T-86.

5141
ENTERPRISE SYSTEMS ARCHITECTURE:

Product Data Management

Asko Martio
Variantum Oy, www.variantum.com
19.9.2006

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 Variantum Oy

New Finnish company, established 2002, 9 owners

Roots in Product Data Management Group (PDMG) of HUT,
established in 1992
First big project: EDMS for KONE Oyj, first remarkable document
management system in Finland. Today’s status: over 1 000 000
documents, over 3000 active users. PDM and configurable
product related research projects with approx. 20 Finnish
companies.
Best imaginable technological know-how
2 D.Sc. (Tech), dissertations within configuration domain, 1 Lic. Sc.
(Tech), 4 M. Sc. (Tech)
approx. 50 man-years of industrial experience in different management
positions
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 Variantum products

System products
VariSelect, Product family selection tool to highlight product
properties and their differences
VariSales, Sales configurator for sales order definition
VariProd, Production configurator that creates Bill of Materials
required by the specified product variant (configuration) for the ERP
system
VariPDM, PDM system for product, document, product model and
workflow management
Service and support products
Expert services for consultation, system training and implementation
After sales support services
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 Contents

References, terminology
Definition of PDM
Background, motivation for PDM
PDM Functionality
Architecture
Summary
KONE case

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 References

Kenneth G. McIntosh I. Crnkovic, U. Asklund, A. P. Dahlqvist

ENGINEERING DATA
MANAGEMENT
A Guide to Successful Implementation,
McGraw-Hill Inc.
Antti Sääksvuori, Anselmi Immonen
Tuotetiedonhallinta PDM,
Talentum Media 2002
Hannu Peltonen, Asko Martio, Reijo
Sulonen
PDM - Tuotetiedon hallinta,
IT Press 2002
M. Eigner, R. Stelzer
Produktdatenmanagement-Systeme,
Springer 2001
Product Data Management and
Software Configuration
Management, Artech House, Inc. 2003
John Stark
Product Lifecycle Management,
Paradigm for 21st century Product
realisation, Springer 2004
Rodger Burden
PDM: Product Data Management,
Resource Pub 2003
www.cimdata.com
www.pdmic.com

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 Terminology: PDM

PIM
PAM PLM PDT TDM
PDM
EDM TIM
cPDm Product Asset

Document Collaborative Management

Enterprise
Electronic Lifecycle Data
Engineering Definition
Technology
Information Technical
Almost any combination of terms is used, PDM (Product
Data Management) and PLM (Product Life-cycle
Management) seem to be most common
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 Definition: Product
Result of industrial activity
Product family, brand, model,
type, product class,
configurable product
Product configuration,
fixed product
Product individual
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general concept
abstract class (cannot
be manufactured)
concrete class
(can be manufactured)
physical artifact,
service activity
Copyright © 2006 Variantum Oy
Definition: Product Data (CIMdata)
All product related
information
Paper documents
Digital files:
Document files: specifications,
configurations, purchase orders
CAD drawings, models,
assemblies, parts lists
CAE analysis, NC programs and
plans
Information stored in data
bases
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PDM manages three different
product data life-cycles
Product type life-cycle:
product development
approval and change processes
beginning and end of production
Product individual life-cycle:
engineering
production, maintenance, recycling
Product process life-cycle
Copyright © 2006 Variantum Oy
 Definition: PDM

ISO 13584-10 Parts Library:

A representation of facts, concepts, or instructions about one or more
products in a formal manner suitable for communication, interpretation, or
processing by human beings or by automatic means.
Crnkovic, Asklund, Persson Dahlqvist (2003):
PDM is the discipline of controlling the evolution of a product and
providing other procedures and tools with the accurate product
information at the right time in the right format during the entire Product
Life Cycle
PDT (Product Data Technology)-advisory group:
Product Data Technology includes all aspects of the definition and
methods of processing information pertinent to product throughout its
development and operational lifecycle.

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 Definition: PLM (CIMdata)

What is Product Lifecycle Management

(PLM)?
A strategic business approach that applies a
consistent set of business solutions in support of
the collaborative creation, management,
dissemination, and use of product definition
information across the extended enterprise from
concept to end of life –– integrating people,
processes, and information
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 PDM system status today

PDM systems coverage is more restricted:

Current PDM systems do not include commercial data (stocks,
purchase orders, invoices, cost accounting, etc.) of the company.
They are managed by Enterprise Resource Planning (ERP)
systems.
Main interest of PDM lays on product support processes (R&D,
etc.)
Many PDM systems do not support configurable products and
product individual and production process life-cycles
PDM system does not create new product data

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 PDM motivation:
Changing business environment

Increased competition
Global markets, aggressive market behaviour
Shrinking budgets, lower production costs
Products are becoming more complex, exploiting more
technologies and built in vast number of variants
Quality requirements (ISO 9000 etc) and customer responsiveness
are increasing
Global manufacturing (expanded teaming)
Government and industry standards
Less time and money for hassling
Requirement for more efficient R&D: Concurrent Engineering
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 PDM motivation:
Data integration by system integration

Design/Engineering Purchasing & Finance

Project
CAD
Management

Manufacturing
MRP System

Production
Process/Plant
Sales/Marketing
Customers & Customer Service
Suppliers
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 PDM costs and benefits

PDM system benefits

direct cost savings
faster time-to-market benefits
change management savings
indirect cost savings
improved quality
other savings
PDM system costs
hardware, software licences
system tailoring, system integration, installation, training
system maintenance

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 PDM Benefits, example

Metric Standard C.E. Delta (%)

Design Hours 5337 5929 4460 16%/25%
Span Time (months) 21 19 11 48%/42%
Tooling Costs $79,461 $49,993 $42,057 47%/16%
No. Changes (15 mo.) 16 24 6 63%/75%
No. Changes (30 mo.) 22 28 6 73%/79%
No. Quality Reports 23 37 4 83%/89%
No. Waivers 36 40 2 94%/95%
Mark Knodle, General Dynamics
Space Systems Division

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 PDM market forecast

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 PDM biggest vendors

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 PDM end user investment

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 PDM Functions

Item and Document Product Structure Workflow and Process

Management Management Management
SPEC ECO ECO
NC

3D Drawings/Documents

+ Support utilities

Classification
& Retrieval
Little
Screw

support As PDM becomes

partno Length implemented across
different industry sectors,
axy1234 10 mm

Program
zvy3245 20 mm
dgf2345 30 mm

Management functional priorities change.

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 Data vault
Central storage for
Documents
Product configuration data
Product model data
Product individual data
Maintains revision and status
data (e.g. electronic approval)
Files (drawings, documents,
etc.) are managed as “objects”
Check-out and check-in control
Query, browsing and reporting
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Benefits
Secure, distributed storage of
data
Elimination of redundant files
Managed data sharing among
team members
Managed electronic review and
approval
Management of data
relationships
Based often on commercial
relational data bases
Copyright © 2006 Variantum Oy
 Data vault

Object: Document
Date: 1/1/95
Project: Motor
Part #: 8893-0A
Revision: 2.3A
Document #: 4569-29
File: A:\PDM\doc\motor\...
Application: MS-Word 6.0

Meta-Database

Managed referenced files

data

PDM Server

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 PDM items

Item definition PDM corner stones

Items from the PDM point of Item categories
view are those product
related business objects Physical items
which are frequently referred systems, assemblies, parts,
in product related processes, components, accessories
e.g. products, materials, Document items
documents, resources,
Product models and
activities. Use of standard
items makes management software
and business transactions Service items
easier

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 Item views
Life-cycle view
Item revisions
Classification (type) view
Classification according to
product properties
Classification hierarchy
Status view
Item approval level
Item efficiency
Language view
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Structure view
Structures dependent on
processes
Sales (offer, sales order)
structure
Design structure
Manufacturing structure
Delivery structure
Installation structure
Maintenance structure
Physical product structure
Functional structure
Spatial structure
Copyright © 2006 Variantum Oy
 Item classification

Required to search and browse items efficiently

Standards: ISO 13584 Part Libraries, IEC 61360 electric
components classification scheme standard
Examples:
Specifying code A Basic mechanical materials and
components
A2 Non-ferrous metals
− A20 Sheets and strips
• A202 Coated sheets and
strips
Parametric class hierarchy Fasteners (Length, diameter)
Screws (Length, diameter, thread length)
− Cross head screws (Length,
diameter, thread length, head diameter,
standard)

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 Basic item data

Identification Status (recommendation

Generally approx. 8 character
code
Classifying v. non-classifying
Local v. enterprize wide
Description
Generally approx. 40
characters of cler text
Classification
Helps to find items
Revising
Revising method
Revision identification
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class)
Manufacturers, vendors
Other data
Big systems: approx. 300
fields/item
Item is specified to the level
that is required by its user
Reference documents
Copyright © 2006 Variantum Oy
 Item revisions

Warning: there is no approved terminology

When an item is changed a new version, which is also an item,
is created. It is
Revision. An item of this type is generated to replace its predecessor
immediately or after a transition period. Therefore, the new revision
must be compatible (form, fit and function) with its predecessor.
Variant. Variant concept is sometimes used for products, parts and
items with small differences. An item in this group is related to a
higher-level product type.
Independent item. An item in this group is neither a variant nor a
revision of any other item. The relation to its origin is lost. Example: a
new independent product
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 Document management
Which document types?
Identification method for
documents, document revisions
and variants
Approval of documents
Security archives
Document tool integration to
PDM
WWW user interfaces
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Document structure
Document revisions
Document variants
Equivalence of documents written
in different languages
Multilingual documents
Subdocuments
Multipage drawings
Figure files
3D models
Representations
Original,, viewing and printing
formats
Copyright © 2006 Variantum Oy
 Product structure

Bicycle

1 2 1 2 1

Handlebars Pedal Frame Wheels Saddle

1 32 1

Tire Spoke Hub

Figure 2.5 Quantified BOM of a bicycle.

© 2003 Crnkovic, Asklund, Persson Dahlqvist, ”Implementing and Integrating Product Data Management and Software Configuration Management”

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 Product (breakdown) structure -
general
All structure items represent elements which can be delivered
with the product. They are often physically attached to it.
Product requisites like coatings, paints, welding wires, packages, adhesives,
lubricants, chemicals are often left out of product structures.
All items are identified with a code. A clear text description is
required as support information.
Physical products include only physical objects as components:
non-decomposable (atomic) component, e.g. bolt, integrated
circuit, cardboard package box, user manual
multipart component
subassembly, e.g. phone receiver
kit (group, no assembly process), e.g. installation accessories
other material, e.g. 50 m rope, 3 l oil
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most common views: product (design/manufacturing), location
Documents and product structures

Documents are linked to products:

Product - parts list, assembly drawing
Often this link is built into the identification system
Product - other manufacturing documents
Assembly instructions
Test instructions
Product specifications
etc.
Product - deliverable documents
deliverable documents are items in product structure
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 References

In addition to document links other type of items can be

attached to product structures
Product - jigs, fixtures
Product - tools
Product - embedded software
Product - NC software

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Product structure links, revisions

1 Quality
2 Attributes
3 Materials
4 Process

Revision A 1 Quality
2 Attributes
Revision A
3 Materials
4 Process

Revision B
Phone Receiver Assembly drawing and BOM

Revision A

Test Data
Revision A Revision A Revision A
Revision A
Revision B
Revision B
Analysis Report

Revision A

Marketing Definition

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 Modelling concepts

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 Workflow management

Defined and automated Change process phases

workflow/processes Change request (ECR,
By project, status level, product type, ... Engineering Change Request)
Sequential, parallel, conditional steps Internal and external product
claims and messages
Voting rules and time-outs
Change proposal (ECP)
Folder/package maintenance
Consolidation of change
Notification and distribution requests
Audit processes and actions “triggers” Evaluation of change effects
Process browse/reporting Change order (ECO)
Decided change actions
Only for stable processes
Change follow-up
Change management
Registration of accomplished
Document approvals actions
etc
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 Utility functions
Communications, E-mail
Data transport
Data translation
Viewing and annotation
Image services
Administration
System security control
System management
Password management
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Data security services
data redundancy, disk
mirroring
fault tolerant disks, RAID-
technology (Redundant Array
of Inexpensive Disks)
automatic back-ups
data encryption
Authentication services
Authorisation services
viewing authorisation
change authorisation
(approvals, document creation
and changes, etc.)
Copyright © 2006 Variantum Oy
 PDM system architecture

Application User PDM User

CAD/CAM, NC, Purchasing Multiple Applications
Documentation, Etc.
Private Files
CAD

data data WEB

control Object: Document User
Date: 1/1/95 Intranet
Project: Motor
Part #: 8893-0A
Meta-Database Revision: 2.3A WEB server
Document #: 4569-29
File: A:\PDM\doc\motor\... Managed Files
data Application: MS-Word 6.0

PDM Server
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 PDM system selection and
implementation
Project definition
Evaluation of the current
status
System scope definition
Prioritised requirements/
feature summary /
configuration plan
Short list selection evaluation
Request for proposals
Demonstration / benchmark
requirements
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Demonstration / benchmark
Evaluation
Reference visit agenda
Reference visit evaluation
Proposal evaluation
Pilot project definition
Pilot project implementation
log
Pilot project analysis (vs.
benefit targets)
Final evaluation summary and
report
Copyright © 2006 Variantum Oy
 PDM Summary

Organisations which do not take PDM seriously will face

difficulties
The following factors increase PDM importance:
organisation size
internationality
product complexity
number of product variants
PDM system implementation without management
support becomes a failure

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 Case: KONE Corporation

World’s fourth largest elevator company, onne of the world’s

leading escalator companies
Modernization and maintenance of existing systems account for
2/3 of the revenue
Growth from the automatic door service business
Present in more than 40 countries with some 800 service centers
Strategic alliance with Toshiba of Japan since 1998
Turnover: EUR 2,814 million
Personnel: 23,800 employees
Sales: 25,000 new elevators and escalators
Maintains about 520,000 elevators and escalators and more than
210,000 automatic building doors
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 KONE business environment

Distributed Order-Delivery Processes

Local front line companies (40 countries) and independent distributors for
sales, delivery, installation and maintenance
Global order engineering, production and logistics
A lot of the production subcontracted to partners
Service Business
Long life cycles of product individuals
ASEA-Graham Lift no 1: 1898
KONE Lift no 27: 1920
Service and spare parts Information must be available
Global, distributed, networked R&D
Global products with regional adaptations
R&D centers in all continents, complex, mass-customized products
A lot of subcontractors and partners involved in the R&D projects
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 Documents at KONE
Commercial Documents
Invoices, order confirmations, shipping
documents etc from ERP
Process and Quality Documents:
ISO9000 etc.
Project Documentation
Project Plans, Specifications, Meeting
Minutes
R&D Projects: Studies, sketches,
informal Excel lists of whatever
Order Projects: Tendering documents,
Order-specific drawings and
calculations
Training Material, Product, Process
and Organisational Training
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Product Documentation
Marketing Material (brochures etc)
Technical Instructions:
Planning (PG) and Sales (DL) instructions
Owners/User's manuals
Product Descriptions and Ordering
instructions (SO)
Installation instructions (AM)
Service, Maintenance and Spare Parts
Instructions (AS,AR)
Drawings
3D Models, Assembly and Part drawings,
Parts lists, Configuration Instructions
Testing instructions
Software Binary Files
Specifications, Certificates
Product Change Requests
Copyright © 2006 Variantum Oy
 KONE document management systems

Variantum EDMS (Engineering Data Management System),

(www.variantum.com)
KONE Global PDM System
Product Documentation: Drawings, Instructions, Certificates
Parts and Product Structures with documents linked into the structures
Engineering Change Management
Documentum (www.documentum.com)
Archiving of ERP data (old invoices etc.)
Production of technical instructions (XML-based information
management)
Management of some business process and quality documentation

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 KONE EDMS
Statistics (13.10.2004):
Number of documents: 953205
(New in 09/2004: 25000)
Number of parts: 286664 (New in
09/2004: 1600)
Users: 6396 (New in 09/2004: 96)
Document files: 320 GB (New in
09/2004: 12GB)
Users in 09/2004: 2950
Amount of data transferred over the
WWW interface: 1.5GB / day
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Software (Server)
Variantum EDMS Application Server
Database: PostgreSQL Version 8.0.3
WWW: CGI scripts written in the TCL
language (http://tcl.activestate.com/)
Full text indexing: Idzebra
(www.indexdata.dk)
Linux (Fedora Core 3)
Backup: IBM Tivoli TSM
Monitoring: Nagios (www.nagios.org)
Copyright © 2006 Variantum Oy
 KONE EDMS – Main screen

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 KONE EDMS- Drawing query

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 KONE EDMS- Query results

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