The document discusses the integration of Product Lifecycle Management (PLM) with shop floor operations, highlighting the shift from traditional design/build processes to a more comprehensive approach that includes design, simulation, validation, and automation. It emphasizes the importance of validating the as-built products against the as-designed specifications to ensure manufacturing accuracy and efficiency. Additionally, it outlines the evolving tools and technologies that facilitate this integration and the need for manufacturers to adopt a more holistic view of product and process design throughout the lifecycle.

1. Integrating PLM with Shop Floor
Operations:
Validating As-Built to As-Designed
Dick Slansky
Senior Analyst
ARC Advisory Group
dslansky@arcweb.com

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© ARC Advisory Group
Evolution of the Design/Build Process
90s
Integration of Production
Process Design and Shop
Floor Operations
80s 2000 2008…..
3D
Digital Mockup
Digital Manufacturing
3D User Experience
2D
TechnologicalAdvance
Design, Simulation,
& Validation of
Manufacturing
Processes

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Today’s PLM: Holistic Approach to Product & Process
• Product, Processes, & Resources have become
“Virtualized”: 3D Experience from Concept to Customer
• PLM Scope has expanded: Design/Build has become
Design/Simulate/Validate/Automate/Build
• PLM Solution Sets Interface with most Enterprise Business
Solutions: ERP, SCM, EAM
• Digital Manufacturing Solutions Extend Virtual
Manufacturing Processes to the Factory Floor
• Integration of PLM with Operations Mgmt Validates the
As-Built to the As-Designed
• Validation of As-Built Product Closes Loop between the
Virtual Build and the Physical Build

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0% 10% 20% 30% 40% 50% 60% 70%
3D CAD
Product Data Mgmt (PDM)
Project/Program Mgmt
Parts Fabrication (CAM)
Product Test (CAE)
Mfg Process Mgmt (MPM)
Knowledge-Based Engr. (KBE)
Digital Manufacturing
2D CAD
Service/Support/Content Mgmt
What PLM Solutions Companies are Using
Growing Adoption Rate

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0% 10% 20% 30% 40% 50% 60% 70%
Mfg Process
Definition/Creation
Process Planning
Production Mgmt/Shop
Floor Execution
Workcell/Production Line
Simulation & Validation
Automation & Controls
Simulation & Validation
Not Important
Somewhat Important
Important
Essential to MPM/Digital Mfg
What is the Importance of Digital Mfg & Shop
Floor Operations Requirements?

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 Manufacturing Planning
• Define High-Level Manufacturing Processes
• Process Planning (Assembly & Installation)
• Define Work Instructions & Work Flow
 Detailed Process Design & Analysis
• Detailed Resource Modeling & Simulation
• Process Definition and Validation
• 3-D Factory Layout
• Equipment, Tool & Fixture Simulation
• Ergonomic Simulation
 Validation & Virtual Commissioning
• Control Logic Simulation & Validation
• Kinematic (Robotic) Simulation & Validation
• Quality Assurance/Process Improvement Validation
• Sensor/Metrology Placement Validation
• Virtual Commissioning & Validation of Automation Systems
• Knowing that the Production System Works Prior to
Launch: Priceless.
Digital Manufacturing Covers the
Entire Build Process
3D
3D

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Digital Manufacturing Enables Product &
Process Validation
• Product Design (CAD) tools
are used to define “What" is
to be built
• Manufacturing Process
Design tools are used to
define “How" it is to be built
• Integration of Product &
Process Design directly
supports concepts such as
Concurrent Engineering &
Mfg Process Validation
Digital Manufacturing facilitates the Holistic
view of Product and Process Design as integral
components of the overall product life cycle

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Integration of PLM and Shop Floor Operations
Enables Validation of the As-Built Product
Managing the Manufacturing Process
 Integration of Product Design with Mfg Processes (Digital Mfg)
Enables Production Management & Shop Floor Execution to be
Integrated with the PLM Solution Set
 Manufacturing Process Design coupled with Digital Mfg
Simulation Integrates the Definitions of the
Product, Processes, Factory, and Resources into a
Comprehensive and Consistent Manufacturing Solution
 Manufacturers want a more direct and horizontal integration
between their PLM/PDM design/build environment and their
shop floor operations. PDM Integration with ERP is not bi-
directional

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Shop Floor Systems Should be an Extension of PLM
Manufacturing
Processes
Product Lifecycle Processes
Create
Processes
Plan
Processes
Simulate & Validate
Processes
Execute
Processes
Digital Manufacturing Solutions + MES
As – Built RecordsEngineering Design
Validate
Design Simulate Automate BuildValidate

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Tailored Work Package
• Process Configuration
• Work Instructions
• Work Flow Routing
• Operations Scheduling
• Shop Floor Requirements
• WIP Tracking
• Process Control
• Quality Assurance
• Labor/Parts/Tooling
PLM Integrated with Shop Floor Execution
PLM
Process
Creation
Product
Design
• E-BOM
• M-BOM
• Bill of Process
• Product Config.
Maintenance
& Support
“As Designed”
Product Data
Production Mgmt
Shop Floor
Execution
(MES)
“As Built” Records
“As Designed”
Process Data
ERP

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Closing the As-Built to As-Designed Loop
FEEDBACK LOOP: Operations Mgmt/PDM Integration
Product & Process
Reqmts: As-
Designed
Simulation Analysis Validation Execution
(Build)
Knowledge:
As-Built Records
Manufacturers Want to Know they are Building
the Product they Designed

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CAD
Product Design
Process Models,3D
Simulations, Work Order
Instructions
Process
Execution
Shop Floor Execution (MES)
Quality
Assurance
Unit Data &
Work History
Data Vault
3D Models
E-BOM Process
Modeling
Digital Manufacturing/MPM
Process
Simulation & Validation
Process
Planning
Inventory
Mgmt
Work Orders
Release & Status
Financials
Invoicing Shipping
Labor
Reporting
Receiving
Parts
Purchasing
ERP
Production
Scheduling
Work Order
Release
Work Order
Status
Material /
Parts
Job Sign
On/Off
Digital Mfg + Shop Floor Execution = Validation
of As-Built to As-Designed
Closing the Loop From As-Built
Records To As-Designed
Master Routings, M-BOM
E-BOM
PDM
Product Data Management
Collaborative

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What are Manufacturers Using for OM/MES
Today and Plan to Use in the Future
0% 10% 20% 30% 40% 50% 60% 70% 80% 90%100%
In-house developed custom solutions
Vertical Industry Solutions from
OM/MES application providers
OM/MES solutions from Automation
provider
OM/MES solution from ERP provider
OM/MES solutions from PLM provider
OM/MES solutions from Supply Chain
Mgmt provider
Current
Future

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At What Stage are Manufacturers with PLM-
OM/MES Integration
0% 5% 10% 15% 20% 25% 30% 35% 40% 45% 50%
Operations/Inspection Records Interface
with some Engr/Business Systems
Operations/Inspection records do not
Interface with any Engr/Business Systems
Have some limited connection between
Work History (Operation/Inspection)
records and PLM/PDM
Have basically closed the loop between As-
Built and As-Designed
Have an accessible Data Repository for
Operations/Inspection (As-Built) records
Best Practice

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0% 10% 20% 30% 40% 50% 60% 70% 80%
Work Flow Routing
Work Order (WIP) Tracking
Quality Assurance Mgmt
Operations & Inspection Records
Production Data Acquisition
Product Tracking & Tracing
Tooling Mgmt
Future
Currently
What Shop Floor Operations Interface with
your Engineering/PLM Solutions?

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What Business & Engineering Systems do your
Operations & Inspection Records Interface with?
0% 10% 20% 30% 40% 50% 60%
ERP
PDM (As-Designed Source)
Other (In-House Systems, etc.)
SCM
CRM
Best Practice

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Effective & Efficient Use of Digital Mfg & OM
Tools: Guidelines for Users
 Integrate Use of DM Tools into the Manufacturing Design Process
• Set and Implement guidelines for application of DM technology
• Provide DM training for Mfg Engineering Discipline & Resources
 Emphasize Re-use & Commonality
• Re-use dependent on a strategy of Common Process design
 Reuse of Virtual Processes is a Key Enabler
 Establish a Library of virtual production systems & equipment
• Use modular approach for efficient use of Virtual Simulation
 Establish basic Virtual Production Equipment building blocks
 Build Virtual Production Systems with Common Virtual Equipment
 Integrate DM Tools with Shop Floor Operations
• Virtual Models Developed & Maintained by multiple engineering
disciplines (Product, Manufacturing, Tooling, Controls)
• Use Latest Production Process Data for Virtual Simulations

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Thank You.
For more information, contact the author at
dslansky@arcweb.com or visit our web pages at
www.arcweb.com