Running your manufacturing operations without PLM software integration is like trying to direct a movie with your cast and crew scattered across different sets — cohesion, collaboration and efficiency go right out the window.

But don’t throw the script out yet! In this article, we’ll share everything you need to take your integration-less product lifecycle from zero to hero. Ready to learn all about the benefits, functionality, implementation and considerations of PLM integration? Let the masterclass begin!

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What Is PLM Integration?

PLM integration is a process that streamlines product development by connecting your PLM system with enterprise systems like ERP, MES and CAD. It allows users to eliminate data silos, improve quality control, access real-time information and collaborate better.

Key Benefits

Investing in integration may sound like an annoyance or a hidden cost tacked on to purchasing new software. However, the good far outweighs the bad in terms of reaching your business goals. Here’s a closer look at the positive impact it can have on your product development process:

Centralized Data Management

Say goodbye to searching through scattered spreadsheets and fragmented information. PLM integration creates a single source of truth for all product data, ensuring everyone has access to the latest specifications, bills of materials (BOMs) and revisions. Reduce double-entry errors and rework, saving your company valuable time and resources.

Better Collaboration

Keeping up with information from different departments with different formats and different owners is as complicated as it sounds. Data cleansing, standardization and automated data exchange eliminate the need for manual data entry between systems. It also ensures all teams receive the same data and keep projects on track.

Faster Time-To-Market

Streamlined workflows and real-time data sharing mean seamless product movement between design, engineering,and manufacturing. Quicker releases help you capitalize on market opportunities and stay ahead of the competition.

Enhanced Cost Control

Improve resource allocation and reduce rework with access to accurate, centralized data. Quicker turnaround times and minimal data silo leads to a cost-effective product development process.

Improved Product Quality and Compliance

Consistent data throughout the product lifecycle leads to fewer errors and higher-quality products. Boost accountability and traceability of materials and components to rapidly identify and resolve quality issues. A complete audit trail of product information simplifies compliance audits and reduces the risk of regulatory non-compliance.

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Key Components for PLM Integration

PLM integration that doesn’t include certain “capabilities” is like building a Lego set without the instructions — it could work, but you’ll definitely struggle a lot more. Here are the key components you need for smooth sailing:

• Data Exchange Capabilities: Transferring information between PLM, MES, ERP and CAD software is a many-splendored thing. You’ll need to ensure wires aren’t crossed and formats aren’t rendered useless when accessing CAD models, BOMs, work instructions and manufacturing processes.
• Bidirectional Communication: Two-way data flow is essential for maintaining consistency across all systems. Changes made in one system should auto-reflect in others, eliminating discrepancies and ensuring everyone uses updated information.
• Integration with Specific Data Models: PLM standardization hasn’t yet reached fruition. Accommodating specific data structures used by your systems is essential. For example, integration with BOM data ensures accurate material planning and production processes.

Common Challenges

Like any new process, PLM integration comes with a learning curve. We asked a few experts for their take on common challenges. Here’s what they said.

Complex Data Migration

We’ve harped on data migration and standardization a fair number of times in this article. According to Karl Threadgold, Managing Director of Threadgold Consultancy — an ERP solution provider — it’s for a good cause. He said,

Transferring existing data into a new PLM system can be complex, especially if the data is scattered across various formats and systems. It’s essential to plan for a clean, organized data migration, possibly requiring data cleansing and standardization to ensure compatibility with the PLM system.”

Ineffective Change Management

Karl also noted the importance of effective change management.

PLM integration often requires changes in workflows and processes, which can meet resistance from staff accustomed to the existing ways of working. Effective change management, including communication, training, and support, is vital to help users adapt to and embrace the new system.”

Endpoint System Changes

Thomas Shoemaker, Vice President at Propel Software believes on-premise solutions may be a culprit for additional challenges:

Complexities associated with either one or both of the endpoint systems changing, such as with a new release may be particularly challenging for on-premise systems where the customer is responsible for the upgrade effort. Modern cloud solutions overcome these challenges by offering a range of integration approaches, such as simple import or export capabilities, standard APIs, or standard middleware connectors.”

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Best Practices

Proper PLM integration can be a game-changer. But, navigating the process requires careful planning and consideration of several key factors:

1. Establish Clear Objectives

Karl has worked with many clients who have implemented a new PLM system within their ERP. He shared his top tip for integration.

For first-time Product Lifecycle Management (PLM) users, my top integration tip is to focus on establishing clear objectives and understanding the specific needs of your organization. It’s crucial to identify what you want to achieve with PLM, such as improving product development processes, enhancing quality control, or streamlining collaboration across departments. This clarity will guide the integration process, helping to ensure the PLM system is tailored to your organization’s requirements and can deliver the desired outcomes.”

2. Understand Your IT Landscape

The foundation of a successful PLM integration lies in compatibility. Before embarking on this journey, thoroughly assess your existing IT infrastructure. Here are some key questions to ask:

• What enterprise systems are currently in use (ERP, CAD, CRM)?
• Are these systems compatible with your chosen PLM solution?
• What is the level of technical expertise available within your IT team?

Understanding your existing infrastructure helps determine the best integration approach. Pre-built connectors might be suitable for common systems, while custom integrations might be necessary for unique setups.

3. Prioritize Data Security

Data is the lifeblood of your product development process. During integration, ensure data integrity and compliance with regulations with the following steps:

• Evaluate the data security protocols offered by your PLM solution and other enterprise solutions.
• Map out the data flow between systems to identify potential vulnerabilities.
• Establish clear user access controls and data encryption practices.

4. Invest in a Cloud-Native Platform: Shelling out extra money on custom integrations isn’t fun. Thomas suggests deploying mission-critical applications on a modern, extensible platform. He said,

There are some cloud-native industry platforms that support a wide breadth of capabilities across many distinct domains and processes that are interrelated to PLM. Consider, for example, how you sell and support your products. Evaluate the upside of having a common environment for performing all tasks related to driving product success. While this won’t eliminate the need for custom integrations, it may reduce it substantially.”

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FAQs

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Next Steps

Even Spielberg would struggle (at least a little) to direct while dealing with data silos, inefficient processes and outdated information. Use PLM integration to transform your product development process from a B-movie blooper reel into an award-winning masterpiece.

Need a helping hand? Try our free requirements template to streamline the PLM features your business has been missing.

What’s one tenant of PLM integration that feels particularly daunting? Let us know in the comments below!

SME Contributors

Tom Shoemaker is the VP of Product Marketing at Propel. In this role, he is responsible for product messaging and positioning, sales enablement, and voice-of-customer programs.

Karl Threadgold is the Managing Director of Threadgold Consulting, a NetSuite ERP Solution Provider. Karl has over 10 years of experience in implementing ERP solutions to businesses across Europe and Asia.