Product Lifecycle Management Process and Software Tools


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Session by Geoff Hammett at ProductCamp Atlanta 6, on August 18, 2012.

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  • Some history, some context and info about the PLM PROCESSThank GTRIContext of the environment in which PLM evolvedA few key pieces of the PLM ProcessAttendee “town hall” discussions
  • (Being from Atlanta…I alsoattended Ga Tech during a couple of summers!)DMX = Digital Music Express, Satellite and Cable delivered 30 channel commercial free digital audio service with 2-way “DJ” remote control displays Title, Track and Artist information.DOCSIS = Data Over Cable Service Interface Specification.VoIP = Voice over IP IP Video Set-top – used primarily for xDSL delivered Video services provided by Telcos worldwide.
  • Glen P. Robinson and six other Georgia Tech researchers founded Scientific Associates in 1951 with the initial goal of marketing antenna structures and antenna measurement instruments.Renamed/Rebranded Scientific Atlanta when another company with the Scientific Associates name requested the change.Robinson worked as the general manager without pay for the first year; after the small company's first contract resulted in a $4,000 loss, Robinson (upon request) refunded five of the six other initial investors. The success of Scientific Atlanta and paved the way for further technology transfer efforts by Georgia Tech's VentureLab and the Advanced Technology Development Center.
  • Very early drawing on Scientific Associates formatted paper.From 1956, the company name had already changed but likely still had pre-printed drawing paper.Drawing is a for part used on the APR (Antenna Pattern Recorder).Part number is APR-MA-2448 (this P/N can foster a lively discussion about part number formats).Drawn and Checked in 1956, Drawing was Approved in 1963! (Document control release procedures and sign-off requirements would not allow this today)
  • Hand Tools Hand tools, used to work and assemble materials by hand. The only option available up through the 17th and early 18th century.
  • Machine Era External Power from Human, Animal, Water, Steam, Internal Combustion Sources Employ mechanisms for mechanical advantage, precision and throughput. Every work piece was a “one-off”. Before the Civil War, Jonathan Norcross, fourth Mayor of Atlanta, built a novel animal powered saw mill in “Terminus”, later renamed Atlanta. The saw mill was designed to produce railroad ties for the three railroads that converged there. Norcross also was granted a patent for new reciprocating mill saw guide design in 1843.
  • Employ mechanisms that provide mechanical advantage and higher precision. Each part still individually made, subject to variations introduced by the operator.
  • Era of Automation A machine that is set up for dedicated repetitive tasks, work pieces are made in batches – mostly identical (to the limits of tool precision and repeatability) Labor saving, improved output, higher consistency Changing the task requires specialized, time consuming and costly re-tooling of the machine New Fixtures, Dies, Jigs, Templates, etc Coupled with the moving assembly line, introduced the era of mass-production
  • Era ofProgrammable AutomationWith the introduction of Programmable Automation, the Machine isalso capable of being programmed to vary work done and make variations in the output without “retooling”. Jacquard Loom – Invented in 1801Used to manufacture textiles with complex patterns using punched cards with punched holesThe Jacquard loom was the first machine to use punched cards to control a sequence of operations. It is considered an important step in the history of computing hardware. The ability to change the pattern of the loom's weave by simply changing cards was an important conceptual precursor to the development of computer programming. Charles Babbage planned to use cards to store programs in his Analytical engine.Unimate industrial robot 1961- the first industrial robot. This unit worked on a General Motors assembly line at the Inland Fisher Guide Plant in Ewing Township, New JerseyIt was created by George Devol in the 1950s using his original patent filed in 1954 and granted in 1961. The patent begins:Devol, together with Joseph Engelberger, started the world's first robot manufacturing company, Unimation.The machine undertook the job of transporting die castings from an assembly line and welding these parts on auto bodies, a dangerous task for workers, who might be poisoned by exhaust gas or lose a limb if they were not careful.The original Unimate consisted of a large computer-like box, joined to another box and was connected to an arm, with systematic tasks stored in a drum memory.In 1961, the Inland Fisher Guide Plant became the first commercial user in the United States to use a programmable industrial robot to replace human workers, installing the 4,000 pounds (1,800 kg) Unimate automated hydraulic arm developed by George Devol and Joseph Engelberger to position into cooling pools units of aluminum door handles and other automotive components weighing as much as 40 pounds (18 kg) that had just been die cast from molten metal, eliminating the risks to employees of handling extremely hot metal pieces and taking over on a permanent basis a task that had previously been performed by three shifts of employees.The first production Unimate was donated to the Smithsonian Institution in 1971 after being used for 100,000 hours during its 10 years of continuous operation at the Ewing plant.
  • 1970’s/1980’s – with the introduction of CAD/CAM, Programmable Automation proliferated all areas of manufacturing from designing and making piece parts to final assembly, testing and shipping.In-line Panasert PCB assembly systemRacal-Redac PCB CAD systemPCB Photoplotter – used to produce PCB artwork “photo masks” and silk screen tooling.Electronic component tape and reel sequencer.
  • Environment and needs driving PLM Evolution
  • Pipeline rationalization is a process of review and optimization of the programs going through the company’s program pipeline.At each Gate Review the PAC can Approve, Reject or Redirect the program.Routinely make sure conditions don’t change that impact the viability/direction of the program: Customers/orders, Competition, Technology, Timing, Materials, Manufacturing.Make sure the “best” programs make it through and resources are applied optimally.
  • One of many slides in Phase Review deck that define the what, who, when of the program.The CFAis the key “Contract” approval document in each PAC Gate Review.
  • Evolution of Computing/Business MachinesAbacus with early adding/tabulating device (from Burroughs Corp.)Hollerith Tabulating Machine – used to tabulate the 1890 US Census in one year, a record feat.In 1911, Hollerith’s Tabulating Machine Company was merged with 3 other companies to form the Computing Tabulating Recording Company. Renamed International Business Machines (IBM) in 1924.Data Processing Center, 1985. Digital Equipment Corporation (DEC) Vax 11/780
  • Progress in Business Communications(Abraham) Stansbury Iron Press – 1821 Edison Business PhonographVibroplex Semi-automatic telegraph key – 1906, made telegraphy 3-5 times faster and mitigated telegraphers’ repetitive stress injury (RSI) called “Glass Arm”. Telegraphers among the first to widely use code book based encryption to obfuscate banking, stock and futures information. Marconi Wireless ApparatusEdison MimeographEngineering Document Central Files (Microfiche and Paper)Part Number Assignment Log Books, for manual assignment of part number, part description and owner information.Telephone Switchboard
  • 9600 Baud to 322 Tbps!DCA System 355 Network Processor, one line card for each terminal, replaced by Ethernet.Manufacturing Automation Protocol (MAP/TOP) rack – (1982-1987) Token Bus protocol (IEEE 802.4) development driven by GM for Programmable Logic Controllers, largely replaced by Ethernet.Hitachi AMS 5000 ATM Multiplexing System – (1994-1996) 5 to 20 Gbps.S-A QAM Cable Modulators – for MPEG Video distribution over coax.Cisco CRS-3 – Carrier Routing System,capacity of 322 Tbps. 322 Tbps throughput could enable the entire printed collection of the Library of Congress to be downloaded in just over one second; or allowevery man, woman and child in China to make a video call, simultaneously; or stream every motion picture ever created in less than four minutes.Cisco/Linksys EA-6500 -802.11ac Wi-Fi Router, 1.3 Gbps peak raw wireless bandwidth.Cisco ASR 9000 – Aggregation Services Router, up to 400 Gbps/slot and 6.4 Tbps of switching performance.From 2010 estimates: Cisco estimated in that each person will (at some point) consume 15TB of data per month (average 315 Mbps) between our personal and professional lives, 91 percent of Internet traffic by 2013 will be video, and overall, IP traffic will grow 40 percent per year.
  • CIMdata divides the PLM market into two software and services portions: Applications that support the authoring and analysis of product definition information (e.g., MDA, EDA, CASE, analysis, and technical publishing). Solutions that focus on collaboration, management, and sharing of product definition information.PDM includes the following basic elements of PLM solutions:• Data vault and document management• Product structure management• Workflow management• Classification management• Program and project managementOther PLM software vendors:Adeon Software House: CXInsight for ElectronicsArena Solutions: Arena PLMAtrion International: Materials Compliance SuiteAgentrics: Product Vine PLMAras Corporation: Aras Innovator PLM Software Solution SuiteBenchmark Vendor: Average SolutionConfiguration Data Services, Inc: PDMTOOLDatastay: Datastay PLMEpicor: Epicor ERPInfor: Infor PLM OptivaLascom: AdvitiumOmnify Software: Omnify Empower PLMProplanner: Proplanner Process Engineering & Management SuiteSofTech: ProductCenter
  • Product Lifecycle Management Process and Software Tools

    1. 1. Product Lifecycle Management Process and Software Tools ProductCamp 2012 Session Leader: Geoff Hammett - GTRI Conference Center 250 14th Street NW Atlanta, GA 30318Geoffrey Hammett – 20120818 © 2012 1
    2. 2. Alternate Session Title How to prevent this…Geoffrey Hammett – 20120818 © 2012 2
    3. 3. Alternate Session Title How to prevent this… …from becoming this!Geoffrey Hammett – 20120818 © 2012 3
    4. 4. Alternate Session Title How to prevent this… …from becoming this! A topic for another day…Geoffrey Hammett – 20120818 © 2012 4
    5. 5. Overview  GTRI – some history  In order to know where you’re going… Tools Machines Automation Programmable Automation  Product Lifecycle Management Process Evolution – One View Some Key PLM Charts  Attendee discussion: PLM Software ToolsGeoffrey Hammett – 20120818 © 2012 5
    6. 6. My Background  Education BSc Mechanical Engineering, University of Virginia MBA, Georgia State University  Product Engineering Experience Ford Motor Co. - Automotive Texas Instruments – Consumer Electronics Scientific-Atlanta – Telecommunications, Cable, Satellite Coggins Systems – Oil/Energy  Program/Product Management Experience Scientific-Atlanta – DMX: 1st all digital cable system, Sega Channel, Cable Modem, Sun/Oracle/Solaris Subscriber Control System HW & SW Cisco Systems – DOCSIS Cable Modem/VoIP, IP Video Set-top Receiver (AT&T U-verse)Geoffrey Hammett – 20120818 © 2012 6
    7. 7. Georgia Tech - GTRI  Thank you for hosting!  Ga Institute of Technology: Founded 1885, opened 1888: Georgia School of Technology Spawned Ga State University in 1955  Ga Tech Research Institute (GTRI): Funded 1934 as Engineering Experiment Station (EES) Renamed GTRI 1984  EES Success Story: 1951: Scientific Associates…Scientific-Atlanta (S-A) RF/Radar antenna performance measurement S-A’s success paved the way for technology “Incubators” 1980: Advanced Technology Development Center (ATDC)Geoffrey Hammett – 20120818 © 2012 7
    8. 8. Scientific Associates Drawing (from Microfiche)Geoffrey Hammett – 20120818 © 2012 8
    9. 9. In Order to Know Where You’re Going… Some History:Geoffrey Hammett – 20120818 © 2012 9
    10. 10. Tools – Cut, Shape, Assemble by HandGeoffrey Hammett – 20120818 © 2012 10
    11. 11. Machines – Harness External Power… Small Engine Power Transfer Belts Watt Steam Engine Steam Engine Speed ControlsGeoffrey Hammett – 20120818 © 2012 11
    12. 12. Machines …Higher Precision and Throughput Lathe Drill PressGeoffrey Hammett – 20120818 © 2012 12
    13. 13. Automation – Repetitive Task Efficiency Assembly Fixture Drill Press Hard ToolingGeoffrey Hammett – 20120818 © 2012 13
    14. 14. Programmable Automation - Flexible/Adaptable First Industrial Robot Jacquard LoomGeoffrey Hammett – 20120818 © 2012 14
    15. 15. Programmable Automation - Flexible/Adaptable PCB Design System In-line PCB Assembly System PCB Photoplotter Photoplotter ControllerElectronic Component SequencerGeoffrey Hammett – 20120818 © 2012 15
    16. 16. Evolution of PLM – Environment  Lots of moving parts to product development, manufacturing, launch and support.  Requirements/Specs, NC Programs, CAD/CAM, SW, FW, QA Data, Materials, Supply Chain, Order Management, Financials, Reporting, Databases, BOM’s, MRP, SCM, ERP, CRM, …  Needed a means to aggregate and manage: Not just the output… Needed to manage the process of creating the outputGeoffrey Hammett – 20120818 © 2012 16
    17. 17. Evolution of PLM – One View Benchmarking – PRTM (Pittiglio, Rabin, Todd & McGrath) 1976: PRTM founded in Palo Alto 1982: Began benchmarking business performance Initially - Catch up to Japanese JIT based processes Go beyond - identify next process improvement to change the competitive balance…found fruit: Product Development Best in class product lifecycle processes: • Speed • Cost • Quality 1986: Initially developed Product and Cycle-time Excellence® (PACE®) 2011: Pricewaterhouse Coopers (PwC) acquires PRTMGeoffrey Hammett – 20120818 © 2012 17
    18. 18. A Few Key Elements of PLM Process  Core Team Building and Consensus Core team structure Upper management Product/Program Approval Committee (PAC)  Program/Project Pipeline Rationalization – Phase Gate Reviews Return On Investment (ROI) Resource Availability/Allocation Schedule  Program/Project Cross-functional Agreement (CFA) Upper Management approval and to track actuals to plan •Key schedule milestones •ROI •Critical quality measures •Resource requirementsGeoffrey Hammett – 20120818 © 2012 18
    19. 19. A Few Key Aspects of PLM Process  Note: Not all PLM Processes, Components or Systems are alike  The PLM process must be tailored to the Company’s products, organization, people and program/project scope  In some cases: PLM process changes the Company… or Company changes the PLM process (Phases, Gates, Approvals, etc.)  “Organize around outcomes”Geoffrey Hammett – 20120818 © 2012 19
    20. 20. Example Core Team Structure Program/Product Approval Committee Corporate (PAC) Legal Customer Engineering Support Core Team Members  Key stakeholders support to the Core Team Leader  Responsible for action and Core deliverables in functional area Sales Team Operations  Make tactical project decisions Leader  Provide required information to the PAC CoreTeam Leader  Focal point of accountability for the Marketing Finance program  Plans and executes the program Product Management tasks and schedule  CTL is the Product Mgr for Concept phase but may be the Program MgrGeoffrey Hammett – 20120818 © 2012 for other phases 20
    21. 21. Product/Program Approval Committee (PAC) Corporate Legal Product/Program Approval Customer Committee Engineering  Upper management stakeholders Support  Guides/determines critical program parameters with CoreTeam  Approves/Rejects/Redirects gate Product reviews Sales Approval Operations  Makes go or no-go decisions Lead  Can make conditional go decision Product Approval Committee Lead Marketing Finance  Leads PAC gate review meetings  Records decisions/action items Product  Accountable for timely decision Management making and issue resolution within the PAC (conductor, mediator)  May be the division ExecutiveGeoffrey Hammett – 20120818 © 2012 21
    22. 22. Program Pipeline Rationalization – Phase Gate ReviewsGeoffrey Hammett – 20120818 © 2012 22
    23. 23. Example PLM Phases and Gate Reviews Concept Development Delivery Customer General End of Review Review Plan Shipment Availability Life Review Review Review Review Concept Plan Develop Validate Launch Sustain EOL• Concept Doc • Detailed • Detailed Specs • Verification Test • Go-to-market • Supply chain • Customer Notice• What, Why, Program Plan • Design • HALT/HASS • Product Release • Forecasting • Material ReviewWhen, ROI • Product • Prototype • BETA Test • Cost reduction • Close Orders Requirements • Unit Test • Improvement • Doc Review • ALPHA Test Corporate/Sector PAC Division PAC Reviews Reviews Note: • Some program Phase overlap is expected/encouraged • Gate reviews “officially” determine program Phase Geoffrey Hammett – 20120818 © 2012 23
    24. 24. Cross-functional Agreement CFA)  Provides Key Program Metrics and Program Team Commitments • Schedule • ROI • Quality • Resources Required • Log of Program Changes  “Contract” signed off/Approved by PAC  Monitored and Reviewed at Each GateGeoffrey Hammett – 20120818 © 2012 24
    25. 25. Program Cross-Functional Agreement <Program/Project Name> ROI Summary Units Plan Required CurrentPhase Schedule Units Plan Required CurrentConcept Phase Date Revenue/Sales $MPlanning/Specification Date Total Variable Cost $MPhase Gross Margin Target %Development Phase Date Engineering Cost (NRE) $MTest/Evaluation Phase Date Incremental Cost $MRelease/Launch Phase Date AllocationEnd-of-Life Phase Year Depreciation $MKey Program Milestones Units Plan Required Current Total Program Cost $M Contribution Margin % NPV $M ROI %Critical Quality Metrics Units Plan Required Current Key Resource Units Plan Required Current Requirements Total # of Person- # FTE months Headcount Expense $M Prototype Expense $MScope Changes Units Plan Required Current Outside Services (NRE) $M Capital Expense $M Program Change Log Requested by JustificationGeoffrey Hammett – 20120818 © 2012 25
    26. 26. Questions?Geoffrey Hammett – 20120818 © 2012 26
    27. 27. Discussion Topics: PLM Software Tools  Best things you like about the tool User Interface? Benefits? Drive Collaboration and Consensus? Help Drive Phase Gate Reviews and Approvals  How long to become a user?  How long to become proficient?  How do you feel it helps the PLM Process?Geoffrey Hammett – 20120818 © 2012 27
    28. 28. Acknowledgements  GTRI Historical Archive  Henry Ford Museum – Dearborn, MI  Coursera/U. of Mich – Internet History, Technology, and Security  Scientific-Atlanta/Cisco Systems, Inc.  PRTM – PricewaterhouseCoopers, LLP  CIMdata, Inc.  WikipediaGeoffrey Hammett – 20120818 © 2012 28
    29. 29. Backup SlidesGeoffrey Hammett – 20120818 © 2012 29
    30. 30. Example: Consumer Products – Vacuum Cleaners Automation Era Products Programmable AutomationGeoffrey Hammett – 20120818 © 2012 Era Products 30
    31. 31. Computing/Business Machines Evolution Abacus and Tabulating Aid Hollerith Tabulating Machine Data Processing CenterGeoffrey Hammett – 20120818 © 2012 31
    32. 32. Communications - Early Semi-Automatic Key Business Phonograph Marconi Wireless Part Number Log Books Stansbury Printing Press Central Files Room Telephone Switchboard Edison MimeographGeoffrey Hammett – 20120818 © 2012 32
    33. 33. Communications - Newer Manufacturing Automation Protocol Rack QAM/QPSK Modulators Async Network Processor ATM Multiplexer ES-6500 802.11ac Wi-Fi Router CRS-3 Carrier Routing SystemGeoffrey Hammett – 20120818 © 2012 ASR 9000 Aggregation Services Router 33
    34. 34. Some PLM Terms You May Hear  Core Team, Core Team Leader  Concurrent Engineering  Cross-functional  ECO/ECN//PCN/PCR – C=Change  Go-to-market – “Everything else” required for launch (Product Manager responsibility)  IPP – Integrated Project/Program Plan  Program/Project/Product  PAC – Program/Project/Product Approval Committee  Phase/Stage  Phase/Stage/Gate Review  Pipeline Management – Align strategy with project/functional management  Product Launch  Time-to-market  xRD – Requirements Document, x= Concept. Product, Market, System, Software  xCD – Control Document, x=Specification, System, Software  SFS – Software Functional Specification  SDD – Software Design DocumentGeoffrey Hammett – 20120818 © 2012 34
    35. 35. Business Layer vs Technical Layer 1. Business Layer The Business Layer provides executive management visibility and control throughout the product lifecycle Concept Development Delivery Customer General End of Review Review Plan Shipment Availability Life Review Review Review Review Concept Plan Develop Validate Launch Sustain EOL 2. Technical Layer The Technical Layer enables the development teams to define, implement and execute throughout the product lifecycleBusiness Planning Program Plan Functional Spec Feature Test Finalize collateral Support Process EOL Development Development For release ProcessProduct Planning Integrate Features On-going Test System Definition Test Plan Finalize pricing Development And product codes Concept Test Strategy System Test and Requirements Definition Detailed Design Regression Release products Development Testing Code Development & Support Process Unit Testing Report and verify Team Reviews Field Validation - EFT/Beta Test Acceptance Testing Prepare for release Integration Plan DevelopmentGeoffrey Hammett – 20120818 © 2012 35
    36. 36. PLM Software Vendors  Autodesk - Autodesk 360 for PLM  Cyco  Dassault Systems – Product Lifecycle Management Portfolio  EDS PLM Solutions  Eigner  IBM PLM Solutions  MatrixOne  Oracle - Agile PLM  PTC – Windchill  SAP – Product Lifecycle Management  Siemens – TeamcenterGeoffrey Hammett – 20120818 © 2012 36