Clarity on PLM

A quick peek into some research on … designing products for environmental compliance from our 2009 report. And maybe more importantly, here is the link to participate in the 2011 study on designing for compliance, cost, and sustainability. This year, I am expanding the research to recognize the trade-offs sometimes required between cost and compliance. Please share the link with your friends in engineering and manufacturing.

Note: For my blogging friends and those in the press, let me know if you are interested in helping gather responses, I will return the favor with some contributed content.

Research Findings – 2011

OK, it is a trick heading. There are no findings yet, take the survey and help me gather a broad perspective on the issue. If you are a consultant or a vendor, please feel free to pass along the link to an engineer or manufacturer. I will share some of the data back on this blog in return.

Research Findings – 2009

One of the most interesting findings from the last report was the broadening view of sustainability. The focus on environmental compliance information was getting the most attention in data collection from suppliers (no surprise) but the growth in focus on a broader view of sustainability was much higher (including carbon footprint, energy usage, waste/recycling). We are looking into that question again in the current survey, it will be interesting to see what has changed in the last year or so. See more of the report findings in my post on making environmental product compliance sustainable.

Cost and Sustainability

I have written about compliance before, and the need to reduce the compliance tax on product innovation. While the prior survey focused primarily on environmental product compliance, the research shows a growing interest in sustainability. But the business reality is that compliance and sustainability can’t always command a higher price, so companies have to continue to focus on controlling product cost to be commercially sustainable. You may have heard my views on designing for product cost and product cost management (PCM) before, it is something I am passionate about. So now is the opportunity to look at these issues in a holistic way.

So that was a quick peek into some recent research on compliance and a request for help in learning more, I hope you found it interesting. Let us know what it looks like from your perspective.

Please feel free to review more free research and white papers about PLM and other enterprise software for manufacturers from Tech-Clarity.

A quick peek into some research on … the benefits and savings available from consolidating onto a common CAD package in your business. Tech-Clarity Insight: Consolidating CAD – Benefits of a Unified CAD Strategy explores the strategic and operational benefits of leveraging a single package. As the research concludes, “… not all businesses have the opportunity to unify their CAD solutions … but there are multiple advantages for those that can.”

The Research Findings

The paper addresses benefits including enabling strategic initiatives and simple cost reduction. Strategically, a single tool can help support business strategies like a “design anywhere – build anywhere” approach. The report also explain how utilizing a single tool can help promote design reuse and simplify collaboration. Of course the biggest benefit may come from the ability to enable a more strategic, integrated PLM environment. These solutions typically involve a suite of pre-integrated solutions that are tailor-made for each other. 

The report also details the very tangible reductions in total cost of ownership for the CAD solution. By evaluating a multitude of cost drivers, the report suggests a framework and a sample set of calculations to quantify the cost savings available from consolidation. Some of the cost drivers are obvious, while others may be more subtle. For example:

• Removal of redundant CAD licenses (ok, no surprise yet)
• Reduce cost of upgrading software tools (maybe less obvious?)
• Eliminate need to develop training for redundant solution (maybe you wouldn’t have thought of this?)

See the report for a more complete listing and an educated (and conservative) example of the cost savings available. While the strategic benefits are compelling, many companies today may consider this strategy simply to achieve leaner IT overhead for their engineering software.

Implications for Manufacturers

What does this mean for manufacturers? I discussed that question with Paul Hoch, Team Leader of Product Engineering Services for lighting solutions manufacturer Zumtobel AG. He echoed a number of the benefits in the report, including cost savings and explaining that they “don’t get the full benefit from <their> 3D CAD models” without PLM. But the most strategic benefit Paul discussed was corporate flexibility, which is critical as companies try to survive in difficult, global markets.

“Our common tool is the basic infrastructure that allows us to make quick decisions on product and plant locations, it provides management with the flexibility and agility they need.“

I am not sure I can add anything more to the power of that statement, other than to suggest again that many companies may pursue consolidation for much more tactical reasons.

So that was a quick peek into some recent research on consolidating CAD, I hope you found it interesting. Does the research reflect your experiences? Do you see it differently? Let us know what it looks like from your perspective.

Please feel free to review more free research and white papers about PLM and other enterprise software for manufacturers from Tech-Clarity.

What I learned this week … is that product cost is not getting the attention it deserves in PLM. I was presenting on the future of PLM in a PLM-focused event last week in Helsinki. My topic was the future of PLM, and I based my discussion on the four dimensions of PLM expansion (recently updated past post). I got a great question from one of the participants. He wanted to know “why I hadn’t included cost in the future of PLM?“ My response? Good question!

Product Cost in PLM

Product Cost Management (PCM) in PLM is something that I used to bring up on a regular basis. Design for cost is an important initiatives. Particularly as companies are trying to remain lean in uncertain economic times, controlling cost is critical. Even in good times, designing products with optimal cost structures is hugely important to driving high profit margins. So why has this dropped off of my radar? Is the problem being addressed? Is the problem solved? No.

The problem still lingers, but I haven’t seen as many companies willing to try to address it. Perhaps this complicates the roles of ERP and PLM, and companies don’t want to deal with a hard decision on which system supports which part of the process. ERP and PLM both have the potential to help, and should be a part of the solution. But neither ERP nor PLM are ready to take on the PCM challenge fully.

• ERP
  • Has historic costs
  • Understands multi-currency, locations, volumes, other sourcing factors
  • Generally handles cost for the execution of procurement and manufacturing
• PLM
  • Has new parts
  • Understands product content early when costs are locked into designs
  • Generally handles product development decisions in the innovation lifecycle

So each system has some thing to offer. So why instead of addressing this properly with the right combination of ERP and PLM, do companies continue to use masses of disconnected spreadsheets to solve the problem? At least I can hope that they are managing the spreadsheets in PLM so it is readily available and can be reused. But that is only a partial solution. We need a better answer.

Challenges

ERP and PLM both bring value as seen above, but both fall short. Here are some of the issues:

• New purchased parts - ERP is not involved in the early parts of design, and doesn’t help with estimating costs of new parts. PLM (for the most part) doesn’t have a rich enough model for sourcing. I have seen “cost” as a single field too many times, without any concept that the cost will change based on volumes, locations, currencies, etc.
• Newly engineered parts – For brand new parts, there is not historic data to work from. Costs need to be developed based on product characteristics like materials and manufacturing complexity. Comparisons can help, but ERP typically doesn’t know enough to determine which parts are similar in their construction

Who will step up?

Are vendors ready for this? Agile has had a cost model for some time. Siemens partnered with ATK. Dassault Systemes invested in this area. PTC just announced that their InSight product analytics product will address cost. So there is hope. There are also specialty vendors like Akoya and aPriori that help engineers estimate cost based on product attributes. Why haven’t SAP PLM and Oracle (with Agile and ERP) done something about it?

More importantly, are manufacturers ready? Adidas CIO mentioned Design for Cost at a PLM user conference (PTCuser) yesterday. But I don’t hear it often enough. I haven’t seen the momentum that something as important to profitability as cost deserves.

Implications for Manufacturers

If manufacturers aren’t willing to integrate cost into their design processes (and PLM), they will be stuck with spreadsheets. And actually, the question was broader. The question also addressed other financials in addition to cost. For example, is PLM addressing product pricing? Product forecasting? While I think that it makes sense for PLM to address this, I have seen little activity in this area to this point. What a shame. What a great opportunity for someone to step up.

So that is my rant for today, I hope you found it interesting. Why did this fall off of my radar? Did it fall off of yours? Have you done something to address this? If you did let us know about it!

A quick peek into some research on … the technology behind PLM applications, and what today’s CIO needs to know to support it. The research from Tech-Clarity, Enabling Product Lifecycle Management: The CIO’s Guide to Supporting a PLM Initiative,  points out unique implementation and support challenges the CIO and their team must be aware of in order to get the most business value out of PLM.

The Research Findings

The CIO’s organization is getting more involved in PLM implementations. While many Engineering IT teams have managed CAD and other engineering software and supporting infrastructure, PLM is getting more attention from the enterprise IT team because it has become – (wait for it) – an enterprise application. I know, it only makes sense. Implementing enterprise class applications has different considerations than installing design tools, and enterprise IT typically has more experience with systems that span the organization and the supply chain.

Having said that, PLM is not ERP. Nor is it CRM, SCM, or any host of other business-oriented enterprise applications. PLM, by the nature of the processes and data it addresses, comes with some unique information technology challenges. Here are some of the considerations discussed in the report:

• Protecting IP – PLM data is concurrently highly confidential, and much more valuable when shared broadly. Intellectual property is more likely to be shared as collaboration expands, and a lot of that collaboration is outside of the control of the corporate firewall.
• Huge Files – Engineering and product development data is different than large volumes of transactional data. There are some potentially significant issues arising from managing and collaborating on large files in order to support PLM.
• Scalability – PLM is expanding to more people, a broader view of the product, to more of the product lifecycle, and supports more processes. Implementations needs to plan for expansion along multiple dimensions, which could potentially create an exponential demand on IT infrastructure.
• Architecture - PLM vendors are moving to enterprise architecture, providing support for the challenges above but also introducing new challenges. The good news, though, is that these challenges are ones that the many corporate IT groups have already addressed.

PLM also brings about integration challenges. Companies have to be ready to support frequent, bi-directional, real-time integration between PLM. If not in the first phase, potentially sooner than they think. See more on ERP-PLM integration in the Evolving Roles of ERP and PLM report and Mythbusting ERP-PLM Integration post. PLM integration with ERP and the rest of the manufacturing systems ecosystem is becoming more important and more prevalent.

Implications for Manufacturers

The good news? The PLM industry has learned from large scale PLM deployments, and has developed technology and best practices to address these issues. IT professionals today are not blazing the trail when they implement PLM. PLM is becoming much more mainstream. But it is also evolving to more of an enterprise application than just product data management (PDM), and moving into the enterprise realm. There is help available, from peer manufacturers that have undergone the transiiton and experienced consultants alike.

So that was a quick peek into some recent research on getting PLM technology right, I hope you found it interesting. Does the research reflect your experiences? Do you see it differently? Let us know what it looks like from your perspective.

Please feel free to review more free research and white papers about PLM and other enterprise software for manufacturers from Tech-Clarity.