Röchling Automotive: 3D PDFs improve digital information flows

All the information in a single 3D PDF

The 3D PDF solution that PROSTEP implemented together with SEAL Systems makes it possible to automatically merge all the data and documents required for downstream processes in a compact, multi-page 3D PDF container for the first time. In addition to the CAD models, this includes classification information for the individual components and the BOMs from SAP PLM in particular. Because the new product data sheet contains all the relevant assembly information, it can be sent by e-mail and if necessary also be used without SAP access.

One of the considerable advantages of the solution is that the information is linked interactively, as Lupfer points out: "If users click on an item in the BOM, the corresponding component is highlighted in color. If they click on a component, they see the corresponding BOM item along with the classification data. They can show and hide components, making it much easier to filter out the information they require for their work."

The possibilities for interaction are not limited to navigation between BOMs, classification information and 3D models. In what is referred to as "Move Mode", users can remove the links between parts manually to create exploded views of assemblies and annotate individual components. This means that the product data sheets also support processes such as customer design reviews or the coordination of engineering changes, for which PowerPoint documents with views of the components to be changed are still often generated today.

Each product data sheet contains a breakdown of the BOM structure with a list of all the components, which can be easily identified with the aid of thumbnails in JPEG format. PDF Generator 3D generates these thumbnails during the conversion of the components into 3D PDFs. They have a significantly better quality than the thumbnails originally used in SAP, which were derived directly from the CAD models. PROSTEP has therefore set up a workflow that automatically replaces the old thumbnails in SAP as part of the process for converting existing product data sheets. A total of approximately 21,000 product data sheets were subsequently converted in order to improve their quality. As mentioned earlier, the old data sheets did not have the same level of detail and were based on STEP data that had not always been converted correctly and in its entirety.

Automatic generation of 3D PDFs

PDF Generator 3D automatically generates new product data sheets as soon as the designed components have reached a specific level of maturity, which is usually when the status changes to "for review". The automated process is based on STEP conversion but is independent of it. Once ECTR implementation has been completed, Röchling Automotive will add the option of manually triggering generation on demand, so that the company's own tool shop can be informed of upcoming projects at an even earlier stage for example.

The 3D PDFs are stamped with a digital watermark to avoid errors resulting from the use of documents that have not yet been approved. It provides information about their status and remains intact even when the 3D PDFs are printed, copied or sent via e-mail. If the status changes, the product data sheet does not have to be generated again, only the stamp has to be updated or, following approval, removed completely. The digital stamp function is part of the conversion solution from SEAL Systems but is triggered via an interface directly from within PROSTEP's 3D PDF solution. Lupfer praises the collaboration between the two partners during implementation of the solution.

While native CAD data and neutral formats were previously stored in different data repositories, the PLM system now manages the product data sheets together with CAD and STEP files as different document types under the same document number. Access is regulated by a differentiated, role-based rights concept that was implemented as part of the project, as Lupfer says: "We've determined which user groups and departments need which information at which point in time, and the status network has been developed in line with the roles so that certain employees can access the product data sheets earlier than others." The design engineers however can always view the native CAD data.

Basis for digital business processes

Approximately 600 employees in different departments around the world currently use the product data sheets as their initial source of information. One immediate beneficial effect as far as the IT department is concerned is the higher quality of the 3D data provided. This is reflected, among other things, by the fact that IT has fewer error messages to process. From the user's point of view, the most important advantage is earlier access to all the relevant product data, which helps to avoid errors in downstream processes and facilitates collaboration especially in global projects, as Dr. Gernot Kramer, Head of Development at Automotive Röchling in Italy, explains.

Implementation of PROSTEP's 3D PDF solution means that the company has now created a basis for digitalizing its business processes, says Lupfer. "Now it's time to think about how the technology can be used to further optimize the processes. We are, for example, thinking about also making the product data available in HTML5 format in the web so that users can access it more easily on their mobile devices." Röchling Automotive also wants to automate the conversion of lightweight JT data with PROSTEP's help so that they can exploit the possibilities offered by 3D views in SAP ECTR.