Manufacturing and engineering are both symbiotic and disjointed. While manufacturing relies on engineering to do their work, engineers are not trained to provide manufacturing exactly what they need at the design phase; that’s further downstream.
These key differences require a bridge between the PLM tools in engineering and production operations on the shop floor.
It All Starts in Design
Engineers create a long list of documents during product design to ensure a product meets the customer’s needs and can be manufactured with the available materials, tools, machinery and people. Different products require different levels of complexity, including drawings, specifications, designs, materials, measurements and other detailed lists of requirements. A Product Lifecycle Management (PLM) system keeps all the information organized for the engineer.
This diversity, however, makes it more difficult for manufacturing, where work moves quickly and there’s not a lot of time to read. The PLM that was so useful during design cannot break down the work into operator-sized information packets for the shop floor.
Manufacturing Pushes the Pace
Manufacturing operates at a much faster pace than engineering. The shop floor doesn’t have time to digest complex information before beginning production. Even in the most labor-intensive, discrete production environments, operators work at the fastest possible pace.
Operators don’t have time to search for information on a drawing or spec sheet. If it’s not on the screen when operators need it, productivity and profitability fall drastically. Even a few minutes spent searching can make the difference between a profitable production run and a project overrun.
Manufacturers need to manage the production process with speed and precision; design engineers need details that inherently slow that production down.
Where is the Bridge?
The bridge lies between design and manufacturing. Design and manufacturing get the specific tools they need to do their jobs – tools that are significantly different.
PLM design is absolutely required in most modern, complex manufacturing settings. Complete control of engineering design increases competitiveness of the resulting product.
Engineering design for complex manufacturing can’t be done by the transactional ERP.
Current PLM product offerings meant to work in manufacturing require far too many interactions by the operators to be effective.
Companies need bi-directional data transfer between design and manufacturing. Production should provide valuable feedback to design.
Traditional MES systems (used on manufacturing shop floors) struggle to get information back to the PLM.
A Solution for Both Manufacturing and Design
Without the proper design, production can’t build correctly and without the detailed instructions, production can’t do its work. There is no sacrifice here that will work. As engineering information flows to the shop floor already, this part of the equation is complete. What’s missing is the critical link for manufacturing back to design and manufacturing engineering (there are holes in both areas traditionally).
What Can Help?
ERP systems can’t. These are transactional systems that will force the design and manufacturing engineers to separate every production step or list them as a single step without the associated, “nested” details that are so critical to the operators.
PLM systems can’t. We’ve already seen how these systems manage documents, but not the associated instructions. Operators can’t build from the documents, as they don’t have the time or experience, typically, to differentiate what specific work needs to be done at each step.
This leaves just the MES and even at that, most MES systems won’t touch the PLM without extensive programming and customization. Manufacturers also need process enforcement, work center or operator-based work instructions, quality control and access to all the PLM documentation that’s required to do the job.
Recently, we introduced a product platform that makes live communication between the PLM and the MES a reality, without the requirement for customization. While we understand many of the problems facing manufacturers, digging into this problem, we’ve found that we have only scratched the surface. Plenty of additional problems exist in connecting systems in the manufacturing environment. What other issues do you have? We’re interested to know.
Our goal is to break down the walls between engineering, design and the shop floor. That is where we see the real power of the Smart Factory or Manufacturing 2.0. Visit us online at www.CIMx.com and let us know what your biggest challenges are.