Finally Succeeded - PLM Implementation!!

Most of PLM blogs tells these days whenever I come across any PLM blog posts about PLM, the first impression I get is that PLM Implementations are  real challenge to take and nothing but failures. There are many blogs which say where, why and how it fails. But there are no PLM blogs ever address these implementation failures or real needs/requirements of PLM Projects.

I get clear understanding that organizations need to implement PLM to address their challenges and later issues will be solved. Is it really true?

PLM Vendors, PLM Implementing teams and PLM Customers need to set a process of implementation usually, what should be the methodology? What should be the road map? Which people are required at many stages of PLM Implementation? Those I already mentioned in my previous posts.

Many have worked on various PLM tools over various domains; I worked in PLM implementation for Plant Design domain and I just want to highlight success stories of my two implementations after all discussions over failures, difficulties and limitations.

I have worked for a client in Energy and Plant Design domain, an EPC compnay, on

Enovia SmarTeam Implementation integration with CATIA V5 for Energy Plant Design industry: where I have got breakthrough and is stating as follow

Project & Technical Lead Role:
Participate in client discussions, understand problems faced by client and articulate same to internal stakeholders to develop effective solution.

>Bring in best practices of industry and provide options & Develop proposal.

>Prepare As-Is and To-be documentation, Technical Scope preparation.

>Provide inputs based on secondary research in Clients Environment.

>Give inputs on solutions; based on areas of expertise.

>Conduct product demonstration and Training on PLM product with Acceptance test Plan document and configuration as per Technical scope.

>Analyse the requirements by demonstrating strong process, solution & product knowledge, IT scenario, implementation and technology constraints, look at end to end perspective with implications in related functional & product areas.

>Lead solution in all engagements and review work of team members as per project schedule.

>Plan activities for configuration, conduct conference and prepare configuration and Project completion Report.

>Customer offline Technical Support & Troubleshooting
Accomplishments:
*Plant Design Layout methodology Establishment in ENOVIA SMARTEAM system,
*Full CATIA Catalogue Management with ENOVIA SMARTEAM,
*CATIA Piping Design Integration and Management with ENOVIA SmarTeam,
*CATIA HVAC, Electrical & Civil Structure Module ENOVIA SMARTEAM Integration
*Brought in Best working Methodology

It is almost two years project and after all initial difficulties, failures; the implementation  went successful and live 1.5 years back and still as of today it is working fine and I am very happy to state here that Implementing ENOVIA V5 SmarTeam and CATIA V5 integration in Energy and Plant Design domain is first in the history and its working fine.

Bye for now,

Anil Kumar J R

People's PLM mindset

Many people assume that PLM is a magic tool that will establish huge ROI once after installed in an organization. It is truly wrong view developed with many organization management people over various sections of PLM focuses.  As per my knowledge PLM domain need vast experienced and visionary people to carry forward the project implementation, unless it would be dead investment. Also it is not so easy to execute the flow process throughout the life cycle of PLM projects in any department of organizations. It is my view that what I observed in two implementations with two minds set people and how it impacts the vision of PLM chooser. It is not only responsibility of the top management to have visionary goal to establish strategic PLM tool, it is also responsibility of each and every senior technical management team and engineers to work collaborative involvement to provide right requirements and questions to address their departments obstacles effectively. The main challenge is to identify the challenges in daily work area rather than finding out unplanned solutions without robust system in place. Mainly one should always think about saving the wastage of time, energy, resource, cost with quality output product, in such cases we can build the vision of PLM implementation.

Constraints for these visions are to have gripped technical awareness over the particular industry domain with knowledge of managing of Data and resource transparently, securely and collaboratively physically and over virtually. 

Bye for now, 

Anil Kumar J R

Challenges – starting PLM Projects till Rollout and Go-Live

Previous posts were discussed on PLM, start of PLM implementation till Roll Out of project. While executing the project most of the PLM vendors will face many challenges, I just want to record the challenges what we faced in two implementation for typical domains, one in Thermal Power Energy & Plant Design Organization and another one Mid-sized Mechanical Design and development for Defense products and automotive supplier Organization.

Ø  Lack of preparations and sudden call to start the PLM Implementation.

Ø  New domain and cumbersome Plant Design process of execution

Ø  Very tight project schedule to complete implementation as per the PO size.

Ø  No prior case studies and expertise guidance in the combination of chosen PLM tool and Plant Design domain.

Ø  Social responsibilities and other organizational regularities.

Ø  Pressure to meet over promises and commitments in presales phase.

Ø  Management Mind set about old PDM system and new PDM system.

Ø  Very beginning of project and no clear visionary path and objectives to drive and setting project best methodology.

Ø  Prestige and Egoism issues between many people, lack of openness, blame games etc.

Above challengers are common in the PLM implementation and we handle effectively the above stoppers, then confidently PLM implementation will be succeeded.

Bye for now,

Anil Kumar J R

Testing Environment and Deployment of Production database of PLM configuration Go-Live phase

As discussed in last post PLM service vendor develops plan of architecture of PLM system, hardware setups and other security prerequisites and later once all set in, the test Database which included OOTB offerings of PLM tool and the special functional Requirements can be customized in the tool as agreed at the scope sign-off level by both customer and service vendor. Once Test DB configured fully, service vendor will start test the system rigorously to get the output properly and effectively in front of customer’s representative. In case if any issues or miss-matches found during the testing phases will be recorded and again discussions will be done to settle out the required solutions and configuration. Once both Customer and Service vendors agreed and sign-off on the Testing Acceptance Certificate, vendor will plan for configuring the Production environment. This phase will take minimum one month to six months depending upon the Technical Scope and functional requirements in the respective organizations.

Deployment phase comes once after testing done and both representitive will be present while deploying the testing configured Database to production environment. Testing Environment database can be replicated to Prodcution ENvironemnt and in most of the PLM systems this the case and the fully tested and approved configured database will be replicated to Production environment to establish strong and robust system in place. Again after deploying Production system, one more round of testing with respect to functional, performance, hardware, will be done till it comes to level of declaring the production system is live and ready to work with users. This phase takes again a month of time depending upon the number client setup and functional setup. Once Server application, database server, vault server, PLM client installations & configurations, Integrations, etc. are completed, training will be given on functional scope of Imlemented PLM system. Once Training completed and users feel comfortable to start work in the system the service vendor will declare PLM Implementation is completed successfully and Proejct is Roll Out and its Go Live, it should be sign-off mutually to agree the project is Live phase.

Depending upon the project and its situation we can set this Go-Livep hase, service vendor will provide handhold support to users at cleitns premises for two to three weeks or a month as decided by both.

Bye for now,

Anil Kumar J R

PLM Implementation Configuration Plan

As we discussed in previous post  As-Is and To-Be process document, which will be base for Technical Scope for whole project, including all the technical statement of work, functions and way of execution of the things are going to implement as per organization’s requirements. Once detailed technical scope is prepared by PLM vendor and it will be submitting to Organization’s team to review and approval. This will be reviewed and modified several times by both PLM vendors and Organization teams to get into good technical scope before starting up configuration phase of PLM tool.  Once after sign-off for Technical Scope done, vendor should plan configuration plan with the Project Manager and other technical experts in place.

PLM Configuration Phase contains:

Ø  PLM Architecture and networking Plan

Ø  Hardware and Software Requirements  

Ø  Database configuration Plan and Precautions

Ø  Details Technical functionalities coverage

Ø  Technical Experts Resource Planning

Ø  Test Environment Plan

Ø  Certificate and Deliverables

o   Test Plan with scenarios

o   Sign-off certificates

o   Installation sign-off

o   Acceptance Test Plan

o   Change Request forms

Next we can discuss about testing and deployment phase

Bye for now,

Anil Kumar J R



As-Is and To-Be Process after Requirement Phase

As we discussed in last post, after requirements captured by all cross functional teams in the organization, it is very important to develop As-Is process documentation.As-Is process is working methodology of an organization at present without any new system implementaion. Once As-Is process document is ready, submit it to management team for review. Management team should review the As-Is process document and reviewed process should be used to create To-Be process with respect to captured information by the organization and PLM tools offerings. It is very important to prepare first level To-Be process document before starting project and organization people and PLM service vendor both should again review To-be process together. To-Be process documents should include the future PLM system technical scope which will be implementing after mutual agreement between both organization and PLM service vendor.

To-Be process is a document which should clearly indicates what and all PLM functionalities will be implemented as per organization requirements, if some of requirements are not able to implement at present chosen PLM software then those functionalities should be clearly mentioned with proper workarounds or customized ways to get it done to match organization’s requirements. And To-Be process document is overview of scope of work document before elaborating the technical scope document of whole PLM implementation project.

Simple Example:

As-Is process:

a.       At present Engineers are generating Part Numbers manually in excel sheet and later entering Part Numbers from excel sheet to CAD model and Drawing manually.

To-Be process:

a.       Automatic Part Number Generation module will be built in out of the box PLM system offering as per Number Logic.

b.      And engineers will use this function to generate Part Number directly in CAD tool and later assign to new CAD Model and same way another Part Number will be generated for respective drawing automatically.

c.       In case of complicated Part Number generation and other reference variable Part Number logic, customization needs to be done and same will be evaluated later.

Some the PLM vendors prepares whole Project Plan before proceeding to requirements phase and some vendors develops Project Resource and Time plan after To-Be process signed-off by the organization team. Both the way is suitable as per their internal process. We developed Project Plan before and after To-be process sign-off again we changed some the Project Plan in our Project.

Next post we can discuss how the technical configuration plan can be preparation and how we can start PLM software configuration.

Bye for now,

Anil Kumar J R

Understand and Capture Requirements across X-functional Teams

As we discussed in previous post about PLM Implementation and egoism, it kills the whole project jointly. The first and most important phase to post sales of PLM tool is to “Understand and Capture Requirements across cross functional Teams in the Organization”. What does it mean by “Requirements” in PLM and how we can define requirements? , are the main concerns.  Requirements come from any organization and its management from beginning of its product establishment. I meant to say every organization have their own objectives with respect to their product output that as product should be Qualitative, competitive, economical, market best etc.

While fulfilling these objectives there are lot of challenges to overcome and for any organization there is a need of strong solution to overcome challenges around the way of their product development. To setup a strong solution in place organization must know their necessity, needs, wants to match and establish a solution to make work to overcome challenges. 

Collecting information on the above said necessity, needs and wants are called as Requirements Phase. As PLM tool will be finalized based on organization basic visionary requirements and post sales of PLM tool is very much important to collect technical requirements across cross functional teams (Design, Production, Suppliers, Inventory, Sales etc.) to defines As-Is and To-Be process documentation which will help to define base of PLM implementation Scope as what and how to configure the PLM Software to address their requirements.

One simple live example from an Organization: Total 100 members in Design Department and in that 50 Design engineers are working concurrently on complex product assemblies and generates various types of 3D models and 2d Drawings with their standard Part Numbering system, having modification writes. 20 Engineers are working in Quality Departments and they check the models generated by Design Engineers only in viewers and do comments and notify design Engineers for changes, 10 engineers are from Supplier Coordinators and they responsible for BOM generation and 10 people are Team Leads they acts as reviewers and for all deliveries from Design Departments and 10 people Project Managers which they approve the Design and delivers to Production Team. Design engineer should send their work to review Team Leads after QC and TL will review for accept or reject. Mangers to approve finally to Production Manager.

In the above scenario we need to identify every need of engineers to fulfill their working ways and it should increase the productivity and efficiency while working with PLM system,

Design Engineers needs various Attributes to create a 3D model, Unique Part Number, User friendly working methods, secured data to save in central server, better performance, quick sharing and viewing others design data, drafting standards in 2D, attributes mapping to 3D to 2D, various drawing templates, BOM generation templates, various report formats, quick viewing of reports, Reviewing workflows, quick change communications, change history track for future references, various reviewing processes: Check Process, Change Request and Order Processes, Release Processes, BOM creation & Modification processes etc.

Collecting all the above important requirements and need to develop As-Is process to get to know the To-Be process. This phase is the first step for good start up of PLM Implementation.

Next post we will discuss about what is To-Be process and how we can build it.

Bye for now,

Anil Kumar J R

Need Management Engagement instead of involvement - PLM and EGOISM

As we discussed in last post regarding PLM Implementation processes, we need to understand engagement of management in PLM Implementation in which it goes towards successful PLM Implementation. PLM is continuous change and continuous improvement system in an organization, where there is change there will be uncommon difficulties comes up. For example in an Organization that too in a mechanical industry, people working from long time with their fully adjusted processes and working styles are more focused to work as they work from long time. When PLM comes into picture there will be surely some process developments and working procedure changes happens. And in most of the cases people are definitely not ready to accept the new CHANGES. Here is EGOSIM comes into picture that Technical people (Tech Leads, Senior Engineers, Technical Managers, Engineers) demands and thinks that thier process is fine and PLM should work as per their process and procedure.

Off course Organization's present process and procedure might be perfect and in most cases it should needs to be tuned to give more productive results. In that case senior level management should engage in defining the requirements, processes development and methodologies as per their strategy by considering joint working the Implementation service vendor. Otherwise the whole PLM implementation mgiht go in wrong path and finally it goes huge loss to organizaiton and repetitive work to carry to come back to correct way.

And main focus in this early phase of Implementation is, key technical persons from management team should have proper understanding of their organization strategy in their area (Design Team, Sales team, Production Team etc.) and some amount of PLM domain knowledge will be added advantage. Defining proper AS-IS process and TO BE processes along with proper Technical Scope in carrying out good PLM implementation is foundation for whole PLM project and it is responsibility of both management and service provider to come up with rigors engagament and discussions across cross functional teams.

If it is new domain to establish PLM system, then for both management and service provider complexity increases and important is to understand PLM tool from management team and as well it is more important to understand new domain for PLM Implementation service provider.

In a real case example where I started a PLM implementation for an organization where it was new domain (Plant Design for Energy Industry) in our area and as well new to organization.

Domain knowledge is key factor to carry out any PLM implementation as working processes are entirely different for various industries, as I was from Automotive and Machine Design Background and Plant Design doamin was totally new to me, and the Implementation Project plan was very tight, I would have to complete in tight time plan. And project started with requirements capturing AS-IS Process across cross functional team and later defined Technical Scope, as mentioned before we both were new to domain and after lot of discussions, analysis we started configuring the Testing database for the same. Due to tight schedule, unclear understanding of processes and poor engagement of management, PLM Implementation completed with no use. Even though there was lot efforts and time spent on the project, it was driving in various directions. Finally it was failure of project. As management was telling this was the way we have to go and we service provider stating management was wrong. In between Clients and Vendor lot of miss-communications, Technical EGOSIMS and lack of doamin knowledge, no idea of objective of PLM in Plant Design, and bad project preparations made Implementation went into bad shape.

We will discuss how we over come with this situation and finally how we succeeded in bringing the PLM implementation to succes right path.

Bye for now,

Anil Kumar J R

PLM Implementation Processes

Last post conveyed How PLM Implementation starts and who involved in starting the process, we discussed things mainly presales of PLM software. Once an Organization buys software, post sales activities are very important in PLM implementation, now we can discuss PLM Implementation Processes and its phases.

Once after sales, management will plan the activities and day to start PLM Implementation by diverse meetings with PLM Software Vendor / Implementation service vendor to understand tool and to provide the requirements.

Some Service vendor (Seller) will circulate Questioner as per understand with their sales team to Organization Management calling as Client (Customer) and, Clients reply for the Questioner as per their strategy and plan to implement PLM tool.

After several discussions and mutual understandings Implementation date and plan will be ready.  This Project plan majorly contains, Resource Allocation, Activities and Time plan, Statement of Work, NDA, Separate commercial Proposal (Implementation Service charge including tax if not decided at presales order). 

There are few phases in the PLM Implementation and it includes different processes which needs to be addressed successfully, following are main phases of PLM Implementation,

1.       Interaction and Requirements phase

a.       Understand the vision/objectives of the organization strategy

b.      Interact to cross functional team to understand the requirements

c.       Gather the requirements and start preparing AS-IS process documentation

2.       Study & Analysis

a.       Study & Analyze the present system with respect to bought out PLM system

3.       Technical Scope definition  

a.       Define the Scope of Implementation

b.      To-Be process preparation

c.       Sing-off both sides 

4.       Technical execution Planning

a.       Plan the activities and define roadmap of configuration

b.      Define Baseline and Methodologies

c.       Sign-off

5.       Implementation and Configuration

a.       Installation & sign-off

b.      Test Environment configuration & sign-off

c.       Test cases preparation & sign-off

6.       Testing phase

a.       Testing with Vendor’s & Client’s representatives

b.      Sign-off

7.       Production Environment

a.       Configure Test Environment to Production Environment

b.       Pre-production test & sign-off

8.       Roll Out and Go-Live

a.       Deployment and Rollout

b.      Sign-off

9.       Training

a.       Users Training on Implemented functionalities

10.   Support

a.       User Handhold support

And I am collecting my own experience and processes followed in my two PLM Implementations and other service vendors might have different roadmaps and processes.

Next post we can discuss deep into each processes and phases.

Bye for now,

Anil Kumar JR

What, Why, When & Who will do PLM IMPLEMENTATION?

In previous post we discussed about the PLM architecture and different layers of modules and their connections as Multi-Tier architecture. Now it is time to know what this PLM Implementation is? Why we need it? When we need it? Who will decide and choose it? And where it will be implemented and finally who will implement PLM tool across an organization? Lot of questions,,,, and answer is here,

Firstly what is PLM Implementation?

Implementation is very simple term that execution of things/tasks. PLM Implementation is carrying out and establishment, setup, configuration of PLM software tool and its modules across an Organization's departments to address their needs to get more profit.

Many companies develop and markets PLM software solutions. These companies’ develops PLM solutions as per different engineering domains requirements across the globe to fit into organization business strategic plans. There are various PLM software tools available in market which will suitable for an organization different working domains, such as Automotive, Aerospace, Energy, Process, Machinery etc. PLM software will be built for these work and processes as per their domain standards.

One industry example: Automotive Industry uses more into APQP and Change Management Processes and for these PLM software modules addresses the best in practice APQP standard processes and related activities; all these processes developed in PLM software and kept as ready to use solutions. And PLM software companies markets & sales these solutions for Automotive Industry Organizations.

How organization will come to know there is need of a PLM Tool?

Earlier days there was not much digital work mode i.e. most of the design and planning work was doing by manually and in turns prone to more human errors. And also in any engineering work; there is recurrence of task is common.

Example1: document numbering: - Engineers were assigning doc number manually for all the parts and document in the design department mandatorily for identification purpose and there was no other way around; users manually had to write or fill the document number, it was really very much common error creating & repetition of work daily.

Example2: All engineers were working in different regions and locations and they didn’t have proper communication between them and there was always duplication of work and no transparency, its caused huge cost for an organization.

Few Visionary People in an organization had thought on these issues and thinking to automate to replace manual works daily to reduce human errors and to reduce time consumption and make them work with centralized data for better communication and transparent way of work to avoid duplication of work. These are few good examples to understand how PLM domain started evolving in all the way of Product Development Processes to get rapid ROI and profit oriented processes.

Now visionary management decided to address above said problems with strong system in place. They started making strategy and finding possible ways to trading off wastage of resources, time, miscommunication and they wanted to build their strong system in their Product Development Stage to give qualitative product output with Faster Design to Market Plan.

So what next, started finding suitable software to address all the above said requirements and with respect to Business and Technical Challenges what we discussed in earlier posts, then PLM software came into picture. Management started looking and approaching to different PLM vendors in the markets, discussed the problems and solution needs with PLM vendors. Finally compared various PLM software tools, their effective solutions to problems, services & supports, cost etc. At the end management finalized suitable PLM software to implement in their organization as strategic Business Tool.

In next post we will discuss How PLM Implementation starts and PLM software post-sales activities?

Bye for now,

Anil Kumar J R

PLM system - Multi-Tier Architecture

Friends,

  

In previous posts we discussed about the overview of PLM, its functions and its path to reach organization’s strategy. Now it is time to understand the technical background of PLM architecture so that it will be helpful to understand the PLM implementation and configuration methodologies in Engineering Domains. As you know PLM tool is a platform for various software tools and varied technology base of an organization and it interacts with different departments in by integrating people and process by the base of centralized and single source of data concept. Now a day’s almost all PLM tools are Multi-tier Architecture.

Multi-Tier architecture is very simple to understand that there will be different Computer server machines connecting each other to run the various modules of PLM tools, let’s say main PLM software for an organization need to serve in different departments requirements and strategy, so there are various modules are split as software modules with respect to varied needs, example: for design department, engineers need CAD software and to manage CAD data there will be s module called PDM CAD Integrations in PLM software, it will mainly manage the data generated from CAD departments. To manage the various BOM; PLM BOM modules will address, for connecting suppliers; PLM Suppliers integration modules, to manage whole project; PLM Project Management modules will address, to work online; PLM Web modules, to store all the information there should be Data Base software to PLM tool integration, to store all the files saving in PLM system there will be File servers.

Like these there are various other modules to address whole Enterprise Requirements, to enhance performance and build strong PLM system, its divided into different layers of PLM modules as Multi-Tier architecture, whatever the configurations and setup of PLM system is in one layer called Servers and the same will reflect to front end users called Clients by connecting through LAN/WAN, this we called 2 Tier Server & Client Architecture, now adding to that there will separate Server Machine to manage the Meta information of data in Data Base Server and all other application services will be installed in one server machine called  Application Server and it will control the other  module  of PLM tools,

And also PLM connects external and internal employees together with same Network WAN/firewall Layer, totally we called PLM System as Multi-Tier Architecture by combining different PLM modules in various servers and network connection.

In next post we will discuss what PLM Implementation is and how it will implement? Who will define the strategy to select PLM to address solutions?

Bye for now,

Anil Kumar J R

How PLM acts as a Business Strategic Tool ?

As we discussed in last post about PLM core areas and PLM tool covers all the important departments in which a Product is going to be produced in an Organization. Hence it is proved that PLM tool is a platform to integrate people and different software tools in different departments with varied technology base.

So from beginning there is a statement repeatedly stating in most of the posts that PLM tool is Business Strategic tool which helps the organization to reach its vision and Rapid ROI. How PLM tool will help to achieve it?

Answer is very simple that,

·         PLM establishes a “single source of truth” in an organization across its Product information and there will be a collaborative working environment between other departments (Project Team, Concept Group, Design Group, CAD group, Analysis Group, Testing Group, Suppliers,  Prototype Group, Manufacturing Division, Inventory, Assembly, Sales and marketing department etc) hence effective communication and sharing of knowledge with transparent data flow which helps management to take quicker decisions on faster Design to Market strategy.

·         Engineers are assigned with well-planned and defined work break down structure so that exact work engagements without confusion.

·         Tracking of activities and quick identification of hurdles in between work to come out quick delivery.

·         As data is more transparent and exposure to concerned Engineers which will develops innovation in thinking in product development.

·         Secured project based authorization and hence safe IP.

·         Quicker communication to suppliers and later tracked change management

·         Saving more time by effective attribute and query based search options.

·         Complicated BOM generation processes and management integration with manufacturing and suppliers group.

·         No repetitive and duplication of data and work hence more into time and cost savings and quicker qualitative output w it  less errors as there is planned WBS and centralized data flow

By concluding all the above points there will be much more savings in time and money hence it will directly impact the Organization’s Business growth by Rapid Return on Investment.

Above few points are with respect to Product Development processes in an organization and managing with a PLM tool tells how a PLM tool acts as a Business Strategic Tool with rapid ROI.

In next post we will discuss, How to Implement PLM tool in an Organization? and What is the process of Implementaiton of PLM?

Bye for now

Anil Kumar J R