OpenPDM integrates the new PLM landscape at Webasto

After a longer selection phase, the project team decided to introduce the SAP-based PLM solution 4PEP from ILC GmbH, a decision that was backed by the assessment of an independent consulting firm. "4PEP gives us the opportunity to better integrate development and production processes by providing all information digitally," says Ortiz, explaining the main reasons for the decision. The flexibility of the software and the willingness of the software manufacturer to consider Webasto's special needs on the basis of the automotive-specific reference approach also spoke in favor of ILC. The software house also had a strong partner in PROSTEP AG for the integration of 4PEP and 3DExperience.

4PEP is an industry-specific PLM solution with preconfigured processes and methods optimized for the supply industry. Among other things, it offers modules for product structure and variant management, configuration and change management, master data management, but also for requirements management, project control and cost management. Webasto thus simplifies variant handling, for example, by no longer defining color variants of roof systems during development, but only during production coordination, explains Ansgar Villis, Deputy Managing Director of ILC GmbH and project manager in the Webasto project.

Cooperation with PROSTEP

The partnership with PROSTEP was very helpful in winning and carrying out the demanding PLM project, as Villis continues. The company is a recognized integration specialist with a wealth of industry experience, process know-how and technological expertise, as well as strategic partnerships with leading CAx and PLM manufacturers, Ortiz confirms. Based on the OpenPDM integration platform, the company has developed standardized connectors for 3DExperience and 4PEP, which can be quickly adapted to customer-specific requirements. Based on PROSTEP technology, Webasto also intends to integrate the Rational RTC software, which is used in the electronics sector for configuration and software management.

In close cooperation with ILC, PROSTEP implemented the data mapping for the various integration cases - starting with the transfer of design orders to the 3D Experience platform. During the pre-delivery of development stages for the procurement process, models and drawings are then converted into the neutral formats JT and 3D PDF, transferred to 4PEP and stamped with the note that they may only be used for requests. Once the design is complete, OpenPDM triggers a complex approval workflow in 4PEP that integrates purchasing, manufacturing, costing and controlling. If everyone approves the release, the integration platform reports the status change back to 3DExperience and ensures that the derived neutral formats are automatically re-stamped. The most complex integration case is the exchange of change orders, because with Webasto individual parts can be changed without immediately versioning the product structure or the parts list. This only happens when the parts are installed.

The integration cases must be partially readjusted, firstly because the new development environment is still under construction and secondly because the processes to be mapped are extended so that changes to the processes in 3DExperience and 4PEP occur. The flexibility of the integration platform, which allows changes or extensions to be implemented with minimal effort, has therefore proven to be an advantage, as Ortiz emphasizes: "OpenPDM is a very robust platform that has been in reliable operation since it was first launched.

The challenge of data migration

In the first project phase, the new CAD and PLM solution was implemented together with the integration platform in the convertible division and tested in a pilot project, which will be followed by others. "However, everything we do here is coordinated with the other divisions, which are already working with the new systems and can contribute their experience," says Ortiz. This is important in order to standardize processes across all divisions.

One of the potential hurdles that arose during the pilot project was the coordination of the product structures between the participating systems 3DExperience, 4PEP and SAP. In principle, Webasto wants to manage E- and M-BOM in 4PEP to ensure consistency between development and production. Which of the three systems, however, is to assume the leading role in the case of changes has not yet been finally clarified. It will be a compromise to ensure the strongest possible link between the systems, without limiting their flexibility too much, as Ortiz says.

The pilot project also showed that the effort for data migration was greater than expected. "Existing parts and standard components lacked certain attribute information that the new systems and processes expect," says Ortiz. "Another critical topic is the handling of the kinematics functions, which are very important for the convertible division. It has changed greatly from CATIA V5 to V6, so that the changed processes had to be taken into account during the migration."

Points in the direction of digitization

At the end of this year, the second project phase will start with a pilot project in the field of roof systems. The biggest challenge will be to completely migrate the Windchill data to 4PEP and then to correctly link it to the CAD data via OpenPDM, which will be migrated in parallel from ENOVIA VPM to 3D Experience. A lot of information, which is represented in the form of tables on the drawings, must be transferred to the models or the PLM system. "Our goal is to no longer have drawings in PLM, but only models and information from which the representations can then be derived," concludes Ortiz. "The PLM project should help us set the course for digitization and industry 4.0."