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Implementing a PLM (product lifecycle management) system is a transformative journey that requires meticulous planning and execution. Whether you’re a startup, SME (small or medium-sized enterprise), or a large enterprise, following a structured approach can ensure a successful rollout. In this article, we’ll outline the common pitfalls, best practices, and essential steps for successful PLM implementation.
Common PLM implementation challenges
Numbering systems
Traditionally, numbering systems for compositions, individual parts and drawings have been used in which the number has meaning. For example, to indicate a machine, product line or model year. In the paper era, this had advantages. The numbering system managed the drawings; meaningful numbers are easier to remember; compositions and individual parts can be recognized by a song, and so on. Over a long period of time, however, these types of systems tend to fail.
For example, when series’ are too restrictive, so that two separate sequences are needed for the same category. Or two digits are needed where a single digit was originally provided. As a result, the encryption is no longer correct. Organizational changes can also destroy a meaningful numbering system.
Drawing-centric thinking
Drawings were the means of communicating engineering information. Even the application of 3D CAD has been used for the past 30 years to produce 2D drawings. Drawings were seen as the most important documents – inside and outside the organization. However, it doesn’t make much sense to cling to this. More and more, the design specification can be used directly to manufacture and produce. In addition to Product Data Management systems, PLM systems are also communication systems. And so, take over the most indispensable function of drawing.
Customizing processes
It’s often assumed that existing business processes must be incorporated into the system on a one-to-one basis. To achieve this, extensive configuration and customization is required. In case of changes in business processes, but also in the case of system upgrades, renewed effort is required to keep your processes up-to-date.
PLM implementation best practices
Simple numbering
Keep it numerical. Between 5 and 7 digit labelling allows for the unique numbering of up to 10 million articles. This numbering can be easily generated by PLM systems, guaranteeing uniqueness. To keep things simple, searching should be refined through description, classification, or information recorded in other attributes.
Model-based definition
Your company’s value is generated through the products it designs and manufactures. By focusing on this, it’s clear to see why PLM should be used to optimize product management. Ultimately, product drawing can be thought of as a secondary priority. You should be ensuring that the relevant product data is communicated to the right people at the right time, so that value is added with the throughout each process, with minimal added effort. MBD (model-based definition) is a good example of this.
Think out-of-the-box
Leading PLM systems included out-of-the-box processes based on industry standards and best practices. It’s often possible to apply these to existing business processes without the need for extensive customization. With the right configuration, you can achieve powerful results.
But, if this isn’t possible for your business, you’ll need to dig into your existing processes to understand any necessary changes before they’re planned and executed. This makes it possible to deal flexibly with organizational changes, and facilitate smooth system upgrades.
Essential PLM implementation steps
Stakeholder management
- Identify and map stakeholders, including influencers and supporters, to ensure comprehensive backing from the outset.
- Communicate the benefits of PLM to each stakeholder group to foster understanding and support for the changes.
PLM is capable of benefiting every area of your organization. So, it’s crucial that everyone is backing the delivery from the outset.
Identifying key stakeholders, including influencers and decision-makers, is crucial for gaining comprehensive backing for the project. By mapping out stakeholders and understanding your roles and interests, you can tailor your communication strategies to highlight the specific benefits of PLM for each group.
This approach fosters understanding and support, ensuring that all parties are aligned with the project’s objectives and are committed to its success.
Strategic planning
- Conduct an in-depth analysis of current business pain points and align your PLM implementation with strategic business objectives.
- Define a detailed implementation roadmap with high-level milestones and trackable activities to guide the process.
Putting the best plan together to implement your PLM platform can become a complex exercise in itself. In-depth stakeholder analysis of current business pain points can be the initial make-or-break point for most PLM implementations.
The rollout of your PLM platform should be considered as a business process initiative rather than a simple software upgrade. You’ll need to build a well-aligned, strategic plan across multiple disciplines of your business.
So, take time to define your implementation roadmap with delivery phases across each business area. Build on this framework with high-level milestones which define the status of each delivery phase.
From here you’ll begin to see the details in your pain points being addressed. Specify trackable activities for each area of your organizational PLM maturity and use these to define critical paths.
Effective communication
- Establish a robust communication strategy to manage cultural change and keep projects on course.
- Use diverse media and approaches to ensure consistent messaging that resonates with all stakeholders.
Effective communication is the backbone of any successful PLM implementation. Establishing a robust communication strategy helps manage cultural change and keeps the project on course.
By maintaining open dialogue and using a variety of communication channels, you can ensure that all stakeholders are kept informed and engaged throughout the process. Consistent messaging that resonates with different audiences helps to build trust and facilitate a smoother transition to the new PLM system.
Learning and adaptation
- Implement regular program health checks and quality standards to adapt practices and maintain alignment.
- Encourage knowledge sharing and collaboration to support ongoing learning and improvement.
Continuous improvement is essential for the long-term success of a PLM system. Implement regular program health checks and adhere to quality standards to ensure that the implementation remains aligned with business objectives.
Encourage knowledge sharing and collaboration among team members to support ongoing learning and adaptation. Foster a culture of continuous improvement to refine your processes and maximize the benefits of your PLM system over time.
Issue management
- Develop systematic processes for managing risks and issues, ensuring they are centrally monitored and escalated as necessary.
- Maintain flexibility in your implementation roadmap to accommodate organizational and cultural changes.
Navigating challenges is an inevitable part of any PLM implementation. Developing systematic processes for managing risks and issues is crucial to ensuring that they are addressed promptly and effectively.
Centralized monitoring and escalation procedures help keep potential problems under control, minimizing their impact on the project. Maintaining flexibility in your implementation roadmap allows you to adapt to organizational and cultural changes, ensuring that the project remains on track despite unforeseen challenges.
Training and development
- Provide comprehensive training to stakeholders, ensuring they are equipped to utilize the PLM system effectively.
- Use a mix of training methods, including written guides, e-learning, and classroom sessions, to cater to different learning preferences.
Providing comprehensive training ensures that all users are equipped to utilize the system effectively and efficiently. Offering a mix of training methods, such as DAS (digital adoption solutions), e-learning modules, and classroom sessions, caters to different learning preferences and helps reinforce understanding. Invest in training and development to enhance user proficiency and drive the successful adoption of your PLM system.
Project closure and evaluation
- Conduct a closure meeting to summarize the project and present initial reports on system performance.
- Use both quantitative (KPIs and ROI) and qualitative (stakeholder feedback) methods to assess the long-term impact of the PLM implementation.
Conducting a closure meeting provides an opportunity to summarize the project and present initial reports on system performance.
Evaluating the project’s success using both quantitative measures, such as key performance indicators (KPIs) and return on investment (ROI), and qualitative feedback from stakeholders, provides valuable insights into the long-term impact of the PLM system.
This evaluation helps identify areas for improvement and informs future initiatives, ensuring that the organization continues to benefit from its investment in PLM.
How can TECHNIA help?
We provide comprehensive support throughout the PLM journey, with a commitment to excellence and a deep understanding of industry best practices.
Our team of experts will work closely with your organization to ensure strategic planning, effective communication, and seamless integration of PLM systems. Taking advantage of our tried and tested tools and methodologies, we’ll help you overcome common pitfalls, optimize processes, and drive innovation.
No matter the size of your company, nor the industry you operate in, our expertise and dedication will empower you to achieve a successful PLM rollout that enhances productivity and nurtures long-term growth.
