SuccessStory Wirtgen Group - DSC Software AG

SuccessStory
Wirtgen Group
PLM in Road Construction
A PLM solution enables the Wirtgen group to provide
comprehensively optimized processes from
development to service. Using SAP PLM, the
companies Wirtgen GmbH and Joseph Vögele AG,
both members of the Wirtgen Group, integrated the
CAD systems Unigraphics and ME10. The product
data is thus available immediately in downstream
processes such as manufacturing and the drawing up
of documentation.
“Innovative products and complete product lines are responsible for our fast growth. For
example, in less than three years our engineers have developed the complete line of small
milling machines, that is nine different machine types. At Joseph Vögele AG, all serial
machines are new developments from the last two years” says Dr. Peter Mielke, head of
information management at Wirtgen GmbH. A high degree of innovation, a high vertical
range of manufacture and increasing delivery figures constitute an enormous challenge for
product development and the smooth cooperation with manufacture, logistics and service”
emphasizes Dr. Peter Mielke. “Thus, an optimization of our engineering and logistics
processes was all the more important” Dr. Peter Mielke explains, “to ensure high
productivity”.
At the start of the project, the initial situation in the companies of the Wirtgen Group varied
considerably. Vögele, for example, was already using SAP as an ERP system and Wirtgen
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SuccessStory
Wirtgen Group
was just introducing SAP into logistics. As of January 1 st , 2006, both companies were to
work within the same client of the central SAP system, hosted by T-Systems in Frankfurt,
Germany. ME10 and Unigraphics were used in construction. Teamcenter Engineering was
used to manage the Unigraphics files, the ME10 drawings and released Unigraphics
drawings were managed in an in-house developed 2D drawing archive, which could be
accessed by the manufacturing, purchasing, service and the technical documentation
departments. A uniform management of all technical documents as well as a programmed
connection between CAD drawings and material masters did not exist.
Keeping in view the complete process
With the introduction of SAP PLM and the direct integration of Unigraphics and ME10,
company-wide uniform product data management was to be implemented. Product
development was to be smoothly integrated into the company processes to make up-to-date
construction data available to all authorized employees. “We have implemented efficient
processes by using an integrated system for ERP and PLM and by no longer redundantly
managing our product data in several systems”, Dr. Mielke emphasizes the decision for SAP
PLM. “Another advantage is a considerable improvement in the cooperation between the
different locations. SAP PLM is our central information and content management platform for
engineering. The direct integration of the technical application systems in SAP PLM allows
us to make data available to all upstream and downstream processes in a centralized and
controlled manner”, explains Dr. Mielke.
SAP PLM at a high speed
SAP PLM and the direct integrations of CAD were introduced in several, partly parallel
project steps. This occurred at the same time as the SAP go-live in logistics and accounting,
the move to a new final assembly plant and the start-up of an automatic high bay rack
system. In the opinion of Dr. Peter Mielke “It was only possible to achieve all of this
successfully because we set up a small and competent project team, because tasks and
responsibilities were clearly defined and because the implementation was based on a strict
time schedule”. One challenge in the project was data transfer. All ME10 drawings and all
Unigraphics data were transferred. The transfer was carried out individually for each
location. The project started on 1 June 2005. By 5 December 2005, Vögele in Mannheim
was already able to go live with the CAD integrations for Unigraphics and ME10. Wirtgen in
Windhagen followed on 27 December 2005. “The project schedule was met and we were
able to implement the project within the time schedule”, praises Dr. Peter Mielke. “From my
point of view, this was due to the success of the teams from Wirtgen/Vögele and the
Karlsruhe service provider DSC supporting the project” says Dr. Mielke.
Today CAD data is managed as documents by the SAP document management system.
Different master document types were set up for this purpose: M10 for ME10 drawings and
UGM for Unigraphics models. Document types UGD for Unigraphics drawings, UGA for
Unigraphics Altreps and UGX for Excel sheets are available for non-master documents.
Master or non-master refers to the differing behavior of the documents within the process.
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SuccessStory
Wirtgen Group
Non-master documents, for example, adopt the document number of the master document
and are also versioned if the master is versioned. All documents use the same status
network.
Wirtgen GmbH is the world market leader in cold milling technology. The company offers 15
different milling machines for all power categories.
Flexible processes
Today, new documents are generated exclusively with an internal number allocation. Only
the existing documents continue to have descriptive numbers. This also applies to the
material numbers. Material numbers are now allocated internally by the SAP system. In
addition, the document number and material number no longer have to be synchronized,
thus permitting a more flexible process design. The connection between document and
material is ensured through object links.
At Wirtgen, a difference is made between prototype phase and serial support. The prototype
phase is characterized by frequent changes; CAD documents and new versions in this state
of development are therefore generated without reference to a change master. In production
on the other hand, documents and material masters are changed with a change master. “At
Wirtgen and Vögele, SAP change management is a central process for business
management. It exists throughout the complete value chain, from prefabrication, steel
construction, mechanical processing and varnishing to pre-assembly and final assembly. It
controls the interaction between document status, document version, material, material
revision and BOM”, Dr. Mielke explains. “Material revisions and document versions are
synchronized by the system”.
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SuccessStory
Wirtgen Group
The new generation of pavers of Joseph Vögele AG, Mannheim, Germany, offers a
completely revised design and an ergonomic and intuitive operating concept.
Controlled release
When generating a new CAD file today, SAP automatically generates a document info
record, document type UGM in the case of Unigraphics or M10 in the case of ME10. A
material master can be generated for each CAD document. This is achieved by using drag &
drop in the user interface of the integration solution. Upon saving, the CAD data is saved in
the respective SAP content server.
The next step in developing a construction document is the prototype phase. It is completed
by prototype release. During this phase, the designer can generate new versions of the CAD
model. Possibly existing related non-master documents, such as drawings, are also
versioned automatically. Integrated test functions ensure that a separate versioning of the
non-master documents is prevented. The link to the material master remains. Once a
document has reached the prototype release – PF – status, the linked master and nonmaster
documents are also subsequently put into “PF” status.
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With the newly developed small tandem rollers of the HD series, roller manufacturer Hamm
AG in Tirschenreuth, Germany is opening up a new segment of the market. Hamm AG was
awarded the “Design Oscar”, the iF product design award 2007 in gold, for its small tandem
rollers HD8 to HD14.
Transfer to serial production
Documents and materials can only go into production if linked to a change master. To create
this link, the user pulls the material in the user interface of the integration solution to a
change master with status 01 – “Change open”. This is only possible if material, model and
drawing have the “PF” prototype released status. Respective checks are performed. When a
material revision is assigned, the material is released for serial production. As a
consequence, the status of the change master is set from status 01 to status 02 –
“engineering released” and the documents linked to the material master are automatically set
to “SF”, released for serial production.
Once a product is in serial production, it has to be changed by using a change number. For
this purpose, the respective material master is pulled to a change master – status 01 – by
using drag & drop. The related documents are thus automatically linked to the change
master. The changes are carried out in the new version of the documents. This process
applies only for materials which can be replaced completely. Otherwise, the designer has to
copy the document to a new number and link it to a new material master. If a new material
revision is assigned, the status of the change master is changed from status 01 to status 02
– “engineering released” and the documents linked to the material master are automatically
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SuccessStory
Wirtgen Group
set to “SF”, released for serial production. The predecessor version of the documents will
then receive the status “AB” respectively “replaced”.
“Within the Wirtgen Group just as in the change master, material and/or material status have
functions which control the enterprise. A great variety of economic functions such as
procurement, sales, supply are triggered via the material status”, Dr. Mielke explains.
Consistency checks and rules for more process security have been introduced in the project.
For example, a configuration was carried out so that during the release of an assembly for
serial production, checks are performed to ensure that all sub-assemblies have the “SF”
status, released for serial production. Upon release of the successor version, appropriate
tests and rules ensure that the predecessor version is set to the “AB” or “replaced” status.
This and a certain further rules were configured via an additional module by DS
Clearly defined project schedule with milestones and responsibilities
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CAD change
SuccessStory
Wirtgen Group
It often occurs that an ME10-drawing in serial production is to be replaced by a new model
designed with Unigraphics. The following sequence has been implemented for this purpose:
when linking the material with the change number, it is checked whether a UGM/M10 pair
with an identical document number exists. If this is the case, together with the related part
and non-master documents the pair is entered in the change number. The user has to
generate a Unigraphics drawing for the higher version of the Unigraphics model. When the
material master is released, the Unigraphics model and the drawing are set to status
“released for serial production”. The ME10-model, which was not changed, is set to the
“replaced” or “AB” status. It can thus be seen immediately, at which point in time ME10 was
replaced by Unigraphics.
Viewing and Plotting
In addition, a conversion process was installed. It is activated automatically in the case of a
status change of the document to “prototype released”, “PF” and “released for serial
production”, “SF”; and provides a wide range of lightweight and interchange formats. These
are saved in the same document info record as the CAD main original. JT files are generated
to display 3D models, CGM, HPGL, PDF, DXF for drawings for lasering and burning and
STEP, IGES and Parasolid for data exchange with suppliers. At every workstation authorized
users can display the respective lightweight formats with the EAI viewer integrated in the
SAP GUI.
“Output management is a central function in the Wirtgen-Group, just as change service”, Dr.
Mielke explains. “For printing/plotting, we use the neutral format files saved in the respective
SAP content servers. For output management, we use a plot management solution by SEAL
Systems, extended by us by means of in-house programs for collecting the documents to be
printed. For example, we can thus print all drawings related to a material number of a certain
material revision. The latest released drawing will be printed, if no material revision is stated.
Additionally, we can print details shown in the viewer. All documents are stamped during
output. Another adjustment concerns automatic scaling. Formats from A0 to A3 are
automatically scaled to A3, and drawings required for lasering and burning are automatically
scaled to A4. It was possible to completely substitute the existing printing/plotting functions
with the introduction of the company-wide output management.
Company-wide use of CAD data
Today, 130 product designers manage their ME10 and NX data in SAP PLM. The product
data is saved per location in a database-based SAP content server, integrated into an SAN
solution at Wirtgen. Above all, it is the downstream processes that benefit from verified and
up-to-date product data:
Today, drawings and 3D models can be displayed in production at every terminal with SAP
GUI at the press of a button. For example, parts, which bogie trucks are to be equipped with
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SuccessStory
Wirtgen Group
for powder coating, can be indicated and thus identified at every terminal. The employees,
who have to store the parts for mounting directly next to the machine mounting site, can
allocate the parts and transport tasks more easily. At any time they can collect information
about the parts on their monitor on the fork-lift. “This considerably improves the in-house
material flow”, emphasizes Dr. Mielke.
In addition, Vögele America is connected to the system via VPN connection/ internet. There
is a separate DSC cache server on site to buffer the drawings downloaded from the central
Vögele content server. In cooperation with Joseph Vögele AG in Mannheim Germany,
Joseph Vögele America constructs pavers for the US market.
The CAD data managed in SAP is used directly for drawing up the technical documentation.
For this purpose, DSC has implemented an integration with the Isodraw program by PTC,
which is used to draw up technical illustrations and spare part catalogues. The illustrations
generated with Isodraw are saved as documents in the SAP content server.
“For us, SAP PLM is the company-wide platform for PLM and ERP. Consistent data,
continuous processes and a company-wide uniform change process are central functions at
Wirtgen/ Vögele. They are the conditions we need to constantly provide new products for our
customers in a fast and flexible manner” Dr. Mielke summarizes the main reasons for SAP
PLM.
Wirtgen Group
The Group with the well-known brands Wirtgen, Vögele, Hamm and Kleemann produces and
sells machines for road construction, road maintenance and material processing. The familyowned
enterprise, founded in 1961, supplies a complete machine program for road
construction. The Wirtgen Group is active world-wide. Apart from the German parent
factories, plants exist in the USA, Brazil and China. Approximately 55 group-owned sales
and service companies as well as a large number of dealers provide services for customers
on all continents. With more than 4,000 employees, world-wide the Group achieved a
turnover of 1,040 million Euros in 2006.
DSC Software AG, Karlsruhe, Germany
Tel. 0721/9774-100, Fax 0721/9774-101
Wirtgen, Windhagen, Germany
Tel. 02645/131-0, www.wirtgen.de