PLMXpertCenter BV - Generic Integration Framework

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Figure 1 Methodology

“Generic Integration Framework” Introduction of a configurator more than a software challenge!

S.W. Verbunt BSc, G.J.H. Kroeze MSc (supervisor)

Master of Engineering, Hogeschool Utrecht, University of Applied Science

June 2010

Introduction PLMXpertCenter BV is a company with a 100% focus on the improvement of engineering- and Product Development processes in the industrial sector and is the official distribution partner for the Product Data Management (PDM) software PRO.FILE. A trend in the industry is the expansion of the use of sales and/or product configurators. In the field the terms sales- and product configurators are used interchangeably to describe computer systems used to configure a product based on the combined parts and their characteristics and to ensure compatibility between the chosen parts. Until now PLMXpertCenter BV had no standard module or best practice to interface with configurators. This article discusses the area of configurators in relation with the PDM system PRO.FILE. Or more in general: How can we use the functional model of the sales engineer over the entire lifecycle of a product in a managed environment? Methodology This research investigated all aspects of the problem (product, process and facilities) in the academic as well as the industry domain. Figure 1 gives a schematic representation of the used methodology. A case study in the industry domain has been used to determine the current situation (IST). A literature study in the academic domain was used to create a theoretical ideal picture for the improved situation (SOLL). A GAP analysis has been conducted in order to determine how the theoretic ideal picture could be translated into reality. In order to reflect this research with actual market circumstances a questionnaire has been developed [1]. The first part of the questionnaire is based on the IO-scan [2] and is used to measure the current performance among customers of PLMXpertCenter BV. The second part consists of specific questions about products, process and facilities in relation with configurators. The questionnaire provided an increased understanding of the market and is used to create a link between the academic and industry domain.

Abstract: Introduction of a configurator (PCF) is definitely not a pure process or ICT problem. It is an interrelated problem which requires an integrated approach which takes all aspects (product, process and facilities) into consideration. The Generic Integration Framework takes all these aspects into account and provides an integrated approach for Engineering To Order (ETO) companies. This new approach supports ETO companies which are considering the use of a configurator to deal with the sometimes conflicting requirements of today’s buyer’s oriented market.

PLMXpertCenter BV - Generic Integration Framework

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Figure 2 Integrated design map improved situation

Results In today’s market the supply driven sellers market of the past has been replaced by a demand oriented buyer’s market [3] [4]. In this market Engineering To Order (ETO) companies are dealing with a conflicting set of internal and external requirements. From a market point of view there is a wish for large variety with short delivery times and low prices. On the other hand the internal organization prefers to reduce risks and uncertainty by decreasing the variety and increasing the product price and delivery time. The analysis of the current situation (IST), identified several disconnects from a product, process and facility point of view. These disconnects revealed that it’s not a pure process or ICT problem, but that we are dealing with an interrelated problem which requires an integrated approach which takes all aspects (product, process and facilities) into consideration. Product: An absence of a proper managed standard at one or more levels of the design complexity (e.g. component, module and product) and the ad hoc application of design strategies (e.g. top down, bottom up and variant design) lead ETO companies to a situation of an unmanageable variety. In the Generic Integration Framework a well defined modular product structure is used to reduce internal complexity while keeping the flexibility to meet specific customer requirements [5]. Application of reverse engineering (translating physical structures into functional structures) and capturing these structures in a single model provides the contents for a possible configurator. Process: Ad hoc project management, pushing information through the process and a lack of knowledge reuse prevent ETO companies in exceeding the control levels as-performed and as-managed of World Class performance [6]. In the Generic Integration Framework a multi process organization is introduced, which split the ETO process in separate processes for standard, generic and special products. A formal decision early in the process is used to determine which strategy, Configure To Order (CTO), Tailor To Order (TTO) or Develop To Order (DTO), is required to meet a customer requirement. Cross functional communication is improved by managing the process and the information using formal knowledge milestones (e.g. as proposed, as designed, as built and as maintained). In this way information and knowledge is made explicit and it can be extracted and reused in order to serve as companywide standards which are manageable with ICT.

PLMXpertCenter BV - Generic Integration Framework

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Figure 3 Possible scenarios

Facilities: After rationalizing the product and redesigning the processes it’s time to investigate to role of ICT. Traditional PDM systems focus on geometric representations (CAD) and physical structures (BOM’s). These systems are insufficient to support a product configuration process, because valuable product knowledge is buried in documents and there is no management for product rules and constraints within PDM [7]. In the Generic Integration Framework a configurator is proposed to automate parts of the design process (CTO/TTO). The configurator requires a tight integration with the PDM system which serves as the product master model. There are two possible scenario’s; separate configurator with integration to PDM (1) and an embedded configurator in PDM (2), see figure 3. Both solutions are capable in supporting CTO, TTO and DTO. Conclusion This research showed that the introduction of a configurator requires an integrated approach which takes all aspects (product, process and facilities) into consideration. Introduction of a well defined modular product structure is the first step in reducing internal complexity while keeping the flexibility to meet specific customer requirements. The introduction of a multi process organization makes it possible to combine the efficiency of standard and generic products with the flexibility of specials by indentifying the appropriate strategy (Configure To Order, Tailor To Order or Develop To Order) early in the process. Finally a configurator with a tight integration with the PDM system can be used as a tool to automate repetitive parts of the design process (CTO/TTO). References [1] Verbunt, S.W. Generic Integration Framework – Optimizing the business performance by integrating products, processes and facilities. Thesis, Master of Engineering, University of applied Sciences Utrecht, 2010. [2] Reader IO Consortium. IO-Scan Kwalitatief meetinstrument voor het bepalen van de innovatie positie in organisaties. [3] Womack, James., Jones, Daniel., Roos, Daniel. The machine that changed the world. New York, 1990. [4] Eerens, F.J. The synthesis of variety, developing product families. Proefschrift, 1996. [5] Mesihovic, Samir., Malmqvist, Johan. Product Data Management (PDM) System Support for the Engineering Configuration Process – A position paper. Berlin, 2000. [6] Kroeze, Jan. IO-landkaart: Model voor het positioneren van verbetertrajecten in de organisatie richting kenniseconomie. [7] Zhang, Jinsong., Wang, Qifu., Wan Li, Zhong Yifang. Configuration-oriented product modeling and knowledge management for made-to-order manufacturing enterprises. 2003. [8] Zaal, Tim. Integrated design and engineering, as a business improvement process. First edition, Hoorn, February 2009.