Product Lifecycle Management Solution to Auto Industry Challenges
Executive Summary
The global economy continues to be turbulent for the last couple of years however the automotive industry, in particular, has been encountering the most challenging environment. Market dynamics are changing fast, thus forcing the car makers to alter their business strategies and to implement them successfully in order to stay competitive. Auto parts makers are further squeezed because they need to satisfy more diverse product requirements with low room for errors inside a relatively much shorter time span. As radical technological trends are inevitable, harnessing this opportunity will enable companies with innovative products to achieve share of the market.
The next key trends have been shaping the auto industry:
Auto-crisis: The latest crisis resulted in excess inventory and massive debt accrual for several big automakers in america and Europe. At the same time, strong growth and a healthy economic outlook in BRIC nations has helped their local companies make headway into local as well as international markets. The financial landscape is forcing the big auto companies in the US, Europe and Japan to rapidly shift their strategy and to innovate faster in order to compete with the Asian auto and auto part makers.
Globalization: The opening of the international trade boundaries has helped companies expand into new growing markets such as Asia; however, it increases the complexity of satisfying various kinds of local customer requirements making auto development complexity increase manifold.
Alternately, globalization can also be increasing the threat of serious competition from Asian OEMs which are buying the anemic divisions of western OEMs thereby leapfrogging into gaining intellectual capital that may be easily exploited along with their cheap labor.
Quality, reliability and product differentiation to suit the local market at affordable prices have become necessary to a successful product portfolio. While protecting intellectual property rights, internal collaboration as well as that over the global supply chain has become paramount.
Regulations and sustainability: Increasing concentrate on pollution and gas mileage regulations is forcing companies to appear beyond gas engines while there is a limit to reducing the emission and increasing fuel efficiency using conventional engines. With the maturity of battery technology, electric cars are changing the landscape rapidly and may even result in the hybrid cars less relevant within the coming years. Issues of safety can result in costly legal battle and evokes for that auto manufacturers. Companies have to exceed the government controls standards for their own good.
Technology: The automobile landscape is evolving rapidly. Newer technologies in auto battery, increased amounts of electronic components and control systems, software/hardware integration etc. are redefining industry. Increased technology together with shrinking product cycles is overburdening the auto industry.
Cost: One of the greatest challenges is to lower the price while maintaining top quality with a faster rate of product innovation in global marketplace, increased quantity of product types to suit local markets, and compliance with multiple group of regulations in different markets.
How does Product Lifecycle Management (PLM) help?
To deal with the automotive industry challenges brought about by the pace setting trends, companies need an in-depth knowledge of trends impacting their specific business areas in addition to a disciplined system and non-system based strategy formulation and execution strategy.
For that system based strategy, a complete solution should be flexible, robust and integrated utilizing Customer Need Management, Customer Relationship Management, Quality Management, Supply Chain Management and Product Lifecycle Management. A holistic system management approach may be the right roadmap for auto companies consider business revolves around these products or services a business offers, PLM could be the single most rewarding area to pay attention to in system implementation.
Integrated or standalone, PLM solutions ought to be given a priority as it can deliver:
Integrated design with product record
Collaborative distributed design and feedback loop
Manufacturer, Supplier and Customer Collaboration
Building the best product the very first time using distributed manufacturing
Tracking and minimizing cost
Protecting intellectual property
Maintaining regulatory, environmental and corporate compliance
Tracking product portfolio, product and project lifecycles
Closed loop quality feedback
Corrective and preventive action
Driving innovation more quickly
Increased profitability
PLM Vendor Selection
Numerous PLM systems can be found in the market today and a cautious is required with respect to cost and benefit analysis while choosing the PLM Vendors. While it may be hard to quantify the benefits of PLM savings as a result of PLM deployment, it can be calculated utilizing a matrix of the following criterion:
* Cost
+ Software and Hardware
+ Business Process Designing/Re-engineering
+ Implementation and support
+ Integration and synchronization with ERP along with other system of product records
+ Training and Change Management
* Benefits
+ Business problems solved e.g. collaboration during new product introduction, change management and CAD management, proprietary information security and use of new markets because of product compliance
+ Quality gains e.g. reduced quality related recalls, quality action requests etc.
+ Process efficiency gains e.g. efficient searches and part reusability, cool product introduction time reduction, change management time reduction and data entry related improvements.
* Roi
A detailed cost and benefit analysis matrix can help companies estimate the ROI along with the overall impact of PLM around the overall productivity.
CAD vs. Non-CAD PLM criteria
Often CAD design becomes the middle of attention while selecting PLM systems in engineering centric sectors such as the automotive industry. Electrical Computer Aided Design (ECAD) and Mechanical Computer Aided Design (MCAD) are critical for engineering functions but the PLM solution must extend across various functional areas within the extended supply chain.
PLM software with strong engineering collaboration and CAD integration capabilities to automate the item/BOM creation in the ERP/PLM system ought to be seriously considered while selecting the right PLM vendor. The best-of-the-breed PLM software with a complete enterprise solution and integrated service oriented architecture capability can easily outdo just the CAD based PLM systems in overall collaboration and efficiency gains.
On one hand, CAD based PLM vendors Dassault Systemes, PTC, and Siemens offer integration from CAD to their own PLM while lacking integration using the other CAD tools. However, software program like Oracle Agile with non-CAD PLM tend to be flexible in integration with the major CAD tools and also provides Application Integration Architecture (AIA) to propagate the merchandise /BOM data into the ERP systems. This can be particularly important for those organizations following a growth by acquisition strategy, as tough to replace CAD systems in acquired/merged entities can be simply integrated with the central PLM and the ERP systems from the parent company thereby lowering the cost substantially.
To sum up, completeness of out-of-the-box features, user-friendliness, integration capabilities, high degree of configurability and extendibility in the product suite are particularly important within the vendor selection as using multiple PLM system can be costly and can result in an inconsistent user application experience. Architecture, data model and process standardization must be integral from the long-term strategy within the PLM system business decision.
PLM Solutions
Companies may be in different phases of the maturity spectrum to formulate, adopt and implement PLM strategies; however, a long term perspective ought to be adopted how the business will morph, thereby, developing a have to deploy future solutions which will forge the best way to stand above the competition.
Auto companies should look into adopting flow-based PLM solutions where streamlining the company processes is the main focus. Business flows can span across the cross-functional business area as well as the product modules. Some of the key business flow solutions can be outlined as:
* Customer Have to Product Formulation
Product design is generally originated through the marketing or product development team who comes out with either a cool product concept or requirement(s) expressed by the customers. Customer needs could be captured from forums, enhancement requests, CRM and quality systems or other documents. Such requirements could be converted into products using collaborative efforts and cross functional interactions.
* Requirements to New Part Introduction (NPI)
When a product idea is approved internally, the part is created within the system. Product bill of material configuration, supplier part numbers, manufacturer’s part number, attachment and other associated detailed attributes are put into the part number as part of the NPI process. Workflow driven processes greatly facilitate the progression and reduce time frame while increasing data accuracy.
* Design release a
Worthwhile change control process to handle the merchandise lifecycle phases ought to be workflow driven to improve efficiency, streamline the procedure and track changes. Various workflows based change types may be used to manage the merchandise, structure, MPN change/ bulk change processes and automatically implement changes upon approval.
* Engineering Design Collaboration
Numerous internal teams in addition to external vendor engineers could work on designing the merchandise at multiple locations and this engineering collaboration can be the key to designing the product right the very first time. Apart from CAD design collaboration, another aspect of engineering collaboration is to automate the creation of the merchandise BOM structure into the central product record system where non- engineering users can make use of the information to fabricate, procure and market.
* Product Record Management
Centralization of product records is important because distributed inconsistent and partial information can boost the data maintenance cost, operation cost and quality cost substantially. A single supply of truth for product, product attributes, BOM, supplier and supplier parts, manufacturer and manufacturer parts and site information is critical to the PLM systems implementation strategy. Product record can be synchronized to another system of records using web services (Service Oriented Architecture) from the record master system.
* Document Management
Intellectual property security protection is all the greater important with global product collaboration. Document management includes check-in, check-out, checksum, document change control and bulk change capability with integrated workflow for review and approval.
* Product Portfolio to Profitability
Companies launch various projects and programs during the product lifecycle to manage, control and track the danger involved in cost, product rollout timeframe and compliance etc. Integration with Microsoft Projects is definitely an important capacity for any product portfolio management solution.
* Quality Review to Conformance
Proactive monitoring and managing of product quality during the entire lifecycle is the key to success for any company. Quality review to conformance deals with the managing process during manufacturing, customer complaints, methodical defects detection, enhancement, and corrective and preventive actions.
* Product Governance and Compliance
Company products have to comply with various standards, regulations or tracking guidelines to work in any country. Product governance and compliance solutions can be used for creating, maintaining and tracking to remain compliant.
* Product Cash strategy
Tracking and managing the product cost against target cost levels is paramount to maintaining profitability. The merchandise cost management option would be used to calculate part and resource costs across the supply chain through the entire product lifecycle.
Conclusions
The automotive market is showing signs of life in the wake of the economic recovery; however, a number of companies continue to be struggling in their product strategy. The auto industry challenges are really the as well as their response can make or break the companies. Product innovation, quality, compliance and product lifecycle reduction while keeping the expense down are fundamental factors to survive and thrive. Implementing PLM can offer the required leverage to companies in catching up and staying in front of the competition. Choosing the right consulting partner can steer you within the right direction.