PRODUCT LIFE CYCLE MANAGEMET (PLM) IN ACCORDANCE WITH ISO 9001:2000 AND THE IMPLEMENTATION AND INTEGRATION BY THE CAD SOFTWARE PACKAGES IN THE CURRENT ENGINEERNG INDUSTRIES. 1
1
VIREN P. PATEL, 2 PROF.NILESH PANCHOLI
M.E.[CAD/CAM] Student, Department Of Mechanical Engineering, INDUS Institute Of Engineering And Technology, Ahmedabad, Gujarat 2
Professors, Department of Mechanical Engineering, INDUS Institute Of Engineering And Technology, Ahmedabad, Gujarat 1
[email protected], 2
[email protected]
ABSTRACT – In the current era of the QMS in engineering industries ISO 9001:2000 certifications is vital. All requirements of this International Standard are generic and are intended to be applicable to all organizations, regardless of type, size and product provided. For the design and the development the product life cycle management is essential, in this paper we will be discussing the PLM in the ISO 9001:2000 and the software packages that can be useful to implement the PLM. Where any requirement(s) of this International Standard cannot be applied due to the nature of an organization and its product, this can be considered for exclusion. Where exclusions are made, claims of conformity to this International Standard are not acceptable unless these exclusions are limited to requirements within clause 7, and such exclusions do not affect the organization's ability, or responsibility, to provide product that meets customer and applicable regulatory requirements.
1. Introduction - This International Standard specifies requirements for a quality management system where an organization a) Needs to demonstrate its ability to consistently provide product that meets customer and applicable regulatory requirements, and b) Aims to enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system and the assurance of conformity to customer and applicable regulatory requirements. The General requirements for the QMS stated in the ISO 9001:2000 are The organization shall establish, document, implement and maintain a quality management system and continually improve its effectiveness in accordance with the requirements of this International Standard. The organization shall
a) Identify the processes needed for the quality management system and their application throughout the organization b) Determine the sequence and interaction of these processes, c) Determine criteria and methods needed to ensure that both the operation and control of these processes are effective, d) Ensure the availability of resources and information necessary to support the operation and monitoring of these processes, e) Monitor, measure and analyze these processes, and f) Implement actions necessary to achieve planned results and continual improvement of these processes. These processes shall be managed by the organization in accordance with the requirements of this International Standard. Where an organization chooses to outsource any process that affects product
conformity with requirements, the organization shall ensure control over such processes. Control of such outsourced processes shall be identified within the quality management system. There is certain documentation need and which is required to be prepared and the documentation need of the ISO 9001:2000 systems related to design and development. By using the CAD software packages the need of the documentation can be fulfilled and traceability of the system is maintained. The software packages we are going to discuss are 1. PDM wind-chill form the Parametric Technology Corporation 2. Team Center by Siemens
Planning output shall be updated, as appropriate, as the design and development progresses.
•
Design and development inputs
Inputs relating to product requirements shall be determined and records maintained (see 4.2.4). These inputs shall include d) Functional and performance requirements, e) Applicable statutory and regulatory requirements, f) Where applicable, information derived from previous similar designs, and g) Other requirements essential for design and development. These inputs shall be reviewed for adequacy. Requirements shall be complete, unambiguous and not in conflict with each other.
2. Product realization steps in PLM
•
In the PLM in ISO 9001:2000 we will focus on the clause no 7.3 Design and Development, it Includes the
The outputs of design and development shall be provided in a form that enables verification against the design and Development input and shall be approved prior to release. Design and development outputs shall a) Meet the input requirements for design and development, b) Provide appropriate information for purchasing, production and for service provision, c) Contain or reference product acceptance criteria, and d) Specify the characteristics of the product that are essential for its safe and proper use.
•
Design and development planning
The organization shall plan and control the design and development of product. During the design and development planning, the organization shall determine a) the design and development stages, b) the review, verification and validation that are appropriate to each design and development stage, and c) The responsibilities and authorities for design and development.
•
Design and development outputs
Design and development review
At suitable stages, systematic reviews of design and development shall be performed in accordance with planned arrangements a) To evaluate the ability of the results of design and development to meet requirements, and b) To identify any problems and propose necessary actions. Participants in such reviews shall include representatives of functions concerned with the design and development Stage being reviewed. Records of the results of the reviews and any necessary actions shall be maintained Fig 1 Quality Management System. The organization shall manage the interfaces between different groups involved in design and development to ensure Effective communication and clear assignment of responsibility.
•
Design and development verification
Verification shall be performed in accordance with planned arrangements to ensure that the design and development outputs have met the
design and development input requirements. Records of the results of the verification and any necessary actions shall be maintained
•
Design and development validation
Design and development validation shall be performed in accordance with planned arrangements to ensure that the resulting product is capable of meeting the requirements for the specified application or intended use, where known. Wherever practicable, validation shall be completed prior to the delivery or implementation of the product. Records of the results of validation and any necessary actions shall be maintained
•
Control of changes
design
and
Fig 3. Windchill user interface The change management workflow of the Windchill system is satisfying the needs of the ISO TS and the ISO 9001:2000 which is showing in the fig 4.
development
Design and development changes shall be identified and records maintained. The changes shall be reviewed, verified and validated, as appropriate, and approved before implementation. The review of design and development changes shall include evaluation of the effect of the changes on constituent parts and product already delivered Records of the results of the review of changes and any necessary actions shall be maintained
3. PLM covered in CAD software •
PDM Windchill by PTC
As an integral component of PTC’s Product Development System, Windchill manages all product content and business processes throughout the product and service lifecycle
Fig 4. Change work flow in WindChill Change terminology for the WindChill with the description is narrated in the Fig 5. That clearly affirm the change control and the change management system required by the ISO 9001:2000 system.
Fig.2 Part Relationship diagram windchill
Fig 5. Change Terminology in PDM Windchill
•
Fig 6. Windchill Product lifecycle Lifecycle management is about work processes, specifically the product development process, as much as it is about data management. PTC has published the Value Roadmap to show how companies can link their business strategies to their product development initiatives. As a part of their process orientation, PTC is structuring product offerings to support best practices across the product lifecycle (Figure 6). In support of this, they have developed a methodology to assess the maturity of best practice adoption in three key technology areas: product development, quality, and platform. The product development best practices are focused on design and collaboration. Quality is focused on incorporating quality planning tools into the product development process. Platform is focused on product development process and product architecture. Four levels of maturity measure the use of best practices. The first level is defined as ad hoc, with best practices being used inconsistently. The remaining three levels are defined by more and consistent use of sophisticated best practices from the PTC Value Roadmap. PTC has associated the best practices with a series of products that support them. A company can assess their maturity level by comparing their processes with those on the roadmap and by reviewing their software inventory and its utilization to support best practices. Just because a company owns the software for a specific maturity level does not mean they are operating at that maturity level. The data obtained from this type of assessment can help define a specific product development process improvement roadmap for a company
•
Team Center By Siemens
The core of Teamcenter was developed internally by Siemens PLM. This includes core foundational capabilities such as:
Engineering data management (MCAD, CAM, CAE, ECAD, and software) • Document and information access, navigation • and retrieval • Change management • Classification management • Structure management • Digital validation • Design in context • Integration with multiple MCAD tools • Audit management • Information security • Issue management • Workflow management However, as with all comprehensive PLM solution Suppliers, other capabilities were incorporated into the overall offering through the acquisition of technology or licensing/partnering to obtain the desired functionality. For Teamcenter, these areas include: • Visualization • Requirements Management and Systems • Engineering • End-user Requirements Management • Project Management • Digital Manufacturing • Portfolio Management • Compliance • Maintenance, Repair and Overhaul • Supplier Relationship Management • Community collaboration Teamcenter 8, first released in March of 2009, is the Culmination of many years of steady development and evolution of the Teamcenter suite by Siemens PLM. It is built on the latest IT technology with a unified SOA and all modules share a common data model and database. It is designed to enable Siemens PLM and its customers to configure and more easily expand Teamcenter’s functionality today and in the coming years. Teamcenter includes three foundational areas: • Enterprise Knowledge Foundation • Platform Extensibility Services • Lifecycle Visualization Teamcenter also contains fourteen functional areas: Supplier Relationship Management • Systems Engineering and Requirements
• • • • • • • • • • • • •
Management Manufacturing Process Management Simulation Process Management Maintenance, Repair, and Overhaul Reporting and Analytics Community Collaboration Mechatronics Process Management Engineering Process Management BOM Management Compliance Management Content and Document Management Formula, Package, and Brand Management Portfolio Program Management
o •
•
•
Improve product price competitiveness
Keys to Success: o Effective configuration management o Life characteristics status of equipment and parts o Establishment of service knowledge environment Results: o Improved equipment efficiency and productivity o Reduced maintenance and repair costs for crucial parts o Increased casting equipment availability o Improved product quality o Transformed from strength in manufacturing to strength in both manufacturing and manufacturing services Client's Primary Business: Baosteel is China’s most competitive iron and steel enterprise producing carbon steel, stainless steel and special steel products that are widely used in many industries.
4.2 Bühler Motor
Fig 7 Product structure in Teamcenter
4. Case studies and the Conclusion 4.1 Baosteel Group ( Siemens Teamcenter) Baosteel virtually eliminates downtime, reduces costs and improves part availability, Shanghai Baosteel Industry Technological Services Co., Ltd. (Baosteel), part of Baosteel Group Co., Ltd., adopted product lifecycle management (PLM) technology from Siemens PLM Software for its maintenance, repair and overhaul (MRO) needs • Challenges: o Improve and prolong the service life of mission-critical spare parts o Reduce downtime, improve equipment productivity o Improve the quality of equipment maintenance services o Reduce maintenance costs
Bühler Motor Uses PTC Windchill to Manage R&D Process Bühler Motor is a pioneering manufacturer of small brushed DC motors and electronicallycommutated (EC), brushless motors. Today Bühler Motor’s expertise extends far beyond DC and BLDC motors, gear motors, water pumps and auxiliary water pumps. Pro-ducts and services range from the deve-lopment and production of challenging actuators via software and electronic con-trollers to injection molded plastic parts, allowing Buehler to be a single source for your complete drive system. • Business Drivers: Bühler Motor needs to make sure it has the right drawings and specifications at the right time and the right place • Solution: Working with INNEO, an authorized PTC Reseller, Bühler implemented PTC Windchill PDMLink, PTC Windchill PartsLink, and PTC Creo Elements/Pro • Results: o High level quality in the design process
o
Controlled and documented workflows from CAD all the way up to SAP
Conclusion - The principal role of Product Lifecycle Management (PLM) is to manage a product’s definition from concept to retirement. To be effective, PLM solutions must completely define all aspects of the product’s Bill of Materials (BOM) – including mechanical and electrical design files (MCAD, ECAD), software, documentation, and service information. PLM enables the definition and synchronization of cross-functional views of the BOM: engineering (eBOM), manufacturing (mBOM), and service (sBOM). Directly, PLM offers significant value to a company, but PLM also enhances other enterprise systems (ERP, CRM) by enabling the sharing of product information throughout the organization. The following business initiatives often represent the areas where PLM can offer the greatest improvement: • Global Product Development • Quality Management • Product Complexity Management • Program & Portfolio Management Deploying a PLM solution is often a complex, long-term program with multiple stakeholders and extensive requirements for process and technology change. To minimize risk and accelerate time to value, the most successful companies pay special attention to four critical success factors in planning, implementation, and adoption. Strategic business alignment: Investing in up-front planning and alignment around detailed implementation roadmaps and scorecards that help ensure program accountability for business value, not just technical improvements. Process-based solution design: Defining priorities for business process improvement and standardization, and then looking to software capabilities that support process change. The process leads and the technology follows. Reduced customization of PLM software: Holding the line on software customization to keep costs in check and preserve flexibility for future growth and change.
Comprehensive, role-based learning and adoption: Taking a strategic and role-based approach to learning and adoption of the new processes and tools, including ongoing communication about the value of change and customized programs for people and work groups with different roles and responsibilities.
5. Reference 1. 2. 3.
4.
5.
http://www.plm.automation.siemens.com/ http://www.ptc.com/appserver/wcms/casestu dies Windchill®: Managing the complete product lifecycle – from concept to service 6862-PTC Windchill Brochure0112-EN PTC Windchill Program Review – NovemberCIMdata, Inc. 3909 Research Park Drive Ann Arbor, MI 48108 +1 734.668.9922 www.CIMdata.com ISO 9001:2000 Quality management systems — Requirements Third Edition 15-12-2000
