From Product Data Management to a Global Change Management

From Product Data Management to a Global Change Management

Orange County Convention Center
Orlando, Florida | May 15-18, 2011
From Product Data Management
to a Global Change Management Solution
Session Code 2907
Uwe Thumlert
MAHLE Industries, Inc
Reinhard M. Staebler
CENIT North America Inc.
]
From Product Data Management to a
Global Change Management Solution
- MAHLE’s Journey in Implementing SAP PLM and future Roadmap ASUG Annual Conference, May 17th, 2011
Uwe Thumlert
MAHLE Industries, Inc.
Reinhard M. Staebler
CENIT North America, Inc.
2
© MAHLE
From Product Data Management to a Global Change
Management Solution
Agenda
3
MAHLE – An Overview
–
Locations
–
Products
SAP @ MAHLE North America
Multi-System Landscape
SAP DMS – Business Integration
From PDM to PLM
PLM @ MAHLE – The Future
Engineering Change Management
PLM Deep Integration
© MAHLE
Partner of the Engine and Automotive Industry
Since 1920
®
ABB, AGCO, Alfa Romeo, Alpina, Alstom, AMG, Ashok Leyland, Aston Martin, Audi,
AvtoVAZ, BAE Systems, Bajaj, Beiqi Foton, Bentley, BMW, Bombardier, Bombardier-Rotax,
Brilliance, Bugatti,Buick, BYD, Cadillac, CAF, Case, Caterpillar, Changan, Chaoyang Diesel,
Chery, Chevrolet, Chrysler, Citroën, CLAAS, CNHTC, Cummins, Dacia, DAF, Daihatsu,
Dalian Diesel, Detroit Diesel, Deutsche Bahn, Deutz, Dodge, Dongan, Dongfeng,
Doosan Infracore, DPCA, Ducati, EADS, Eicher Motors, Embraco, EMD, Escorts, EvoBus,
FAW, FAW-Volkswagen, Ferrari, FIAT, Force Motors, Ford, Freightliner, Fuso, Gamesa,
GAZ, GE Transportation, Geely, General Dynamics, General Motors, GMDAT, Great Wall,
Harley-Davidson, HATZ, Hindustan Motors, Hino, Hitachi, Holden, Honda, Hummer,
Husqvarna, Hyundai, Hyundai Heavy Industries, Infiniti, Irisbus, Isuzu, IVECO, Jaguar, JCB,
Jeep, Jinan Diesel, JMC, John Deere, KAMAZ, Kia, Komatsu,®Krauss Maffei, Kubota,
Lamborghini, Lancia, Land Rover, Lexus, Liebherr, Liuji, Lycoming Engines, Mack Trucks,
Mahindra & Mahindra, MaK, MAN, MAN Diesel & Turbo SE, Maruti Suzuki, Maserati,
Maybach, Mazda, McLaren, Mercedes-Benz, Mercury, Mini, Mitsubishi, Mitsubishi Heavy
Industries, MTU, MWM, MWM International, Navistar International, Neoplan, New Holland,
Nissan, Nissan Diesel, Opel, Otosan, Paccar, Perkins, Peugeot, Piaggio, Polaris, Pontiac,
Porsche, Proton, Qingling Motors, Renault, Renault Trucks, Rheinmetall, Rolls-Royce,
Rotax, Saab, SAIC, SAME, Samsung, Scania, Scion, SEAT, SEMT, SGM, SGMW, Shanghai
Diesel, Siemens, Sisu, Škoda, Smart, SsangYong, Star, Steyr, Stihl, STX, Subaru, Sullair,
Suzuki, SVW, Tata Motors, Tecumseh Teledyne Continental Motors, Tognum, Toyota,
Triumph, Vauxhall, Vestas, VM Motori, Volkswagen, Volvo, Volvo Penta, Volvo Powertrain,
Volvo Trucks, Vossloh, Wärtsilä, Waukesha Engine, Weichai Power, Wuxi Diesel, Yamaha,
YaMZ, Yangzhou Diesel, Yanmar, Youngman, Yulin Diesel, Yunnei, ZMZ
4
© MAHLE
Locations
MAHLE an Overview - Worldwide
47,457 Employees in 118
locations
with €5.26 Bio in Sales
USA
Ann Arbor (MI)
Atlantic (IA)
Belmont (MI)
Farmington Hills
(MI)
Franklin (KY)
McConnelsville
(OH)
Morristown (TN)
Murfreesboro (TN)
Muskegon (MI)
Novi (MI)
Nowata (OK)
Olive Branch (MS)
Russellville (AR)
St. Johns (MI)
Trumbull (CT)
Mexico
Winterset (IA)
Canada
Niagara-on-theLake
Tilbury
Great Britain
Bilston
Kilmarnock
Northampton
Rugby
Stoke-onTrent
Telford
Wellingboroug
h
Worcester
France
Chavanod
Dardilly
Décines
Ingershei
m
Orange
Poissy
Rungis
Seboncou
rt
Spain
Alcalá de
Henares/Madrid
Vilanova I la Geltrú
Aguascalientes
Lerma
Naucalpan
Ramos Arizpe
Santa Catarina
Portugal
Murtede
Switzerland
Grenche
n
Production locations
R&D centers
April 2010
Brazil
Indaiatuba
Itajubá
Jundiai
Limeira
Mogi Guaçu
Queimados
São Bernardo do
Campo
China
Changchu
n
Chongqing
Guangzho
u
Macheng
Nanjing
Shanghai
Tianjin
Poland Yingkou
Krotoszy
n
Austria
Mattighofen
Rankweil
St. Michael ob
Bleiburg
Vöcklabruck
Wolfsberg
Korea
Hwasun
g
Ulsan
Japan
Fukushim
a
Ibaraki
Kawagoe
Okegawa
Tochigi
Tokyo
Tsuruoka
Yamagata
Slovakia
Dolný Kubí
Italy
Bomasco
LaLoggia
Saluzzo
Trento
Argentina
Buenos Aires
Rafaela
Netherlands
Alkmaar
Lochem
Germany
Albershausen
Barsinghausen
Brattendorf
Eislingen/Fils
Fellbach
Flintbek
Freiberg
Gaildorf
Hamburg
Leibertingen
Lorch
Markgröningen
Öhringen
Plettenberg
Reichenback
Roßwein
Rottweil
Schorndorf
Stuttgart
Wölfersheim
Wustermark
Zell im Wiesental
Romania
Timisoara
Turkey
Gebze
Izmir
Konya
Philippine
s
Cavite
Thailand
Bangkok
Samutprakarn
India
Gurgaon
Maraimalainager/Chenn
ai
Parwanoo
Pithampur
Pune
Australia
Laverton
North/Melbourne
© MAHLE
Locations
MAHLE an Overview - North America
24 locations in the North America region
With 6940 Employees and ~ € 1.0 Bio in sales
Atlantic
Winterset
Franklin
Murfreesbor
o
Nowata
Russellville
Olive
Branch
Santa Catarina
Ramos Arizpe
Aguascalientes
Naucalpan
Lerma
6
Farmington
Hills
Novi
St. Johns
Muskegon
Belmont
Ann Arbor
Niagara-On-The-Lake
Tilbury
Trumbull
McConnelsville
Morristown
Fletcher
ENGINE SYSTEMS AND
COMPONENTS
Piston Systems
Cylinder Components
Valve Train Systems
FILTRATION AND ENGINE
PERIPHERALS
Air and Liquid Management Systems
INDUSTRY
Industrial Filtration
Thermal Management
AFTERMARKET
Aftermarket
PROFIT CENTERS
Small Engine Components
Motorsports
Engineering Services
© MAHLE
Product Portfolio
Business Units
ENGINE SYSTEMS AND COMPONENTS
FILTRATION AND ENGINE PERIPHERALS
Piston Systems
Cylinder Components
Valve Train Systems
Aluminum pistons for
gasoline and diesel
engines, articulated
and steel pistons for
commercial vehicle
engines, piston
assemblies, complete
power cell modules.
Piston rings, piston
pins, connecting rods,
cylinder liners, bearings
and bushings for
combustion engines
and other automotive
applications, cast
piston inserts.
Complete valve train
systems as well as
their components.
Machined and
assembled cylinder
heads. Machined
engine blocks and
assembled complete
engines, precision
sintered parts,
turbocharger
components.
Air Management Systems Liquid Management
Systems
Complete air intake
systems, air filtration
Oil filter modules, oil and
elements, cylinder head
fuel spin-on filters, fuel
covers, crankcase
filter modules, fuel
ventilation systems,
pressure regulators, inline
design and acoustic
fuel filters, automatic water
covers, EGR modules,
disposal systems,
mechatronics
transmission oil filter
components, EGR
modules, oil pan modules,
valves, electrical
hydraulic oil filters, carbon
actuators, heating
canisters, heat exchangers
elements, pressure
for engines and
regulation valves.
transmissions, air driers.
© MAHLE
Product Portfolio
Business Units
INDUSTRY
Industrial Filtration
Liquid filtration, liquid
separation, aerosol
separation, process
filtration, and dedusting
for mechanical
engineering, in marine
technology, for large
engines, for industrial
vehicles, in process
technology and general
industry.
AFTERMARKET
Large Engine
Components
Pistons and additional
engine components for
gas, diesel, heavy-oil
and dual-fuel engines for
marine, locomotive,
building machinery and
industrial applications,
as well as for energy
production.
Thermal Management
Aftermarket
Air conditioning and
cooling products for
military, marine, aircraft
and others, motorcycle
products.
Pistons, piston rings,
bearings, washers,
bushings, gaskets and
filters for passenger cars
and commercial vehicles.
© MAHLE
SAP @ MAHLE North America
1998/99 – SAP R/3 Implementation – FI, CO, MM, SD, PP
2000/01 – SAP DMS Implementation along with PM and QM
–
9
Included the generation of TIFF files for drawings and a manual check in / out
2002 – EHS Implementation (Substance Management & ISO 14001 Audit System)
2003 – SAP cProjects at MAHLE N. A. (SAP Ramp-up Partner)
2004/5 – Globalization of regional cProjects implementation
2006 – Global Sales Opportunity Form Development & Implementation driven by Europe
2006 – Seal Systems PLOSSYS implementation for document stamping
2007 – Harmonization of DMS systems
2008 – 2010 North America SAP CAD Integration Implementations
2010 – Right Hemisphere Conversion Server with CENIT’s SAP Integration
2011 Global Engineering System Implementation
2011 Global Engineering Change Management Implementation
2012 Centralized CAD Integration via Global Engineering System
Future: PLM Deep Integration at MAHLE North America
© MAHLE
MAHLE’s Multi System Landscape
Tilbury, CA
CSC
CS
Detroit, MI
Atlantic, IA
CSC
CSC
CS
AP1 R/3 System
JP
DMS & KPRO
DMS & KPRO
CS
NA R/3 System
Morristown, TN, USA
DMS & KPRO
CS
CSC
CSC
DMS = Document Management
KPRO = Knowledge Provider
CS = Content Server
CSC = Content Server Cache
Global Engineering
Master
SAP Portal w/
cProjects, cFolders
Sales Opportunity Form
Engineering Change
Management
Work Reques Systems
Disbribution of:
eBOMS, Material Master
Material Classification
Aguascalientes, MX
10
EU R/3 System
Stuttgart, DE
CS
AP2 R/3 System
China
DMS & KPRO
SA R/3 System
Mogi Guaçu, BR
DMS & KPRO
© MAHLE
PDM / PLM Implementation Path
- CAD Integration Business challenge:
Build a system, which integrates the product drawings to the business utilizing a system
Ensure data consistency providing direct CAD application integration
Integration has to support a non-sequential product design process by avoiding information islands
Enable design collaboration
Make design data available at an early stage during product development
CAD
Management of
files and structures
(checkin and checkout)
Implementation path:
CATIA Integration
Pro/E Integration
Autodesk Integration
NX Integration
(Solidworks only in Europe)
BAPI
CADRFC
Document
and material-BOMs
Fully, bi-directional
integration
of
CAD into SAP
Parameters and meta data
Viewing files
Application
11
SAP
© MAHLE
PDM / PLM Implementation Path
- CAD Integration Results Definition of document types (specific document
types for different business units and drawing
file types allow a separation of documents and
offer additional security
CATIA
Meta data: Material master link, eBOM link
Definition of processes and the DMS status nets
Handover of all necessary information (e.g.,
transformation matrices) to SAP
5003-40017853-S00
Integration of the ECL Viewer (TIFF Files)
Viewing of the complete assembly using a
neutral format
Switching the single components on or off
With Digital Mockup, it is possible to collaborate
by bringing components together that originated
from different CAD systems
CAD Desktop with tight integration to CAD
applications
12
© MAHLE
PDM / PLM Implementation Path
- Conversion and Viewing Business challenge:
Provide model viewing capabilities to non designers
Automatically convert to neutral formats for viewing purposes
Generate neutral formats based on status changes
Document status representation on 2D views for various file types
HPGL – TIFF – PDF
Document type 200
Includes stamping of
document status
13
JT & Native CAD files
Document type 201
© MAHLE
SAP DMS – Business Integration
USA
Ann Arbor (MI)
Atlantic (IA)
Belmont (MI)
Farmington Hills
(MI)
Franklin (KY)
McConnelsville
(OH)
Morristown (TN)
Murfreesboro (TN)
Muskegon (MI)
Novi (MI)
Nowata (OK)
Olive Branch (MS)
Russellville (AR)
St. Johns (MI)
Trumbull (CT)
Winterset (IA)
~1,400 SAP users
access the SAP
System in
North America to retrieve:
Mexico
Aguascalientes
Product drawings,
Lerma
Naucalpan
Tooling drawings,
Ramos Arizpe
Santa Catarina
Machine drawings,
Product meta data,
Product related office documents
…
Shopfloor
Control
Environmental, Health
and Safety
Material
Management
14
Canada
Niagara-on-theLake
Tilbury
SAP
Document Management
System
and
CAD Desktop
Quality
Management
Mold
Construction
CAD Applications
CATIA
NX (former UG)
Pro/E
Autodesk
Solidworks
I-DEAS
Plant
Maintenance
Machine Build,
Jigs & Fixtures
© MAHLE
From PDM to PLM
Application
Engineering
& Design
EU R/3 System
Stuttgart, DE
Production
Material
management
Quality
EHS
DMS & KPRO
NA R/3 System
Morristown, TN
DMS & KPRO
15
Global Engineering
Master
SAP Portal w/
cProjects, cFolders
Sales Opportunity Form
Engineering Change
Management
Work Reques Systems
Disbribution of:
eBOMS, Material Master
Material Classification
Application
Engineering
& Design
Production
Material
management
Quality
EHS
Production
Material
management
Quality
EHS
Application
Engineering
& Design
Application
Engineering
& Design
SA R/3 System
Mogi Guaçu, BR
DMS & KPRO
Production
Material
management
Quality
EHS
AP1 R/3 System
JP
DMS & KPRO
AP2 R/3 System
China
DMS & KPRO
Scenario allows:
• Regional flexibility
• Regional processes on lower levels
• Global processes (high level)
• Global standardization
© MAHLE
Engineering Change Management
16
Ongoing implementation project
–
Global scope, across multiple international MAHLE locations
–
Also covering regional change management requirements
–
Business unit 2 Filter Systems is pilot user
Supporting Global Engineering Master SAP instance
Engineering change processes and data integrated into distributed, regional SAP
instances
Based on CENIT‘s SAP PLM 7 add-on product cenitCONNECT
–
Seamless integration into SAP PLM 7
–
Accelerator for the implementation of PLM 7
–
Advanced process management capabilities
–
Supports scenarios with multiple SAP instances
© MAHLE
cenitCONNECT Core Components
Advisor
Technology
Visual Process
Management
Combines visual and enterprise
data within business process
content
Support through
Selection Advisor
Analysis Advisor
Execute Advisor
Dashboard
Technology
Monitoring of projects
Analysis
Reports
Controlling
Process Management
Flexible Process Control for workflows, activities and checklists
Facilitates the definition of complex workflows notably
Supports different use cases and business scenarios
17
cenitCONNECT Process Header
18
Dynamic process template
selection based on header
characteristics
Configurable, custom
attributes
Direct file attachments
cenitCONNECT Process Workbench
Multi-phase, template based
workflows
Ad-hoc workflow changes
19
cenitCONNECT Process Workbench
Agents
20
Single or multiple users
Groups, org units
Dynamic agent assignment
cenitCONNECT Process Workbench
Configurable Email Notifications
Email Templates
Notes on task level
21
cenitCONNECT Process Workbench
Checklists
22
cenitCONNECT Process Workbench
Automated background tasks
23
DIR status change
MM x-plant status change
BOM item change
cenitCONNECT Process Workbench
SAP Transactions
24
cenitCONNECT Process Workbench
Approval
25
Digital Signatures
Approval List
cenitCONNECT Selection Advisor
26
Navigate all object relationships and dependencies in one screen
– Multi-level BOM “where used”
– Overview of ongoing and planned changes
PLM @ MAHLE – The Future
27
Global Engineering System
SAP cProject (status: implemented)
SAP easyDMS (status: implemented)
Engineering Change Management Solution (status: ongoing implementation)
SAP Resource and Portfolio Management (RPM)
Global Master Data
Customer and customer hierarchy data (ongoing implementation)
Engine data base (currently implemented)
Material master information
Engineering Bills of Material (eBOMs)
....
© MAHLE
PLM Deep Integration
NA R/3 System
Global EngineeringSystem
SAP Portal w/ cProjects, cFolders,
Sales Opportunity Form, easyDMS
Technical
Asset
Management
Machine
Capabilities
Global Master Data
Document
management
Master Data
EHS
Material
characteristics
Material Master
Material Master
Classification
BOMs
QM
Inspection
characteristics
and plans
Engineering Services
Appl. Engineering,
Design, Engine
Testing,
Material Lab,
Metrology Lab
Product Development
&
Engineering Change
Management
Information access
Data exchange
28
© MAHLE
Summary
29
Phased implementation from PDM to PLM
Base SAP modules
CAD integrations
Expand into new product development solution
Engineering Change Management
Comprehensive, yet cost effective multi CAD data management environment
Committed to SAP‘s PLM 7.x solution
© MAHLE
[
]
Thank you for participating.
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evaluation form following this session.
For ongoing education in this area of focus, visit
www.asug.com.
SESSION CODE:
2907
Real Experience. Real Advantage.