Different Product Structures with Windchill MPMLink

Different Product Structures
with Windchill MPMLink
Stephan Monsieur
EMEA Channel Program Manager
November 29th 2012
Agenda
• Different Product Structures?
• Limitations of Basic PDMLink
• Additional functionality offered by MPMLink
• MPMLink can do even more
• Q&A
2
Different Product Structures?
3
One of the Product Lifecycle Challenges …
Managing the many different, but related product-related structures
Plan
Requirements
Structure
Concept
System /Logical
Structure
Design
Engineering
Structure
Validate
Simulation/
Testing Structure
Production
Manufacturing
Structure
Support
As-Supported
Structure
4
Single Source of Truth for the Entire Product Lifecycle
Associative Plan
Structure
Requirements
Structure
Concept
System /Logical
Structure
Design
Engineering
Structure
Validate
Simulation/Testing
Structure
Production
Manufacturing
Structure
Support
As-Supported
Structure
5
Single Source of Truth for the Entire Product Lifecycle
Plan
Requirements
Structure
Concept
System /Logical
Structure
Design
Engineering
Structure
Associative Validate
Structure
Simulation/Testing
Structure
Production
Manufacturing
Structure
Support
As-Supported
Structure
Main focus of this presentation
6
Concurrent Product and Manufacturing Process Design
is Key to Drive Profitable Growth
Concept Development
System Design
Limited opportunity for Manufacturing to influence design and reduce cost
Reduce
Time To
Market
Detailed Design
Manufacturing Process
Management
Production
Ramp-up
Full scale
Production
Reduce Cost of Change
Number of
Changes
Reduce
MFG Cost
Concurrent
MPM
Process
Typical
MPM
Process
Product Development Lifecycle
“ [Manufacturing companies] identified that the need to reduce manufacturing costs was driving their need to improve their manufacturing planning process at practically the same rate as compressed development schedules.”
Aberdeen Group, Digital Manufacturing Planning – Concurrent Development of Product and Process, 11/2007
7
Optimizing Product Development Processes is Critical
PRODUCT LIFECYCLE
Organization
Design
Concept
Plan
Validate
Production
Support
Program and Portfolio Management
Project Management
Environmental Performance Management
Management
Regulatory Compliance
Quality & Reliability Management
Change and Configuration Management
Concept Development
System Architecture Design
Hardware &
Software
Engineering
Detailed Development
Verification and Validation
Variant Design & Generation
Product Cost Management
Supply Chain
&
Manufacturing
Design and Manufacturing Outsourcing
Component and Supplier Management
Manufacturing Process Management
Tooling Design and Manufacture
Application Engineering
Requirements Definition and Management
Product Support Analysis & Planning
Sales & Service
Technical Information Creation & Management
Product Support Information Delivery & Field Knowledge Management
Equipment Lifecycle Management
Service Order & Delivery
Performance Analysis & Feedback
8
Optimizing Product Development Processes is Critical
PRODUCT LIFECYCLE
Organization
Design
Concept
Plan
Validate
Production
Support
Program and Portfolio Management
Project Management
Environmental Performance Management
Management
Regulatory Compliance
Quality & Reliability Management
Change and Configuration Management
Concept Development
System Architecture Design
Hardware &
Software
Engineering
Detailed Development
Verification and Validation
Variant Design & Generation
Product Cost Management
Supply Chain
&
Manufacturing
Design and Manufacturing Outsourcing
Component and Supplier Management
Manufacturing Process Management
Tooling Design and Manufacture
Application Engineering
Requirements Definition and Management
Product Support Analysis & Planning
Sales & Service
Technical Information Creation & Management
Product Support Information Delivery & Field Knowledge Management
Equipment Lifecycle Management
Service Order & Delivery
Performance Analysis & Feedback
9
Limitations of Basic PDMLink
10
How one typically works …
CAD
Structure
EBOM
(WT Parts)
MBOM
(WT Parts)
11
PDMLink Basic concept – eBOM and mBOM contexts
Historically, Windchill proposes to use
the “view” concept in order to manage
mBOM Parts as it provides the following
advantages:
• Allow to manage different BOM’s for the
same Part (eBOM versus mBOM)
• Allow to manage different values for the
same attribute of the same Part
• Allow separate configuration and
approval between eBOM and mBOM for
the same Part
• Allow concurrent work on eBOM and
mBOM for the same Part
• Allow the re-use of eBOM parts into
mBOM parts based on view network.
• Allow a traceability on the revision level
between eBOM and mBOM using the
revision label
Part101 A.1 (Design)
Part201 A.1 (Design)
Part301 A.1 (Design)
Part302 A.1 (Design)
Part303 A.1 (Design)
Part202 A.1 (Design)
Part101 A.A.1 (Manufacturing)
Part201 A.A.1 (Manufacturing)
Part301 A.1 (Design)
Part302 A.1 (Design)
Part202 A.1 (Design)
Part203 A.1 (Manufacturing)
12
PDMLink Basic concept – View Hierarchy
• Windchill organizes views as a hierarchy
Upstream
Design
Manufacturing
Plant 1
Plant 2
Downstream
– A “New View Version” creates a downstream part version
• Design  Manufacturing
• Manufacturing  Plant 1
• Design  Plant 2
– Parts can be initially created in any view
– New View Version can only go downstream
• By default the hierarchy has two views, Design and Manufacturing (EBOM and MBOM)
13
Applied to our assembly …
Part101 A.1 (Design)
Part201 A.1 (Design)
Part301 A.1 (Design)
Part302 A.1 (Design)
Part303 A.1 (Design)
Upstream
Part202 A.1 (Design)
Design
Part101 A.A.1 (Manufacturing)
Manufacturing
Part201 A.A.1 (Manufacturing)
Downstream
Plant 1
Plant 2
Part301 A.1 (Design)
Part302 A.1 (Design)
Part202 A.1 (Design)
Part203 A.1 (Manufacturing)
14
View Limitation – Assembly Splitting
– When an assembly is split, new Part
Numbers are created in mBOM
– View mechanism cannot anymore
ensure traceability/change process
(Based on Part Number)
mBOM
Front Brake Assy
Front Brake
Front Brake
eBOM
Rear Brake Assy
Brake System
Rear Brake
Front Brake
Front Brake
Rear Brake
Rear Brake
Rear Brake
Where is the
Brake System
Assy in the
mBOM?
15
View Limitation – Renumbering
– Some customer are re-numbering Parts
when creating their mBOM
• e.g. document based eBOM
– View mechanism cannot anymore ensure
traceability/change process (Based on
Part Number)
mBOM
WHEEL_ASSY
WHEEL
eBOM
?
123456.asm
WHEEL_SHAFT_ASSY
WHEEL
12.prt
What is
what?
SHAFT
34.prt
12.prt
16
View Limitation – Revision Schema
– The “View” mechanism relates
Parts through revision scheme
– The revision schema can be
rapidly obsolete
mBOM
WHEEL (Mfg) A.A.1
eBOM
?
WHEEL (Design) A.1
WHEEL (Design) A.2
?
Revision schema
becomes
irrelevant
WHEEL (Mfg) A.A.2
WHEEL (Mfg) A.B.1
WHEEL (Design) B.1
Previous work
lost
Which way to
go?
17
Additional functionality
offered by MPMLink
18
Associative mBOMs from eBOM
• Practice:
– Create mBOMs directly from the eBOM
– Start the creation of the mBOM before design
release
Engineering
eBOM
(As Designed)
equivalent
Assy 1100
Part 100
– Leverage 3D data
equivalent
Part 200
Part 300
Assy 1500
Part 100
Assy 1200
Assy 1300
• Capabilities:
Manufacturing
mBOM
(As Planned)
Part 700
Assy 1500
equivalent
Part 300
Assy 1600
Part 400
Part 400
Part 500
Part 500
• Create mBOM from engineering 3D mockup
• Dynamically generate mBOM 3D mockup
PLANT 2
Part 800
– Flexibility
• Mfg equivalent parts
• Plant specific BOMs
– Traceability
• Bidirectional associativity
– Control and manage
• Analyze and resolve BOM discrepancies
• Change and Configuration Management
eBOM
mBOM
19
MPMLink Key Concept – Equivalent link: Definition
– To over come the view mechanism
limitations, MPMLink has introduced the
Equivalent Link concept
– Definition: It relates an iteration of an
upstream Part (eBOM) to its equivalent
downstream (mBOM) iteration.
Downstream
mBOM
Upstream
eBOM
123 A.1 (Design)
Equivalent Link
WHEEL A.4 (Mfg)
20
MPMLink Key Concept – Equivalent link: Purpose (1/3)
– Purpose: the Equivalent Link
provides “associativity” between an
upstream Part and its equivalent
downstream one, for supporting:
mBOM
Front Brake Assy
• Traceability and Conformity
• Change Processes
• Concurrent Product and Process
Front Brake
Front Brake
Equivalent Link
eBOM
Equivalent Link
Brake System
Rear Brake Assy
Rear Brake
Front Brake
Front Brake
Rear Brake
Where is the
Brake System
It hasinbeen
Assy
the
split!!
mBOM?
Rear Brake
Rear Brake
21
MPMLink Key Concept – Equivalent link: Purpose (2/3)
– Purpose: the Equivalent Link
provides “associativity” between an
upstream Part and its equivalent
downstream one, for supporting:
mBOM
• Traceability and Conformity
• Change Processes
• Concurrent Product and ProcessEquivalent Link
eBOM
WHEEL_ASSY
WHEEL
?
WHEEL_SHAFT_ASSY
There you
are!
123456.asm
Equivalent Link
12.prt
SHAFT
What is
what?
WHEEL
34.prt
12.prt
Equivalent Link
Equivalent Link
22
MPMLink Key Concept – Equivalent link: Purpose (3/3)
– Purpose: the Equivalent Link provides
“associativity” between an upstream Part
and its equivalent downstream one, for
supporting:
mBOM
WHEEL (Mfg) A.A.1
• Traceability and Conformity
• Change Processes
• Concurrent Product and Process
eBOM
?
Equivalent Link
Revision schema
becomes
irrelevant
WHEEL (Design) A.1
WHEEL (Mfg) A.A.2
WHEEL (Design) A.2
Equivalent Link
WHEEL (Design) B.1
WHEEL (Mfg) A.B.1
?
Equivalent Link
relates Parts
Which way to
instead of
go?
Revision scheme
Previous work
lost
23
MPMLink Key Concept – Equivalent link: Context
– For the Equivalent Link, the context
is a pair of Views e.g. upstream
context = design view and
downstream context = manufacturing
view. (Upstream context can be the
same as the downstream context or
be empty)
– The same Part can have different
equivalent Parts depending where
it’s used in mBOM
mBOM (Plant1)
WHEEL ASSY (Plant 1)
eBOM
WHEEL (MFG)
mBOM (Plant2)
WHEEL ASSY (Plant 2)
Equivalent Link
eBOM
450 (MFG)
WHEEL ASSY (Design)
(Design)
Equivalent Link
WHEEL (Design)
24
Equivalent link: Features
– The Equivalent Link has a
direction and it’s owned by the
downstream iteration
– The Equivalent Link is a 1-N or
N-1 relationship meaning one
upstream iteration can have
multiple downstream equivalent
Parts and vice versa
– Upstream versus downstream
contexts should (strongly
recommend) follow the network
view so that it is possible to reuse
upstream Parts is into
downstream BOM’s
mBOM
Front Brake Assy A.1 (Mfg)
Equivalent Links
eBOM
Brake System A.1 (Design)
Equivalent Links
Rear Brake Assy A.1 (Mfg)
View Network
eBOM
Design
mBOM
PLANT 1
Manufacturing
PLANT 2
25
Equivalent link: Features
– When a new iteration of a linked
downstream Part is created, the
Equivalent Link is duplicated
– When a new iteration of a linked
upstream Part is created, no
Equivalent Link is duplicated
(Out-of-date)
Downstream
Equivalent Links
Upstream
Part 222 A.1
Part 222 A.2
Part100 A.1
Part100 A.2
Upstream iteration
without a downstream
equivalent
26
Equivalent link: Features
– When an Equivalent Link is updated
for a downstream Part:
• the system proposes to display
differences between latest version
and the currently linked iteration
• a new Equivalent Link is created to
the latest upstream iteration
– In future, the Equivalent Link could
be used to propagate modifications
from Upstream to Downstream
Downstream
Equivalent Links
Upstream
Part 222 A.1
Part 222 A.2
Update
Equivalent
Link
Part100 A.1
Part100 A.2
27
Report differences between associated BOMs
• Quickly identify quantity discrepancies between associated BOMs
–
–
–
–
Compare two or more structures and supports multi-level comparisons
Part quantity comparison analysis using the associativity links
Highlight parts in Creo View or in the Process Plan Explorer
Displays quantity comparison results in a color coded table, which can be easily navigated by
discrepancy type (equal to, greater than, less than)
28
Status Indicator for Equivalent Link (1/3)
– Indicators in Product Structure tree
are used in order to asses the
status of the Equivalent Links.
– Equivalent Links Status:
• No Equivalent Link exist
Upstream
Part100 A.1
Part100 A.2
Part100 A.3
Downstream
Part 222 A.0
Part 222 A.1
Part 222 A.2
29
Status Indicator for Equivalent Link (2/3)
– Indicators in Product Structure tree are
used in order to asses the status of the
Equivalent Links.
– Equivalent Links Status:
• No Equivalent Link exist
• Equivalent Link exist and points the latest
iteration in the system
Downstream
Upstream
Equivalent Links
Part100 A.1
Part100 A.2
Part 222 A.0
Part 222 A.1
Part 222 A.2
30
Status Indicator for Equivalent Link (3/3)
– Indicators in Product Structure tree are
used in order to asses the status of the
Equivalent Links.
– Equivalent Links Status:
• No Equivalent Link exist
• Equivalent Link exist and points the latest
iteration in the system
• Equivalent link exist but not on the latest
iteration
Downstream
Upstream
Equivalent Links
Part100 A.1
Part100 A.2
Part 222 A.0
Part 222 A.1
Part 222 A.2
Part100 A.3
31
MPMLink Key Concept – Equivalent Occurrence Link
– Definition: The Equivalent Occurrence Link relates an occurrence of Part in an
upstream context to its equivalent occurrence in an downstream context. (Path to
Path Link)
– Purpose: To allow monitoring discrepancies on the occurrence level between a
downstream BOM and its upstream equivalent one.
Part222 A.1 (Mfg)
Part100 A.1 (Design)
Part333 A.1 (Mfg)
Part200 A.1 (Design)
Part300 A.1 (Design)
Part300 A.1 (Mfg)
Part300 A.1 (Manufacturing)
Part300 A.1 (Design)
32
Paste with Associative BOM Links (1/2)
– Allow to transform
eBOM into mBOM by
picking eBOM Parts
and pasting them into
mBOM.
– Copy of eBOM Parts
can be done from
any eBOM Tree
(Selection or another
Explorer) or from 3D
but the paste with
associative BOM
Links is only possible
in the tree
33
Paste with Associative BOM Links (2/2)
– When pasting an eBOM part into an mBOM assembly
– If an equivalent part exists for the downstream context, the system will reuse that equivalent Part.
– If no equivalent link exist, then the system displays a panel for the user to specify:
• If a new view version is needed (“New View”)
• If a completely different Part is needed (“Duplicate”)
• If the Part should be used as is (“Same”)
– If an assembly has been pasted as-is (“Same”) in mBOM, associative BOM links are created only
on pasted assembly, not on the children.
Equivalent iteration in
downstream found and
will be re-used
34
Creo View for Windchill MPMLink
– “Creo View for Windchill MPMLink”
can read information from
Manufacturing Product Structure
Explorer:
• Structure: Leaf .ol positioned with
values from the occurrence
• Upstream Equivalent Part
• Downstream Equivalent
Occurrence
• Upstream Equivalent Occurrence
• Common Parent
• Representation
35
Associative eBOM – mBOM Practice
• Restructure eBOM into mBOMs, with
maximum flexibility and detailed traceability
links
► Storyboard Overview
Use PLM system and directly access
evolving engineering design
• Visualize multi-level eBOM
• Visualize 3D mockup
eBOM
Vehicle eBOM
• Derive multiple mBOMs from eBOM
• Automatically generated mBOM 3D
mockup
mBOM
Vehicle mBOM
Manufacturing
Engineer
Frame Assy
Sub-Assy
Part 1
Part 1
Part 2
START
Part 2
Rear Frame
Part 9
Part 8
Analyze eBOM
Rear Frame
• Release to production systems
Restructure into
mBOM
• Standard integration with leading ERPs
• Flexible integration framework
• Stay informed through change process
and update mBOM accordingly
• Integral change and
configuration management
Update and Maintain
mBOM
Ensure BOM
conformity
Release to production
systems
• Visual indicators based on
traceability BOM links
• Automatic propagation of part
attributes and CAD viewables
• Ensure all eBOM parts are accounted for
• Multi level BOM compare
END
© 2009 PTC
36
MPMLink can do even more
37
Digital Process Plans
Digitally define and manage process plan in Windchill
MPMLink:
– Define plant-specific process plans with multiple
sequences of operations (supporting sub-operations,
parallel and alternates)
– Define different process plan types (machining,
assembly, quality, maintenance, repair,…)
– View the in-process state of assembly at any operation
using embedded Creo View 3D visualization
– Define process plan operations by allocating parts,
manufacturing resources, skills, documents, operator
instructions and time/cost breakdowns
– Reuse the same process plan to manufacture multiple
parts (example for variant parts or left/right hand parts)
– Define alternate process plans for the same part
– Reuse standard process plans from a standards
library
Op
020
Op
010
Main
Sequence
Op
030
Op
025
Sequence 1 (Parallel)
Op
025
Op
035
Sequence 2 (Alternate)
38
Manufacturing Resource Management
Define and manage manufacturing resources and
skills with Windchill MPMLink:
– Define and manage resource libraries including
plants, work centers, tooling, skills and process
materials
– Reference resources within process plans to build
parts
– Define technical compatibilities between
resources and standard manufacturing
capabilities
– Link CAD files to resources for reuse in process
plan and work instruction 3D representations
39
Dynamically Generated Visual Work Instructions
Op
020
Op
010
Op
030
Sequence Main
Op
025
Sequence 1 (Parallel)
Op
025
Op
035
Sequence 2 (Alternate)
Work instructions
are dynamically
generated
documents
40
Integral Change Management
– Change management of process plans,
sequences and operations
– Manufacturing change as integral part of
engineering change management
– Easily update as-planned BOMs and associated
plans upon engineering change
– Reduce overall cost and eliminates
miscommunication issues
41