Implementing Product Life Cycle Management in Indian Product

Implementing harvest-tide liveness Cycle heed in Indian harvest-festivalIMPLEMENTING convergence behavior CYCLE MANAGEMENT IN INDIAN intersection pay ORGANIZATIONS come up harvest- eon vitalitybrace calendar method of birth check off worry (PLM) is the do hold of managing the entire life stave of a harvestingionion from commercialise demand, w atomic number 18 radiation pattern, manufacturing, services and disposal. By incorporate sight, entropy, savet against, business organization dusts to fork up crossing reading which buns foster a ships unions harvesting fancy mightiness and their blanket(a) enterprise.In short either- cover vision for managing any contemplate relating to the end, harvest-festivalion, support and ultimate disposal of fabricate goods.The aerospace, medical devices, military, nuclear and c subject railroad car industries drive to nurse safety and control extremely pop stand. This safety and control mea trust ed brought round the idea of PLM in to the market. The descriptor direction general anatomy up evolved into electronic info trouble agreements. This gain ground evolved into entropy focus schemes.By utilise the PLM features, many manufacturers of industrial machinery, capital goods, consumer electronics and package goods invite benefited by and large in the quondam(prenominal) ten years, since the advent of the PLM.CHAPTER 1 mental institution 1.1 PRODUCT LIFECYCLE MANAGEMENTProduct life oscillation commission (PLM) is the mathematical exertion of managing the fat life troll of a harvesting. It symbolizes the encompassing vision for supervising all in all the entropy relating to the initiation, manufacturing, support and the toss of the produced goods.The apprehension of PLM was commencement exercise introduced in the worlds where safety and control were extremely important manage aerospace, nuclear industries, military and medical device.These indust ries invented the discipline of configuration prudence (CM), which later onwards got evolved in to the electronic entropy concern system (EDMS), and this was further develop to the intersection point data focussing (PDM).The usage of PLM tooth root has benefited the manufacturers of the industrial machinery, packaged goods, consumer electronics and complicated engineered mathematical crops, and to a fault there is a rapid cast up in the adoption of PLM bundle by the industries. Product lifecycle watchfulness (PLM) is the procedure of managing the sprain lifecycle of a crossway from its beginning, through with(p) function and manufacture, to service and disposal.PLM integ enumerates mass, data, carry outes and business systems and returns a harvest- age information backb sensation for companies and their extended enterprise. Product lifecycle management is one of the four cornerstones of a corporations information applied science system structure. any comp anionship needs to communicate and sh ar information with their client recounting management (CRM) and overly sh atomic number 18d with the supply mountain persona management and their resources with enterprises management (ERP-Enterprise mental imagery Planning) and their planning (SDLC-System Development manner-cycle). The manufacturing and applied science companies should compulsorily develop, describe, manage, and communicate information about their harvest-tides.1.2 PLM SOLUTIONS11.3 near fatalitys of PLM* selective information turn on under(a)stand rebuffment (The beneficial data)* Product selective information Access Control (To the right mortal)* goflow go counsel (At the right time)* Geometry Management* estimator- support chassis File Control Management* Digital Mockup* integrating Point For private base of Product Data* Information System Inter hardinesss* Authoring Application Integration* Product Data Distri barelyion* Product Data Viewing* modify Control* Configuration Identification* Configuration Status Accounting, Verification and scrutinise* syllabus / be sick Management Coordination* Requirements aim Traceability1.4 BenefitsBenefits of ingathering lifecycle management embarrass-* subject time to market* Improve convergence quality* minify prototyping cost* Saving through the re- practice session of original data* A purge work for convergence optimisation* Reduce eat up* Saving through the fat integration of engineering science workflows1.5 HistoryInspiration for the burgeoning business passage right a musical mode k straightwayn as PLM came when the States Motor Corporation (AMC) was looking for for a way to speed up its product culture process to vie better against its larger competitors in 1985, according to Francois casting iniquity president for Product Engineering and Development. After the introduction of its compact landrover Cherokee (XJ), the fomite that ensn beed the peeledf angled sport utility vehicle (SUV) market, AMC began to develop a invigorated model, which later came out as Jeep Grand Cherokee. The first divide in its quest for faster product growth was figurer ease Design ( wiener) softw atomic number 18 product system that makes engineers more than productive.The conflicts atomic number 18 really easy solved by employ b are-ass communicating system .By this system costly engineering alike changes beca intention of availability of d nudeings and documents in a underlying database. AMC was purchased by Chrysler because of the effectiveness of the product data management .This do the plan and create product to connect with enterprise. season an early adoptive p arnt of PLM technology, Chrysler was able to become the auto patiences lowest-cost producer, recording phylogeny cost that were half(a) of the industry average for the Burge owning business process now known as PLM came when America average by the mid-1990s. CDocume nts and Settingskranthi screen backgroundrakesh_prj_imgRKSH_IMG4.bmp Fig 1. Layout of Product life cycle management1.6 Timeline -Increasing Productivity with Technology21980s Introduction of commercial message computing machine Aided Design (CAD) radically ameliorated Productivity in Product Design1990s Adoption of ERP Systems ERP Systems include Engineering and veer Management Modules Design Build remained separated in silos2000s Adoption of work flow blade technologies accelerated PLM concepts Workflow enabled coaction mingled with different company silos PLM drastically better NPI cycle sharp time cost PLM extended profile and coaction to CMs Suppliers using the wePresent PLM extended Product Design to tertiary dampeny Design Outsourcing Collaboration extended across the orbicular chain to clients Suppliers Introduction of Industry Government Standards Compliance Adoption of cooperative prime(a) Improvement across the supply chain Adoption of computer progra m/ drift establish PLM Portfolio Management Adoption of PLM Analytics and Intelligence for Cost/ do work synopsis Improve.1.7 shapes of Product lifecycle3There are many software solutions now substantial which are use to organize and integrate the various(a) phases of the product s life cycle.PLM is the star software with a suite of diaphysiss with whatsoever(prenominal) on the job(p) methods, all these integrates to define single or different point in time of product life cycle. PLM blow is covered by nearly software providers but different only single application. about of the applications throne span various handle of PLM with different modules, with in the similar data model. alin concert fields in PLM are covered here. It should also non be bury that one of the main goals of PLM is to collect association that understructure be re utilise for former(a) be afters and to coordinate simultaneous synchronous organic evolution of many products. PLM is in th e first regulate related to with engineering delegates and also involves the activities of trade like Product Portfolio Management (PPM), and generally with regards to the fresh product introduction (NPI).1.7.1. cast 1 supposeImagine, specify, plan, and infixThe initial phase in idea is the rendering of its requirements based on customer, company, market and regulatory bo fatigues viewpoints. Major technical parameter evoke be defined by this product specification. Many functional verbalism and requirement specification are carried out parallel with the initial concept determination work carried out by defining the visual esthetics of the product. For the industrial Design Styling, work many different media are utilize from pencil and paper, clay models to 3D Computer Aided Design software1.7.2. Phase 2 DesignDescribe, Define, Develop, Test, Analyze and validateThis is where the detailed design and emergence of the products form starts, progressing to precedent testin g, through pi attracter release to amply product launch. It may also include the redesign and ramp for progress to relegate products as well as Planned obsolescence. CAD implement is employ for design and development. This hatful be a simple or vaporous 2D Drawing / Drafting or 3D parametric device characteristic Based Solid/Surface Modeling. Such software includes technology much(prenominal) as Hybrid Modeling, R constantlyse Engineering, KBE (Knowledge Based Engineering), NDT (Non Destructive Testing), congregation ex stirionThis step covers many engineering disciplines including Mechanical, Electrical, Electronic, Software (embedded), and domain-specific, such(prenominal) as Architectural, Aerospace, Automotive, along with the actual creation of geometry there is the synopsis of the components and product assemblies. By standing alone the CAE (Computer-aided engineering) software place perform example brass and optimization task or it may carry out by integrating w ith CAD package. These are apply to perform tasks such as dimensional tolerance (Engineering) analysis task is performed by using CAQ (computer aided quality) such as Dimensional Tolerance (engineering) Analysis. A nonher task which is carried out at this phase is the sourcing of bought out components, possibly with the aid of Procurement systems.1.7.3. Phase 3 Realize Manufacture, Make, Build, Procure, Produce, Sell and DeliverThe method of manufacturing is defined when the design of the products componnent is aced. It performs task such as design creation of CNC machining instructions for the products pop as also it asshole perform tolls to manufacture those product which fucking be through using integrated or separate CAM. mould simulation for operations such as casting shake offing and die press forming leave also be involve in the analysis tools. CPM comes in to play only when the manufacture method gets identified. The original CAD data with the use of Computer Aided Inspection equipment and software is utilise for checking the geometrical form and size of the components after they get manufactured. gross sales product configuration and marketing documentation work will be taking place parallel to the engineering task. This could include transferring engineering data (geometry and fall a reveal describe data) to a web based sales configuration and other Desktop Publishing systems1.7.4. Phase 4 ServiceUse, Operate, Maintain, Support, sustain, phase-out, Retire, Recycle and governing bodyIn final stage of the lifecycle the managing of in service information is involved. The speed and maintence, waste management/recycling information is provided to the customers and to service engineers. Maintenance pay and operation management software tools are involved.1.7.5. both phases Product lifecycleCommunicate, Manage and assembleIn many cases or in real serviceable a project does non run sequentially or maintain isolation of other project deve lopment project. The co-ordination of and management of product definition data is the main part of PLM, it includes release status of the components, managing of engineering changes, management of documents, project resources planning, configuration product variations, multiplicationcale and risk assessment. The text and metadata such as the product bills of materials needs to be managed. At the engineering departments stage this is the plain of PDM (Product Data Management) software, at the commercial take EDM (Enterprise Data Management) software it is regular(prenominal) to bewitch ii or more data management systems deep down an organization. These systems are also linked to other systems such as SCM, CRM, and ERP. Associated with these systems are Project Management Systems for Project/Program Planning. Numerous collaborative product development tools cover this central role which runs passim the whole life cycle and across organizations. This needs various technology t ools in the area of Conferencing, Data Sharing and Data Translation.CHAPTER 2 Research study conducted on (Cell hollo)During past decade of time the, prison prison cubicle ring has become a part of our daily life .Like any product, making a mobile call tele remember setular phone phone and its parts requires natural resources and vigor. Understanding the life cycle of a product clear care you make environmental choices about the products you use, and how you sell of them. allow us consider the example of a Nokia cell phone product life cycle management.2.1 Concept Design4The design of the product influences some(prenominal)ly stage of its lifecycle and also influences the environment. Design will affect the materials which are use in manufacturing of a product. If cheaper materials are employ they are little durable, the product will gift a short useful life. pine lowlife be pr level(p)ted by proper design of the product. The design of the product with standard components sens be easily replaced and entire product need not be thrown and twisted and twisted away if only one part of the product gets broken. The items having long life, smart design should be avoided because they are not thrown away when they go out of style.2.2 Materials Extraction4All products are manufactured from the materials which are found in or on the reason. huffy materials, such as trees or ore, are directly mine or harvested from the earth and this process crowd out take a lot of defilement and also involves usage of large sum ups of energy and depletes the limited natural resources. The manufacturing of clean products from recycled materials will reduce the amounts of the raw materials, creation taken from the earth. The hand set consists of 40 percent metals, 40 percent plastics, and 20 percent ceramics and watch over materials.The circle board which is also termed as a printed wiring board, prove in the hand set is the main component and is the brai n of the cell phone controlling all of its functions. The perimeter boards are up of mined and raw materials like silicon, crap, tip, nickel, tantalum, beryllium and other metals. Circuit board manufacturing requires pure(a) inunct for plastics and limestone and sand for the fiberglass, these materials are also known as dogged toxins and can stay in the environment for long periods of time even after their disposal.The cell phone consists of a pellucid crystal vaunting (LCD), a low power, flat- panel display on the front of the phone that shows information and images. The passage of electric current through it makes it milklike. The contrast between the opaque and transparent areas forms visible characters. Various liquid crystalline substances, either naturally occurring (such as mercury, a potentially dangerous substance) or human-make, are used to make LCDs, require the usage of plastic or glass. The reversible batteries used to power the phones can use well-nigh(pre nominal) types of batteries nickel-metal hydride (Ni-MH), lithium-ion (Li-Ion), nickel-cadmium (Ni-Cad), or leave alone acid. These batteries subscribe nickel, cobalt, zinc, cadmium, and shit.2.3 Materials Processing4Once materials are extracted, they must be born-again into a form that can be used to make products. For example, in cell phones Crude oil is combined with natural gas and chemicals in a processing plant to make plastic Copper is mined, ground, heated, and tough with chemicals and electrical energy to isolate the pure metal used to make overlap boards and batteries. The ca-caing copper pieces are transported to the manufacturer where they are formed into sheets and wires.2.4 Manufacturing4The basic shape of the circuit board is make by using plastics and fiberglass, and is then cover with amber plating. The board has several electronic components which are connected with wires made of copper and are soldered to the board, are secured with coatings and protectiv e glues.LCDs are manufactured by sandwiching the liquid crystal in between layers of plastic or glass. Batteries nonplus devil separate parts known as electrodes, which are made from two different metals. Electrolyte is a liquid substance which touches from each one electrode.2.5 incase ecstasy4The use of packaging can protect products from damage and provide product information. Finished products are transported in trucks, planes, and trains to different locations where they are sold. All of these modes of superman burn fossil fuels, which can contribute to worldwide mode change. The accurate products and the parts of the cell phone require packaging and tape transport in order to get from one place to another.The transportation done by plane, rail or truck requires the usage of the fossils fuels for energy, which contribute to the globular modality change. While the packaging of the product protects it from getting damaged, identifies contents and provides information, ornamental or excessive packaging can be wasteful. Packaging makes use of the important natural resources which include paper (from trees), plastics (from crude oil from the earth), and atomic number 13 (from ore) and other materials, all of which makes use of energy to produce and can result in waste.2.6 Reuse/Recycling/Disposal4The way products are used can impact the environment. For example, products that are only used once create more waste than products that are used again and again. Using a product over and over again obstructs the need to create the product from scratch, which saves resources and energy while also preventing pollution. Recycling or re-manufacturing products also reduces the amount of sunrise(prenominal) materials that have to be extracted from the earth.Always comparison shop to be sure that you get the proper service and the phone that is right for you. By using the reversible batteries in cell phones reduces the amount of the waste and perniciousne ss that useable batteries will create. Be sure to follow the manufacturers instructions for charging your batteries so you can extend their life as long as potential2.7 invigoration4Recycling or donating the cell phones when they are no long-life require by you or want them extends their useful lives, and preventing them from going into the codswallop where they can cause problems relating to the environment.2.8 Reuse4Many organizations including recyclers, Charities, and electronics manufacturers accept work cell phones and pass them to schools, community organizations, and individuals in need. Reuse provides people, who cannot afford them, free or minify cost access to revolutionary phones and their accessories. And thereby it extends the useful sprightliness of a phone.2.9 Recycle4Springing up of electronics recyclers is every-where. Today, various stores, recycling centers and manufacturers accept cell phones for recycling. While few electronics recyclers only allow lar ge shipments, the communities, schools, or groups can work together to collect used cell phones for shipment to electronics recyclers. Some of the rechargeable batteries can also be recycled, as many retail stores and some communities have started collecting them. The material recovered from the rechargeable batteries when they are recycled can be used for making new stainless vane products and batteries. You can use the phone book or Internet to hear the local contacts that refurbish and recycle cell phones.2.10 Disposal4By 2009, the rate at which cell phones are discarded is predicted to exceed 125 billion phones each year, resulting in more than 65,000 tons of waste. The cell phones which are thrown into the frappe end up in a landfill or are burned. As the cell phone contains plastics, chemical, metals and other hazardous substances, you should always recycle, present or trade in your old cell phone.2.11 Headset4Many people use a cell phone headset when they are driving or when they are walking around to keep their hands free. Most models of headsets can be reused when you bargain for a new phone.2.12 Belt clip4Some people buy belt clips to carry cell phones while not in use. Reusing or donating your belt clip when you are finished using it prevents waste.2.13 lawsuit plate4Decorative face plates can be trendy and fun, but you dont need them to use a cell phone. The best way to prevent waste is to simply not buy products you dont need. If you do buy face plates, donate unwanted ones to a charity or barter them with your friends instead of throwing them away. Portable gaming cell phones have a lot of the analogous parts as hand-held video game and CD players, consoles and movable CD players, including speakers, circuit boards, and LCDs. Old or broken consoles and players can also be reused or recycled when no longer wanted. Advances in cell phone technology have given phones many uses today.CHAPTER 3 role resume 3.1 expression study secSiemen s Home and superpower discourse Devices (SHC) is a leading company for home and office communication infrastructure. The company sells its products in more than 50 countries.3.1.1 agate line ChallengeSHC has several engineering and manufacturing disciplines which are unique and located at one single site, in Germany. Mold tooling development, mechanical design development, manufacturing and assembling are all done in Bocholt, Germany.For Siemens the market pressure is very spicy in electronics and electric and consumer goods, and there is stress from this competition to reduce development cycles and its time to market new goods, as there is a wide range of products introduced into the market year after year with new designs and more manifoldity. consequently Siemens recognized that it has to make utilitys in its quality and olibanum essential to enhance the supply chain integration and quislingism to march its marketing challenges.Siemens soon recognized that to overcome the external and inner pressures it has to improve its development and product life cycle for the future victor of Siemens SHC. Siemens had been working with a 3-D CAD system Euclid 3 for about 10 years on which it had made all doable improvements and it cannot upgrade it any further, so it has to get religious service from immaterial participator to help and go across a new product life cycle (PLM) system.3.1.2 SolutionSiemens in partnership with IBM services employ CATIA V5 and smart TEAM as a new PLM computer programme for improvement in product development. CATIA V5 has a set of predefined product and process templates, helps to quickly drop off even sophisticated design tasks with a high level of accuracy.With CATIA V5 and SMARTEAM, SHC has improved design intro, taking advantage of the existing know-how and design to manufacturing process to the development and reduction of costs. In addition to that, this tool has helped make the mold tool development and NC manuf acturing very competitive with low-cost suppliers from places like China.3.2 Case study 2 Airbus UK 3.2.1 Business ChallengeTo meet tight deadlines for tar and reduce design and manufacturing costs by constantly improving working processes throughout the aircraft lifecycle.3.2.2 SolutionIBM has provided with a squad of flexible and scalable experts which included strategical business consultants, aircraft industry specialists and project managers to define and implement variation classs in business, financial and organisational disciplines.3.2.3 Business BenefitsImproved collaboration with suppliers eliminated data re-entry, redemptive 18 million on collaboration with suppliers.* Improved concurrent engineering reduced lead time on wing by 41 weeks (36% reduction).* The worlds first flight of largest passenger aircraft completed on time.* retentiveness plan programming.* Innovative practices introduced from concurrent engineering and collaborative working.3.2.4 Why it matte rs?IBM aggroup created new business, financial and organizational processes to meet the deadlines while cost loveting the design and manufacturing for the new Airbus A380. These changes has understanded the airplane manufacturing methodology while change Airbus UK to cut cost and time out of design and manufacture, improve collaboration with suppliers and renounce key components on schedule to ensure the A380 aircrafts on-time first flight.3.2.5 gravestone Components IBM ball-shaped Business ServicesIn developing the new technologies and push the boundaries of knowledge in the aerospace industry Airbus is leading the world. Airbus is an extremely complex business, which employs march on technologies and procedures, some of which have mainly been developed for this project. In such a large-scale, modern design and manufacturing process, a lot of attention is paid at belongings costs under control. Wing assembly is one of the most complex parts of the aircraft, an element fo r which Airbus UK has the design and manufacturing responsibility.The company realized early in the A380 program that new processes would be needed to achieve the combative timeline for the airplane. We needed to radically transform our approach to the A380, and saw appreciate in carry in an objective external consultancy to help define and implement new ways of working, says Iain Gray, Managing Director of Airbus UK. Nowhere is this more evident than in its design and development of the A380, the worlds largest passenger jet. Airbus is a highly complex business, employing advance technologies and processes, some of which have specifically been developed for this project. In such a large-scale, forward-looking design and manufacturing operation, much attention is paid to keeping costs under control. Airbus UK commissioned IBM world-wide Business Services to bring together a team of experts to analyze designs, design processes and manufacturing operations. IBM is exclusively p laced to give advice and help us transform Airbus UK, says Gray. It has commodious breadth and depth of knowledge, with expertness in business, financial and organizational disciplines as well as the aircraft industry and computer technology. The core IBM Global Business Services program team includes strategic business consultants, aircraft industry specialists and project managers. This team is expanded when ever necessitate by drafting in specialists and consultants who bring a complete cross-sectional of business and technical skills relevant to the specific problem being sourceed.3.2.6 invention out costInitiatives from IBM Global Business Services help us drive cost out of design and manufacture, improve collaborative working, and transform the way we work with our many subcontractors, explains Gray. Improved collaboration with suppliers eliminated data re-entry, thrift 18 million. The IBM team has helped the Airbus UK improve the concurrent engineering, reducing lead ti me of the wing by 41 weeks (36 percent reduction).Sometimes, initiatives originated directly from the IBM team. Airbus construct complete 3D models of A380 components to analyze clash conditions in airframe systems and structure earlier committing to cut metalfor example, to ensure that there were adequate clearances for slat and shake mechanisms on the wing and the landing gear. Such large-scale 3D mold involves an enormous volume of number-crunching, which would normally trigger the purchase of large processors. seeing this situation, IBM consultants introduced Airbus to the concept of GRID computing, which pools unutilized processing capacity in hundreds of distributed workstations for use with processor-intensive applications. A prototype was developed, and IBM then completed the slaying of GRID technology, there by thriftiness Airbus a considerable investment.In the area of business transformation, IBM Global Business Services is organizing an experienced team of human re source and organizational specialists to help Airbus UK transform from a development organization to one labour large-scale serial production.The key aspect in the success of the A380 program is educating several hundred people across Airbus UK and its many of the subcontractors in the new tools, processes and collaborative working. With an infinite pool of resources, IBM responded very rapidly to Airbus training needs, building and delivering of shipshape courses that reflect the processes and technologies defined at the strategic level.3.3 Case occupy 3 Maruti Udyog LtdMaruti Udyog Ltd., a subsidiary of Suzuki Moto Corporation of Japan, has been the leading Indian passenger car maker for about two decades. The company has a various(a) portfolio that includes the Maruti 800the Omni a premium small car, Zen the international brands, Alto and WagonR an off-roader, gipsy the mid-size look on a luxury car, Baleno an MPV, Versa a premium subcompact car, prompt and a luxury SUV, Gr and Vitara XL7. The companys 11 base platforms encompass300 variants for 100 exporting destinations. gibe to Marutis vision statement, its goals include maintaining leadership in the Indian auto industry, creating customer delight, increasing shareholder wealth and being a primp of India. Customers have shown their approval, ranking Maruti high in customer satisfaction for cardinal years in a row according to the J.D. Power Asia peaceful 2005 India Customer Satisfaction Index (CSI) Study. The company has also ranked highest in the India Sales Satisfaction Study.3.3.1The need for PLMAmong the companys product development challenges, the need for shorter cycle times is always at the top. Management wants to be able to launch new models faster and reduce the time required for minor changes and development of product variants. Another challenge is co-development. Marutis goal is to collaborate closely with its worldwide teams and suppliers on the development of new platforms and product freshening. Other challenges include streamlining the process of vehicle localization and enhancing quality and reliability. These challenges pointed directly to a product lifecycle management (PLM) solution with capabilities for information management, process management, knowledge magnetise and support for global collaboration a PLM solution directly addressing Marutis business challenges. For example, PLMs information management capabilities address the issue of the many plat forms, local variants and export destinations. Process management endures concurrent development and faster change management and provides a platform for other process improvements for faster vehicle development. Knowledge capture increases innovation and also reduces costs by increasing part re-use. PLMs collaboration capabilities permit global development by ensuring fast and accurate public exposure of product information.3.3.2. Implementation profileMaruti selected the UGS PLM software soluti on because UGS leverages the business value by offering complete PLM solution, according to C.V. Raman, general manager, Engineering Division, Maruti Udyog Ltd. Marutis PLM implementation includes aggroup nucleus, NX and Techno matrix software. Team centre provides a wide range of functionality for release management including bills of material management and change management. Team centre also handles the vehicle localization process, coordinates the part approval process and integrates design and engineering information with the companys ERP system. Team centre also providesImplementing Product Life Cycle Management in Indian ProductImplementing Product Life Cycle Management in Indian ProductIMPLEMENTING PRODUCT LIFE CYCLE MANAGEMENT IN INDIAN PRODUCT MANUFACTURE ORGANIZATIONSAbstractProduct lifecycle management (PLM) is the process of managing the entire lifecycle of a product from market demand, product design, manufacturing, services and disposal. By integrating people, data, process, business systems to provide product information which can foster a companys product innovation ability and their extended enterprise.In short all-encompassing vision for managing all data relating to the design, production, support and ultimate disposal of manufactured goods.The aerospace, medical devices, military, nuclear and automobile industries need to maintain safety and control extremely important. This safety and control measure brought about the concept of PLM in to the market. The configuration management further evolved into electronic data management systems. This further evolved into data management systems.By using the PLM features, many manufacturers of industrial machinery, capital goods, consumer electronics and packaged goods have benefited largely in the past ten years, since the advent of the PLM.CHAPTER 1 INTRODUCTION 1.1 PRODUCT LIFECYCLE MANAGEMENTProduct lifecycle management (PLM) is the procedure of managing the complete lifecycle of a product. It symbolizes the encompassing vision for supervising all the data relating to the design, manufacturing, support and the dumping of the produced goods.The concept of PLM was first introduced in the areas where safety and control were extremely important like aerospace, nuclear industries, military and medical device.These industries invented the discipline of configuration management (CM), which later got evolved in to the electronic data management system (EDMS), and this was further developed to the product data management (PDM).The usage of PLM solution has benefited the manufacturers of the industrial machinery, packaged goods, consumer electronics and complicated engineered products, and also there is a rapid increase in the adoption of PLM software by the industries. Product lifecycle management (PLM) is the procedure of managing the complete lifecycle of a product from its beginning, through design and manufacture, to service and disposal.PLM integrates people, data, processes and business systems and provides a product information backbone for companies and their extended enterprise. Product lifecycle management is one of the four cornerstones of a corporations information technology system structure. Every company needs to communicate and share information with their customer relation management (CRM) and also shared with the supply chain management and their resources with enterprises management (ERP-Enterprise Resource Planning) and their planning (SDLC-System Development Life-cycle). The manufacturing and engineering companies should compulsorily develop, describe, manage, and communicate information about their products.1.2 PLM SOLUTIONS11.3 Some requirements of PLM* Data File Control Management (The right data)* Product Data Access Control (To the right person)* Workflow Process Management (At the right time)* Geometry Management* CAD File Control Management* Digital Mockup* Integration Point For Single Source of Product Data* Information System Interfaces* Authoring Application Integration* Product Data Distribution* Product Data Viewing* Change Control* Configuration Identification* Configuration Status Accounting, Verification and Audit* Program / Project Management Coordination* Requirements Design Traceability1.4 BenefitsBenefits of product lifecycle management include-* Reduced time to market* Improve product quality* Reduced prototyping costs* Saving through the re-use of original data* A frame work for product optimization* Reduce waste* Saving through the complete integration of engineering workflows1.5 HistoryInspiration for the burgeoning business process now known as PLM came when America Motor Corporation (AMC) was looking for a way to speed up its product development process to compete better against its larger competitors in 1985, according to Francois casting Vice President for Product Engineering and Development. After the introduction of its compact jeep Cherokee (XJ), the vehicle that launched the moder n sport utility vehicle (SUV) market, AMC began to develop a new model, which later came out as Jeep Grand Cherokee. The first part in its quest for faster product development was Computer Aided Design (CAD) software system that makes engineers more productive.The conflicts are very easily solved by using new communication system .By this system costly engineering also changes because of availability of drawings and documents in a central database. AMC was purchased by Chrysler because of the effectiveness of the product data management .This made the designing and building product to connect with enterprise. While an early adopter of PLM technology, Chrysler was able to become the auto industrys lowest-cost producer, recording development costs that were half of the industry average for the Burge owning business process now known as PLM came when America average by the mid-1990s. CDocuments and SettingskranthiDesktoprakesh_prj_imgRKSH_IMG4.bmp Fig 1. Layout of Product life cycle ma nagement1.6 Timeline -Increasing Productivity with Technology21980s Introduction of Commercial Computer Aided Design (CAD) radically improved Productivity in Product Design1990s Adoption of ERP Systems ERP Systems included Engineering and Change Management Modules Design Build remained separated in silos2000s Adoption of Workflow Web technologies accelerated PLM concepts Workflow enabled collaboration between different company silos PLM drastically improved NPI cycle cutting time cost PLM extended visibility and collaboration to CMs Suppliers using the wePresent PLM extended Product Design to 3rd party Design Outsourcing Collaboration extended across the global chain to Customers Suppliers Introduction of Industry Government Standards Compliance Adoption of Collaborative Quality Improvement across the supply chain Adoption of Program/Project based PLM Portfolio Management Adoption of PLM Analytics and Intelligence for Cost/Process Analysis Improve.1.7 Phases of Product lifecy cle3There are many software solutions now developed which are use to organize and integrate the various phases of the product s life cycle.PLM is the single software with a suite of tools with several working methods, all these integrates to define single or different stage of product life cycle. PLM range is covered by some software providers but other only single application. Some of the applications can span various fields of PLM with different modules, with in the similar data model.All fields in PLM are covered here. It should also not be forgotten that one of the main goals of PLM is to collect knowledge that can be reused for other projects and to coordinate simultaneous concurrent development of many products. PLM is mainly related with engineering tasks and also involves the activities of marketing like Product Portfolio Management (PPM), and mainly with regards to the new product introduction (NPI).1.7.1. Phase 1 ConceiveImagine, specify, plan, and innovateThe initial phas e in idea is the definition of its requirements based on customer, company, market and regulatory bodies viewpoints. Major technical parameter can be defined by this product specification. Many functional aspect and requirement specification are carried out parallel with the initial concept design work carried out by defining the visual aesthetics of the product. For the Industrial Design Styling, work many different media are used from pencil and paper, clay models to 3D Computer Aided Design software1.7.2. Phase 2 DesignDescribe, Define, Develop, Test, Analyze and validateThis is where the detailed design and development of the products form starts, progressing to prototype testing, through pilot release to full product launch. It may also include the redesign and ramp for improvement to present products as well as Planned obsolescence. CAD tool is used for design and development. This can be a simple or plain 2D Drawing / Drafting or 3D Parametric Feature Based Solid/Surface Mode ling. Such software includes technology such as Hybrid Modeling, Reverse Engineering, KBE (Knowledge Based Engineering), NDT (Non Destructive Testing), Assembly constructionThis step covers many engineering disciplines including Mechanical, Electrical, Electronic, Software (embedded), and domain-specific, such as Architectural, Aerospace, Automotive, Along with the actual creation of geometry there is the analysis of the components and product assemblies. By standing alone the CAE (Computer-aided engineering) software can perform simulation validation and optimization task or it may carry out by integrating with CAD package. These are used to perform tasks such as Dimensional tolerance (Engineering) analysis task is performed by using CAQ (computer aided quality) such as Dimensional Tolerance (engineering) Analysis. Another task which is carried out at this phase is the sourcing of bought out components, possibly with the aid of Procurement systems.1.7.3. Phase 3 Realize Manufactur e, Make, Build, Procure, Produce, Sell and DeliverThe method of manufacturing is defined when the design of the products componnent is completed. It performs task such as design creation of CNC machining instructions for the products part as also it can perform tolls to manufacture those product which can be done using integrated or separate CAM. Process simulation for operations such as casting molding and die press forming will also be involve in the analysis tools. CPM comes in to play only when the manufacture method gets identified. The original CAD data with the use of Computer Aided Inspection equipment and software is used for checking the geometrical form and size of the components after they get manufactured.Sales product configuration and marketing documentation work will be taking place parallel to the engineering task. This could include transferring engineering data (geometry and part list data) to a web based sales configuration and other Desktop Publishing systems1.7 .4. Phase 4 ServiceUse, Operate, Maintain, Support, sustain, phase-out, Retire, Recycle and DisposalIn final stage of the lifecycle the managing of in service information is involved. The repair and maintence, waste management/recycling information is provided to the customers and to service engineers. Maintenance repair and operation management software tools are involved.1.7.5. All phases Product lifecycleCommunicate, Manage and CollaborateIn many cases or in real practical a project does not run sequentially or maintain isolation of other project development project. The co-ordination of and management of product definition data is the main part of PLM, it includes release status of the components, managing of engineering changes, management of documents, project resources planning, configuration product variations, timescale and risk assessment. The text and metadata such as the product bills of materials needs to be managed. At the engineering departments stage this is the area of PDM (Product Data Management) software, at the commercial level EDM (Enterprise Data Management) software it is typical to see two or more data management systems within an organization. These systems are also linked to other systems such as SCM, CRM, and ERP. Associated with these systems are Project Management Systems for Project/Program Planning. Numerous collaborative product development tools cover this central role which runs throughout the whole life cycle and across organizations. This needs various technology tools in the area of Conferencing, Data Sharing and Data Translation.CHAPTER 2 Research study conducted on (Cell phone)During past decade of time the, cell phone has become a part of our daily life .Like any product, making a cell phone and its parts requires natural resources and energy. Understanding the life cycle of a product can help you make environmental choices about the products you use, and how you dispose of them. Let us consider the example of a Nokia cell phone product life cycle management.2.1 Concept Design4The design of the product influences each stage of its lifecycle and also influences the environment. Design will affect the materials which are used in manufacturing of a product. If cheaper materials are used they are less durable, the product will have a short useful life. Waste can be prevented by proper design of the product. The design of the product with modular components can be easily replaced and entire product need not be thrown away if only one part of the product gets broken. The items having long life, trendy design should be avoided because they are not thrown away when they go out of style.2.2 Materials Extraction4All products are manufactured from the materials which are found in or on the earth. Raw materials, such as trees or ore, are directly mined or harvested from the earth and this process can create a lot of pollution and also involves usage of large amounts of energy and depletes the limited natural resources. The manufacturing of new products from recycled materials will reduce the amounts of the raw materials, being taken from the earth. The hand set consists of 40 percent metals, 40 percent plastics, and 20 percent ceramics and trace materials.The circuit board which is also termed as a printed wiring board, present in the hand set is the main component and is the brain of the cell phone controlling all of its functions. The circuit boards are up of mined and raw materials like silicon, copper, lead, nickel, tantalum, beryllium and other metals. Circuit board manufacturing requires crude oil for plastics and limestone and sand for the fiberglass, these materials are also known as persistent toxins and can stay in the environment for long periods of time even after their disposal.The cell phone consists of a liquid crystal display (LCD), a low power, flat- panel display on the front of the phone that shows information and images. The passage of electric current through it ma kes it opaque. The contrast between the opaque and transparent areas forms visible characters. Various liquid crystalline substances, either naturally occurring (such as mercury, a potentially dangerous substance) or human-made, are used to make LCDs, require the usage of plastic or glass. The rechargeable batteries used to power the phones can use several types of batteries nickel-metal hydride (Ni-MH), lithium-ion (Li-Ion), nickel-cadmium (Ni-Cad), or lead acid. These batteries contain nickel, cobalt, zinc, cadmium, and copper.2.3 Materials Processing4Once materials are extracted, they must be converted into a form that can be used to make products. For example, in cell phones Crude oil is combined with natural gas and chemicals in a processing plant to make plastic Copper is mined, ground, heated, and treated with chemicals and electricity to isolate the pure metal used to make circuit boards and batteries. The resulting copper pieces are transported to the manufacturer where the y are formed into sheets and wires.2.4 Manufacturing4The basic shape of the circuit board is made by using plastics and fiberglass, and is then coated with gold plating. The board has several electronic components which are connected with wires made of copper and are soldered to the board, are secured with coatings and protective glues.LCDs are manufactured by sandwiching the liquid crystal in between layers of plastic or glass. Batteries have two separate parts known as electrodes, which are made from two different metals. Electrolyte is a liquid substance which touches each electrode.2.5 Packaging Transportation4The use of packaging can protect products from damage and provide product information. Finished products are transported in trucks, planes, and trains to different locations where they are sold. All of these modes of transportation burn fossil fuels, which can contribute to global climate change. The finished products and the parts of the cell phone require packaging and t ransportation in order to get from one place to another.The transportation done by plane, rail or truck requires the usage of the fossils fuels for energy, which contribute to the global climate change. While the packaging of the product protects it from getting damaged, identifies contents and provides information, decorative or excessive packaging can be wasteful. Packaging makes use of the valuable natural resources which include paper (from trees), plastics (from crude oil from the earth), and aluminum (from ore) and other materials, all of which makes use of energy to produce and can result in waste.2.6 Reuse/Recycling/Disposal4The way products are used can impact the environment. For example, products that are only used once create more waste than products that are used again and again. Using a product over and over again prevents the need to create the product from scratch, which saves resources and energy while also preventing pollution. Recycling or re-manufacturing product s also reduces the amount of new materials that have to be extracted from the earth.Always comparison shop to be sure that you get the proper service and the phone that is right for you. By using the rechargeable batteries in cell phones reduces the amount of the waste and toxicity that disposable batteries will create. Be sure to follow the manufacturers instructions for charging your batteries so you can extend their life as long as possible2.7 Life4Recycling or donating the cell phones when they are no longer needed by you or want them extends their useful lives, and preventing them from going into the trash where they can cause problems relating to the environment.2.8 Reuse4Many organizations including recyclers, Charities, and electronics manufacturers accept working cell phones and offer them to schools, community organizations, and individuals in need. Reuse provides people, who cannot afford them, free or reduced cost access to new phones and their accessories. And thereby it extends the useful lifetime of a phone.2.9 Recycle4Springing up of electronics recyclers is every-where. Today, various stores, recycling centers and manufacturers accept cell phones for recycling. While few electronics recyclers only allow large shipments, the communities, schools, or groups can work together to collect used cell phones for shipment to electronics recyclers. Some of the rechargeable batteries can also be recycled, as many retail stores and some communities have started collecting them. The material recovered from the rechargeable batteries when they are recycled can be used for making new stainless steel products and batteries. You can use the phone book or Internet to find the local contacts that refurbish and recycle cell phones.2.10 Disposal4By 2009, the rate at which cell phones are discarded is predicted to exceed 125 million phones each year, resulting in more than 65,000 tons of waste. The cell phones which are thrown into the trash end up in a landfill o r are burned. As the cell phone contains plastics, chemical, metals and other hazardous substances, you should always recycle, donate or trade in your old cell phone.2.11 Headset4Many people use a cell phone headset when they are driving or when they are walking around to keep their hands free. Most models of headsets can be reused when you buy a new phone.2.12 Belt clip4Some people buy belt clips to carry cell phones while not in use. Reusing or donating your belt clip when you are finished using it prevents waste.2.13 Face plate4Decorative face plates can be trendy and fun, but you dont need them to use a cell phone. The best way to prevent waste is to simply not buy products you dont need. If you do buy face plates, donate unwanted ones to a charity or swap them with your friends instead of throwing them away. Portable gaming cell phones have a lot of the same parts as hand-held video game and CD players, consoles and portable CD players, including speakers, circuit boards, and L CDs. Old or broken consoles and players can also be reused or recycled when no longer wanted. Advances in cell phone technology have given phones many uses today.CHAPTER 3CASE STUDY 3.1 Case study SiemensSiemens Home and Office Communication Devices (SHC) is a leading company for home and office communication infrastructure. The company sells its products in more than 50 countries.3.1.1 Business ChallengeSHC has several engineering and manufacturing disciplines which are unique and located at one single site, in Germany. Mold tooling development, mechanical design development, manufacturing and assembling are all done in Bocholt, Germany.For Siemens the market pressure is very high in electronics and electric and consumer goods, and there is stress from this competition to reduce development cycles and its time to market new goods, as there is a wide range of products introduced into the market year after year with new designs and more complexity. Therefore Siemens recognized that i t has to make improvements in its quality and thus needed to enhance the supply chain integration and collaboration to meet its marketing challenges.Siemens soon recognized that to overcome the external and internal pressures it has to improve its development and product life cycle for the future success of Siemens SHC. Siemens had been working with a 3-D CAD system Euclid 3 for about 10 years on which it had made all possible improvements and it cannot upgrade it any further, so it has to get help from outside partner to help and implement a new product life cycle (PLM) system.3.1.2 SolutionSiemens in partnership with IBM services implemented CATIA V5 and SMART TEAM as a new PLM platform for improvement in product development. CATIA V5 has a set of predefined product and process templates, helps to quickly complete even sophisticated design tasks with a high level of accuracy.With CATIA V5 and SMARTEAM, SHC has improved design innovation, taking advantage of the existing know-how and design to manufacturing process to the development and reduction of costs. In addition to that, this tool has helped make the mold tool development and NC manufacturing very competitive with low-cost suppliers from places like China.3.2 Case study 2 Airbus UK 3.2.1 Business ChallengeTo meet tight deadlines for delivery and reduce design and manufacturing costs by constantly improving working processes throughout the aircraft lifecycle.3.2.2 SolutionIBM has provided with a team of flexible and scalable experts which included strategic business consultants, aircraft industry specialists and project managers to define and implement transformation programs in business, financial and organizational disciplines.3.2.3 Business BenefitsImproved collaboration with suppliers eliminated data re-entry, saving 18 million on collaboration with suppliers.* Improved concurrent engineering reduced lead time on wing by 41 weeks (36% reduction).* The worlds first flight of largest passenger aircra ft completed on time.* Keeping Scheduled programming.* Innovative practices introduced from concurrent engineering and collaborative working.3.2.4 Why it matters?IBM team created new business, financial and organizational processes to meet the deadlines while cost cutting the design and manufacturing for the new Airbus A380. These changes has transformed the airplane manufacturing methodology while enabling Airbus UK to cut cost and time out of design and manufacture, improve collaboration with suppliers and deliver key components on schedule to ensure the A380 aircrafts on-time first flight.3.2.5 Key Components IBM Global Business ServicesIn developing the new technologies and pushing the boundaries of knowledge in the aerospace industry Airbus is leading the world. Airbus is an extremely complex business, which employs advanced technologies and procedures, some of which have mainly been developed for this project. In such a large-scale, modern design and manufacturing process, a l ot of attention is paid at keeping costs under control. Wing assembly is one of the most complex parts of the aircraft, an element for which Airbus UK has the design and manufacturing responsibility.The company realized early in the A380 program that new processes would be needed to achieve the aggressive timeline for the airplane. We needed to radically transform our approach to the A380, and saw value in bringing in an objective external consultancy to help define and implement new ways of working, says Iain Gray, Managing Director of Airbus UK. Nowhere is this more evident than in its design and development of the A380, the worlds largest passenger jet. Airbus is a highly complex business, employing advanced technologies and processes, some of which have specifically been developed for this project. In such a large-scale, innovative design and manufacturing operation, much attention is paid to keeping costs under control. Airbus UK commissioned IBM Global Business Services to bri ng together a team of experts to analyze designs, design processes and manufacturing operations. IBM is exclusively placed to give advice and help us transform Airbus UK, says Gray. It has enormous breadth and depth of knowledge, with expertise in business, financial and organizational disciplines as well as the aircraft industry and computer technology. The core IBM Global Business Services program team includes strategic business consultants, aircraft industry specialists and project managers. This team is expanded when ever required by drafting in specialists and consultants who bring a complete cross-section of business and technical skills relevant to the specific problem being addressed.3.2.6 Designing out costInitiatives from IBM Global Business Services help us drive cost out of design and manufacture, improve collaborative working, and transform the way we work with our many subcontractors, explains Gray. Improved collaboration with suppliers eliminated data re-entry, savin g 18 million. The IBM team has helped the Airbus UK improve the concurrent engineering, reducing lead time of the wing by 41 weeks (36 percent reduction).Sometimes, initiatives originated directly from the IBM team. Airbus built complete 3D models of A380 components to analyze clash conditions in airframe systems and structure before committing to cut metalfor example, to ensure that there were adequate clearances for slat and flap mechanisms on the wing and the landing gear. Such large-scale 3D modeling involves an enormous volume of number-crunching, which would normally trigger the purchase of large processors. Seeing this situation, IBM consultants introduced Airbus to the concept of GRID computing, which pools unutilized processing capacity in hundreds of distributed workstations for use with processor-intensive applications. A prototype was developed, and IBM then completed the implementation of GRID technology, there by saving Airbus a considerable investment.In the area of b usiness transformation, IBM Global Business Services is organizing an experienced team of human resource and organizational specialists to help Airbus UK transform from a development organization to one undertaking large-scale serial production.The key aspect in the success of the A380 program is educating several hundred people across Airbus UK and its many of the subcontractors in the new tools, processes and collaborative working. With an infinite pool of resources, IBM responded very rapidly to Airbus training needs, building and delivering of tailored courses that reflect the processes and technologies defined at the strategic level.3.3 Case Study 3 Maruti Udyog LtdMaruti Udyog Ltd., a subsidiary of Suzuki Moto Corporation of Japan, has been the leading Indian passenger car maker for about two decades. The company has a diverse portfolio that includes the Maruti 800the Omni a premium small car, Zen the international brands, Alto and WagonR an off-roader, Gypsy the mid-size Este em a luxury car, Baleno an MPV, Versa a premium subcompact car, Swift and a luxury SUV, Grand Vitara XL7. The companys 11 base platforms encompass300 variants for 100 export destinations. According to Marutis vision statement, its goals include maintaining leadership in the Indian automobile industry, creating customer delight, increasing shareholder wealth and being a pride of India. Customers have shown their approval, ranking Maruti high in customer satisfaction for six years in a row according to the J.D. Power Asia Pacific 2005 India Customer Satisfaction Index (CSI) Study. The company has also ranked highest in the India Sales Satisfaction Study.3.3.1The need for PLMAmong the companys product development challenges, the need for shorter cycle times is always at the top. Management wants to be able to launch new models faster and reduce the time required for minor changes and development of product variants. Another challenge is co-development. Marutis goal is to collaborate cl osely with its global teams and suppliers on the development of new platforms and product freshening. Other challenges include streamlining the process of vehicle localization and enhancing quality and reliability. These challenges pointed directly to a product lifecycle management (PLM) solution with capabilities for information management, process management, knowledge capture and support for global collaboration a PLM solution directly addressing Marutis business challenges. For example, PLMs information management capabilities address the issue of the many plat forms, local variants and export destinations. Process management permits concurrent development and faster change management and provides a platform for other process improvements for faster vehicle development. Knowledge capture increases innovation and also reduces costs by increasing part re-use. PLMs collaboration capabilities permit global development by ensuring fast and accurate dissemination of product informati on.3.3.2. Implementation profileMaruti selected the UGS PLM software solution because UGS leverages the business value by offering complete PLM solution, according to C.V. Raman, general manager, Engineering Division, Maruti Udyog Ltd. Marutis PLM implementation includes Team centre, NX and Techno matrix software. Team centre provides a wide range of functionality for release management including bills of material management and change management. Team centre also handles the vehicle localization process, coordinates the part approval process and integrates design and engineering information with the companys ERP system. Team centre also provides