PLM (Product Lifecycle Management)

Engineering changes automatically propagate to all related departments

2-stage ECR → ECO change management enables pre-assessment of change impact and systematic execution.

When an Engineering Change Request (ECR) is received, impact analysis is performed across 7 areas (inventory, cost, schedule, tooling, quality, supplier, customer). Approved ECOs are managed through 10 status stages (Draft → Impact Analysis → Engineering Change → Verification → Pending Approval → Approved → In Execution → Complete/Rejected/Cancelled), providing immediate visibility into the current stage.

• 7-area impact analysis: inventory/cost/schedule/tooling/quality/supplier/customer
• CCB (Configuration Control Board) review required flag
• Customer approval required flag: automatic notification when OEM customer approval is needed
• Existing inventory disposition policy: select from use up/scrap/rework/return/mixed use
• Sequential Approval workflow
• ECO notification and design review document auto-generation

E-BOM, M-BOM, S-BOM, and P-BOM managed in a single system

4 BOM types are connected, and engineering changes are automatically reflected across all BOMs.

Engineering BOM (E-BOM), Manufacturing BOM (M-BOM), Service BOM (S-BOM), and Procurement BOM (P-BOM) are managed in a single system. N-Level recursive BOM structure supports any depth of decomposition, and Where-Used reverse tracing immediately identifies which parent products a specific component is used in.

• N-Level recursive BOM + Find Number
• Alternative material management: priority, conversion ratio, validity period, approval status
• Scrap rate-reflected total requirement auto-calculation
• 150% BOM (Super BOM): supports automotive OEM Feature-Based BOM concepts
• Variant BOM: automatic BOM resolution based on option combinations
• Effectivity management by date/serial number/LOT

PPAP 18 elements prepared in parallel via workflows

The PPAP preparation process is systematized, with per-assignee progress visible at a glance.

A workflow for parallel preparation of PPAP 18 elements (design records, FMEA, Control Plan, MSA, process capability, etc.) is built in. Each element's readiness status is tracked in real time, and when all elements are complete, a PSW (Part Submission Warrant) is automatically generated. Customer 3-way decisions (approval/conditional approval/rejection) and their history are managed.

• 18-element parallel preparation + real-time progress tracking
• PSW auto-generation
• PPAP Level 1-5 support
• Customer decision history management (approval/conditional approval/rejection)

Mold life tracked by shot count with automatic response

Remaining mold life is auto-calculated, and tiered response rules are applied.

Current shot count is compared against design life to automatically calculate remaining life. Based on remaining life, 4-tier differentiated response (Normal/Caution/Warning/Replace) is automatically executed. Mold transfers include an 8-stage process and 3-stage checklist to manage quality risk during transfers.

• 6 mold types supported
• Shot count-based remaining life auto-calculation
• 4-tier differentiated response (Normal/Caution/Warning/Replace)
• Automatic Cp/Cpk calculation during mold trials
• Maintenance/repair history management
• Mold transfer: 8-stage process + 3-stage checklist
• Mold life report auto-generation

Traceability maintained from requirements to verification

The entire path from requirements → design → testing → production is traceable.

8 requirement types (functional, performance, safety, environmental, specification, regulatory, customer, internal) can be registered and hierarchically decomposed. A Requirements Traceability Matrix (RTM) provides 4-directional traceability (upward/downward/forward/backward), confirming which design and which test verified a specific requirement in an N x M pivot view.

• 8 requirement types
• Hierarchical decomposition (parent requirement → child requirements)
• Traceability Matrix: 4-directional (upward/downward/forward/backward)
• Verification methods: Test, Analysis, Inspection, Demonstration
• V-Model traceability support

Design and deploy PLM without code

Configure PLM processes on the visual canvas and modify as needed.

A PLM data model with 56 tables and 131 relationships is pre-defined and can be deployed with one click. 6 workflows are built in -- PPAP, drawing distribution, mold life, requirements verification, certification renewal, mold transfer -- and can be directly modified on the canvas when business processes change.

Specialized for automotive parts manufacturing

Mold/tooling management, PPAP automation, and OEM approval processes are built into the system. In large-scale PLM solutions, these features are provided as separate modules or require custom development, but in this system they are included as standard functionality. In particular, mold lifecycle management (shot count-based remaining life, 4-tier differentiated response, transfer processes) provides a level of detail not found even in major PLM solutions.

Shorter implementation time

The average implementation time for large PLM solutions is 12-24 months with high customization costs. This system dramatically reduces implementation time by deploying pre-defined 56 tables and 6 workflows with one click, then modifying only necessary parts on the canvas.

Real-time design collaboration support

In markup sessions, annotations can be added to drawings or 3D models and discussed through comment threads. 3D view states (camera position, cross-section, exploded view, PMI, comparison view) can be saved and shared, enabling remote design/quality/production personnel to collaborate while viewing the same screen.

Engineering changes automatically sync with ERP/MES

When an ECO is approved in PLM, ERP product information (BOM, item master) is automatically updated. Changed drawings and BOMs are reflected in MES work orders, ensuring shop-floor workers always work with the latest version. No separate data transfer work is needed.

Engineering change management

• Prevent change omissions: ECO workflow automatically notifies all related departments of changes, preventing omissions due to email/verbal communication.
• Reduced change lead time: Impact analysis and approvals are processed in the system, shortening the engineering change cycle. Industry experience indicates ECO processing time is reduced by 30-50% on average.
• Clear existing inventory disposition: Disposition policies for existing inventory are recorded in the system during changes, eliminating shop-floor confusion.

PPAP efficiency

• Reduced PPAP preparation time: Parallel preparation of 18 elements and progress tracking reduce PPAP preparation from weeks to shorter timeframes.
• PSW auto-generation: PSW previously prepared manually is now automatically generated by the system.
• Customer response history: Approval/conditional approval/rejection history is systematically managed, enabling reference to previous feedback during resubmission.

Mold management

• Defect prevention: Life warnings enable advance identification of mold replacement timing, preventing defects from end-of-life molds.
• Maintenance cost optimization: Maintenance/repair history analysis optimizes preventive maintenance cycles and predicts mold replacement timing.
• Transfer quality assurance: 8-stage transfer process and checklists manage quality risk during mold transfers.

BOM accuracy

• Elimination of cross-department BOM discrepancies: 4 BOM types connected in a single system ensure consistent updates across all BOMs during engineering changes.
• Alternative material management: Approved alternative materials can be immediately identified during material shortages, preventing production stoppages.
• Where-Used utilization: Immediately identify where specific components are used to accurately assess change impact scope.

Scenario 1: Customer engineering change request

An automotive OEM customer requests a dimensional change to a part. An Engineering Change Request (ECR) is registered in the system, and 7-area impact analysis is executed. Inventory impact (3,000 existing parts in stock), cost impact (mold modification cost estimate), and schedule impact (2-week mold modification lead time) are calculated. After CCB review and ECO approval, existing inventory disposition policy (use up existing stock then change) is set, and related BOMs/drawings are automatically updated. Changes propagate to ERP item master and MES work orders.

Scenario 2: PPAP submission for a new part

A PPAP workflow is initiated for new part production approval. 18 elements (design records, DFMEA, process flow diagram, PFMEA, Control Plan, MSA, initial process capability, dimensional measurements, material testing, etc.) are assigned to responsible personnel in parallel. Real-time progress tracking for each element automatically highlights bottlenecks (delayed elements). When all elements are complete, a PSW is auto-generated and submitted to the customer. Customer conditional approval feedback is recorded, and previous feedback is referenced when preparing resubmission.

Scenario 3: Mold life warning response

When a mold's current shot count reaches 80% of its design life, a "Caution" alert is triggered. The mold manager reviews maintenance history and performs a mold trial to measure Cp/Cpk. If process capability falls below standards, mold replacement/repair is decided, and at 90% the status transitions to "Warning" with preparation of alternative molds initiated. When mold transfer is needed, the 8-stage transfer process and 3-stage checklist are applied.