Success Story Gillet Tenneco - DSC Software AG

MySAP PLM at Heinrich Gillet GmbH:
One step ahead with SAP PLM
Dr. Arne Gaiser, DSC Software AG
Page 1 of 6
Success Story
Gillet Tenneco
Today, a modern supplier, such as Gillet, is more and more integrated into product
development of automobile manufacturer. This requires an IT infrastructure
seamlessly supporting product development processes. At Gillet, mySAP PLM
provides the basis to directly integrate CAD applications in use. The following report
focuses on the introduction of mySAP PLM Integration for Unigraphics supported by
DSC Software AG.
The Gillet exhaust system product range covers manifolds, pre-tubes, converters, and exhaust
silencers (Image: Gillet GmbH)
Gillet at Edenkoben, Palatinate is part of Tenneco Automotive, one of the worldwide
largest suppliers of chassis and exhaust system components. Tenneco Automotive
located at Lake Forest, Illinois, (USA) has a global staff of 23,000. As original
equipment manufacturer (OEM) the company serves more than 25 automotive
manufacturer. Additional 500 customers including wholesale are provided with spare
parts. Moreover, Tenneco Automotives markets dampers and exhaust systems as
Monroe®, Walker® and Gillet trademarks.
In 2002, Gillet with a staff of 3,350 in the OEM exhaust system branch had a turnover
of approximately 720 million Euro.
The close cooperation in product development with automotive manufacturer premises
that Gillet uses the CAD systems of the respective manufacturer. Next to the main
system CATIA, these are the systems I-Deas and Unigraphics.

Page 2 of 6
Success Story
Gillet Tenneco
In order to consistently manage all existing CAD systems at Gillet in Europe, and to
ensure audit compatible release strategies, all CAD systems were integrated into
mySAP PLM by respective CAD integration solutions.
This allowed to achieve a more efficient integration of product development into the
overall development process. "Our staff now is able to access all relevant documents
they need to do their job," explains Axel Dörr, Head of PDM Project at Gillet.
In May of 2000, the persons in charge at Gillet decided to introduce mySAP PLM, and
the CAD integration solutions for CATIA, I-Deas and Unigraphics. Preceding this
decision, an extensive process analysis and a system selection were on the agenda.
Approximately five months later, mySAP PLM Integration for Unigraphics was
implemented on a mySAP "sand box system". The objective was to demonstrate the
efficiency of the interfaces. In the following, the Gillet team jointly with consultants of
the software producers of the CAD integration solutions specified the target processes,
the so-called Business Blueprint, which was completed and released in March of 2001.
The processes defined there were subsequently realized in the mySAP system.

Page 3 of 6
Success Story
Gillet Tenneco
Now implementation of the solution was on the agenda. In the context of the
preparation phase between July and October of 2001, the migration of existing data
to mySAP PLM was pursued. "Altogether, we transferred 25,000 CATIA drawings,
and related derived drawings in TIFF format. To accomplish this, we used the SAP
LSMW migration software," mentions the Head of PDM Project. "Since at that time,
only a small inventory of Unigraphics and IDEAS drawings existed, we decided for a
direct, that is a manual import." In addition, missing material master were created in
mySAP PLM, document info records of CAD models were object-linked to related
material master, and the existing classification was migrated.
"Concluding, we introduced the authorization concept, user were trained, and we
prepared implementation," remembers Dörr. Beginning October 2001, the complete
solution went productive.
Core of the mySAP PLM solution realized at Gillet is the document management. Here
several document types were created which are linked to a specific status network.
This status networks controls the release management of documents. Important is that
today all processes are supported by a single workflow.

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Success Story
Gillet Tenneco
"On creation of a new model, automatically a new document number is created in the
mySAP system. At the same time, a corresponding material master is generated, and
the document is linked with the material master," describes the Head of PDM Project
this workflow. Then the engineer supplies product relevant data in the context of
classification. This information is entirely defined by the designer according to the
philosophy 'data input is effective where data is generated'.
Data exchange with the manufacturer is key
Since Gillet is extremely closely integrated in manufacturer process flows when
developing new products, the data exchange has to be designed especially effective. In
addition, a steady data replication is required. "In the daily routine, we receive
designed space data our data and processes rely on. After order accomplishment, we
have to provide manufacturer with the relevant information in an accurate way to
enable them to directly integrate this information into their processes," describes Axel
Dörr existing requirements. Moreover, all content versions and deliveries have to be
completely documented. "Currently, we work at a complete integration of the data
exchange into mySAP. This represents a further piece in the mosaic of our mySAP
solution," adds the PDM person in charge.
Today, access to standardized master data and released drawings in TIFF format is
possible from any location - directly from the SAP Graphical User Interface (SAP-GUI).
Each authorized user has access to material master data, drawings, and engineering
BOMs. In addition, drawings can be visualized - due to the EAI viewer integrated into
the SAP-GUI.

Thanks to mySAP PLM data redundancies are history
Page 5 of 6
Success Story
Gillet Tenneco
On the basis of mySAP PLM today all product-specific data is managed in a single
system only. This is imperative to prevent data redundancies. Moreover, by a
consequent use of classification, the re-use of components has become considerably
convenient for the engineer.
Meanwhile, document distribution takes place electronically only. The data validity for
subsequent processes is ensured by stamping the electronic documents with up-todate
status information.
By using further mySAP modules, persons in charge at Gillet pursue an ever increasing
data integration. One example is the 'SAP Project System' successfully introduced in
March of 2003, to manage sample and prototype production.
Then, next to CAD data, also test and check reports are to be managed in mySAP
PLM. At the end of 2003, this project is to be integrated in the SAP Project System.

Page 6 of 6
Success Story
Gillet Tenneco
"By introducing mySAP PLM as continuous solution, we were able to optimize and
shorten product development processes from first part sampling to production
release," sums up Axel Dörr. "The direct integration of all CAD applications in use at
Gillet in Europe was easily achieved by the mySAP PLM integration. The early
involvement of all departments in product development, and also the option to access
all documents from all locations are but two factors which will secure our market
success".
User contact
Heinrich Gillet GmbH
Axel Dörr, Head of PDM Project
Axel.Doerr@taeu.com