World’s fourth largest elevator company, onne of the world’s leading escalator companies

� Modernization and maintenance of existing systems account for 2/3 of the revenue

� Growth from the automatic door service business � Present in more than 40 countries with some 800 service centers� Strategic alliance with Toshiba of Japan since 1998� Turnover: EUR 2,814 million� Personnel: 23,800 employees� Sales: 25,000 new elevators and escalators� Maintains about 520,000 elevators and escalators and more than

210,000 automatic building doors


KONE business environment

� Distributed Order-Delivery Processes� Local front line companies (40 countries) and independent distributors for

sales, delivery, installation and maintenance� Global order engineering, production and logistics� A lot of the production subcontracted to partners

� Service Business� Long life cycles of product individuals

� ASEA-Graham Lift no 1: 1898� KONE Lift no 27: 1920

� Service and spare parts Information must be available

� Global, distributed, networked R&D� Global products with regional adaptations� R&D centers in all continents, complex, mass-customized products� A lot of subcontractors and partners involved in the R&D projects


Documents at KONE

� Commercial Documents� Invoices, order confirmations, shipping

documents etc from ERP

� Process and Quality Documents: ISO9000 etc.

� Project Documentation� Project Plans, Specifications, Meeting

Minutes� R&D Projects: Studies, sketches,

informal Excel lists of whatever� Order Projects: Tendering documents,

Order-specific drawings and calculations

� Training Material, Product, Process and Organisational Training

� Product Documentation� Marketing Material (brochures etc)� Technical Instructions:

� Planning (PG) and Sales (DL) instructions� Owners/User's manuals� Product Descriptions and Ordering

instructions (SO)� Installation instructions (AM)� Service, Maintenance and Spare Parts

Instructions (AS,AR)

� Drawings� 3D Models, Assembly and Part drawings,

Parts lists, Configuration Instructions

� Testing instructions� Software Binary Files� Specifications, Certificates� Product Change Requests


KONE document management systems

� Variantum EDMS (Engineering Data Management System), (www.variantum.com)� KONE Global PDM System� Product Documentation: Drawings, Instructions, Certificates� Parts and Product Structures with documents linked into the structures� Engineering Change Management

� Documentum (www.documentum.com)� Archiving of ERP data (old invoices etc.)� Production of technical instructions (XML-based information

management)� Management of some business process and quality documentation


KONE EDMS

Statistics (13.10.2004):� Number of documents: 953205

(New in 09/2004: 25000)� Number of parts: 286664 (New in

09/2004: 1600)� Users: 6396 (New in 09/2004: 96)� Document files: 320 GB (New in

09/2004: 12GB)� Users in 09/2004: 2950� Amount of data transferred over the

WWW interface: 1.5GB / day

Software (Server)� Variantum EDMS Application Server� Database: PostgreSQL Version 8.0.3� WWW: CGI scripts written in the TCL

language (http://tcl.activestate.com/)� Full text indexing: Idzebra

(www.indexdata.dk)� Linux (Fedora Core 3)� Backup: IBM Tivoli TSM� Monitoring: Nagios (www.nagios.org)


KONE EDMS – Main screen


KONE EDMS- Drawing query


KONE EDMS- Query results

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