How to Manage Product Lifecycle Workflows

Implementing Configuration Management Best Practices in PLM, and Why Parts with Revisions Cause Problems Many PLM implementations unknowingly violate fundamental configuration management principles, even though the system is working exactly as designed and configured. One of the most common issues? Treating parts as revisioned objects. According to established configuration management best practices (ISO 10007, ANSI/EIA-649, ASME Y14.35/41/100, MIL-STD-3046), parts do not have revisions. Documents and specifications do. Whether the specification is a 2D drawing or a 3D model in a Model-Based Engineering (MBE) environment, the principle is the same: 👉 The definition changes, not the identity. Yet in many PLM systems, parts are routinely revised alongside drawings or models. While this may feel logical in the tool, it creates significant downstream challenges, especially in BOM management. Why do part revisions break BOMs? When parts carry revisions, every change to the part introduces side effects and potentially causes huge downstream work: • Assemblies suddenly reference outdated part revisions (if the BOM is released and points to a specific revision of a part used in the BOM, every BOM that uses the part now has to be changed as well to reflect the new part revision) • BOMs fragment into multiple near-identical structures • Manufacturing sees “new” parts that are actually interchangeable • ERP integrations explode with unnecessary item/version proliferation • ERP and PLM are out of sync, because most ERP systems do not manage part revisions • Change impact analysis becomes unreliable In other words, the BOM starts reflecting document history instead of product configuration. A cleaner, standards-based approach looks like this: • Part = stable product identity • Specification (drawing or model) = revision-controlled definition • BOMs reference parts, not document revisions • Changes are managed through document/model revisions, effectivity, and lifecycle state transitions This approach dramatically simplifies: ✔ BOM stability and consistency ✔ Manufacturing trust ✔ Change control ✔ Digital thread continuity (especially in MBE) ✔ Interface and data exchange with ERP systems The uncomfortable truth Many PLM systems encourage part revisions because it’s easy to configure, not because it’s correct configuration management. But PLM tools should support CM principles, not redefine them. If your BOMs are constantly chasing “latest part revisions,” the problem is rarely your engineers, it’s your data model. If you’d like to discuss how to align PLM data models with true configuration management best practices (drawing-centric or model-based), let’s talk. Contact us at results@plmadvisors.com #PLM #ConfigurationManagement #MBE #DigitalThread #EngineeringBestPractices #ProductLifecycleManagement

If your requirements live outside the tools your teams use to design and validate, you’re managing blind. That’s when change sneaks in, spreadsheets drift, and decisions get made on stale context. I’ve watched capable teams burn weeks on late change notices and heroic integrations because the requirements weren’t connected to the work.     The cost of ignoring this is well documented. A landmark study by Texas Instruments found runaway costs 7 out of 10 times when teams failed to keep requirements current. Projects that relied on documents or databases alone still saw high runaway rates. Add that test and integration often consume 50 to 60 percent of the lifecycle, and you can see why linking each requirement to test cases and design items is non‑negotiable. Another lesson from that research. Nearly all of your cost is locked in by the time you hit development. Decisions made early, with live requirements, decide whether your program will be late or lean.     Here’s the practice that consistently stabilizes complex, multi‑site programs. Treat requirements as a living system. Map each requirement to a specific design item, a test case, and a program constraint. Make the system web‑accessible and usable from common desktop tools so every entitled person can read, edit, and trace without a learning curve. Use notifications to flag parts and schedules at risk when a requirement changes.     The payoff for energy and utilities teams is concrete. Faster change assessment because every requirement has a home. Shorter test cycles because reruns automatically verify compliance. Better supplier conversations because requirements arrive early enough to adjust parts or propose alternatives. Most important, quality is designed in upstream, not inspected downstream. 

A broken BOM process can stall an entire manufacturing line, long before production even starts. A BOM (Bill of Materials) touches every part of product development, and when the flow isn’t tight, nothing else works smoothly. Here is a simple walkthrough of the end-to-end BOM lifecycle and how a product moves from design → production → service. Step 1 - Product Design (CAD) Engineers create 3D models and assemblies that form the initial design structure. Step 2 - Engineering BOM (EBOM) Generated The CAD structure is converted into an EBOM listing all parts, quantities, and hierarchy. Step 3 - EBOM Stored in PLM The EBOM is saved in PLM as the system of record with metadata, ownership, and lifecycle states. Step 4 - EBOM Validation Engineering checks for missing parts, wrong quantities, and invalid attributes before approving. Step 5 - Engineering Change Management Any design updates move through ECR/ECO to assess cost, supply, and manufacturing impact. Step 6 - EBOM → MBOM Transformation The manufacturing view is created by reorganizing parts for build sequence and adding non-design items. Step 7 - MBOM Validation Manufacturing verifies feasibility, routing, and plant-specific constraints before approving. Step 8 - BOM Released to ERP An approved MBOM goes to ERP for MRP, procurement, costing, and planning. Step 9 - Production Planning & Execution Production orders are created, materials are issued, and manufacturing begins. Step 10 - MES Execution (As-Built BOM) MES records what was actually built, including consumption, scrap, and deviations. Step 11 - Quality & Manufacturing Feedback Issues, improvements, or deviations trigger engineering updates if required. Step 12 - Service & Lifecycle Extension (Optional) A Service BOM is created for spare parts, maintenance, and aftermarket support. A great product isn’t just engineered well, it’s managed well through every BOM transition. Tight BOM governance = faster production, fewer errors, lower costs. For a deep dive into PLM, MES, or CAD and to elevate your understanding of PLM, connect with us at PLMCOACH and Follow Anup Karumanchi for more such information. #plmcoach #plm #teamcenter #siemens #3dexperience #3ds #dassaultsystemes #training #windchill #ptc #training #plmtraining #architecture #mis #delmia #apriso #mes

PLM is the most critical piece to Digital Thread - When we open up the hood of Digital Thread, PLM is the most critical piece for several reasons. Digital Thread refers to the seamless flow of information that connects all aspects of a product's lifecycle from design and manufacturing to service and disposal. Here's my reasons why End-to-End Visibility: PLM provides a centralized platform that allows organizations to manage and track every aspect of a product's lifecycle. This end-to-end visibility is crucial for understanding and optimizing each stage of the product development process Data Consistency and Accuracy: PLM systems help ensure that data related to the product is consistent and accurate across all stages of the lifecycle. This consistency is vital for preventing errors reducing rework and ensuring that all stakeholders have access to the latest and most reliable information Collaboration and Communication: PLM facilitates collaboration among cross-functional teams enabling seamless communication and information sharing. This collaborative approach ensures that everyone involved in the product lifecycle, from design engineers to manufacturers and service teams has access to the same data fostering efficiency and reducing miscommunication Change Management: Products often undergo changes during their lifecycle, whether due to design improvements regulatory requirements or other factors. PLM systems help manage these changes efficiently ensuring that all stakeholders are aware of modifications and that they are implemented in a controlled and documented manner Regulatory Compliance: Many industries have strict regulatory requirements that products must adhere to. PLM systems can help organizations ensure that their products comply with these regulations by providing tools for documentation traceability and reporting Continuous Improvement: PLM supports the concept of continuous improvement by providing insights into the entire lifecycle of a product. Analyzing data collected through PLM systems helps organizations identify areas for optimization cost reduction and innovation Integration with Other Systems: The Digital Thread involves the integration of various technologies and systems across the product lifecycle. PLM acts as a central hub that integrates with other tools such as CAD CAM ERP and IoT ensuring a seamless flow of information between these systems Traceability and Quality Assurance: PLM systems enable traceability allowing organizations to track the origin evolution and impact of every component and process in the product lifecycle. This traceability is essential for quality assurance risk management and addressing issues promptly PLM is the backbone of the Digital Thread providing the foundation for seamless collaboration data consistency and end-to-end visibility throughout product lifecycle. This integration and connectivity are crucial for achieving efficiency innovation and competitiveness. #plm #cad

🚀 Part 4 of my Rethinking Change Management: Collaborative Workspaces for Product Data (Sample Technology Stack and Workflow) In Parts 1, 2, and 3 of my recent series on modern change management, we explored how to evolve beyond traditional methods to tackle the complexities of managing product data across systems and disciplines. In Part 1, I introduced the concept of a collaborative workspace—a dynamic environment enabling real-time collaboration and change tracking (https://lnkd.in/e9V9phpE) In Part 2, I outlined the transition from traditional check-in/check-out methods to a single source of change, paving the way for better traceability and control. (https://lnkd.in/eRwFkXGD) In Part 3, (https://lnkd.in/eCCAbn23) I explore the coexistence of this new collaborative change management architecture with legacy file-based PDM and PLM systems. In the fourth part of my “Rethinking Change Management” series, I explore the technical architecture and workflows behind modern collaborative workspaces. This new approach moves beyond traditional PDM/PLM check-in/out models, enabling real-time, multi-user collaboration and smarter workflows. https://lnkd.in/eSTR4jcj ✨ Here are key highlights: Leverages Product Knowledge Graphs, API integrations, and polyglot persistence 📊 Scalable, traceable workflows for improved collaboration 🤝 and decision-making ✅ Real-time collaboration, like a “Google Doc” 📝 for product data 💡 I draw a sample workflow to demonstrate how it can work: 1️⃣ Retrieve Up-to-Date Data 📁 from CAD, PDM, or cloud systems. 2️⃣ Structure Data into a Knowledge Graph 🔗 capturing dependencies and metadata. 3️⃣ Collaborate in Real-Time ⏱️ without locking others out. 4️⃣ Approve Changes ✅ via transparent workflows. 5️⃣ Save Immutable Baselines 🛠️ of product revisions. 6️⃣ Browse Revision History 📜 for better traceability. The future of PLM is cloud-native ☁️, collaborative 🤝, and data-driven 📈, enabling companies to accelerate change management while ensuring governance and scalability. What are your thoughts on evolving change management in PLM? Let’s discuss! 💬 Looking forward to your comments Dr. Yousef Hooshmand Martijn Dullaart Jos Voskuil Matthias Ahrens Alex Bruskin Michael Finocchiaro Adam Keating Kevin Schneider Martin Eigner Prof. Dr. Jörg W. Fischer Ismail Serin Peter Bilello [sorry, I cannot put everyone here...] #PLM #ChangeManagement #Collaboration #DigitalThread #OpenBOM