© MAHLE

One PLM

Integrated digital PLM processes of

a global automotive supplier

Dr. Alexander Burger

Head of One PLM

16.05.2018

1

MAHLE International GmbH © MAHLE

1 Overview on MAHLE

2 One PLM

3 MAHLE Change Processes – Case Example

Agenda

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MAHLE International GmbH © MAHLE

Overview on MAHLE

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MAHLE International GmbH © MAHLE

MAHLE is one of the world’s largest automotive suppliers

with solutions round the powertrain

MAHLE DUAL STRATEGY

Strengthen our existing market

position

Shape the future in a changing

mobility world

105% GROWTH WITHIN LAST 5 YEARS

Employees: 77,000

Sales: EUR 12,3 billion (2016)

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MAHLE International GmbH © MAHLE

Requirements for modern mobility and MAHLE solution

portfolio

Surface Heating

Thermal Management

Connectivity

48V Twin Power

Thermoelectric Heatpump

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MAHLE International GmbH © MAHLE

One PLM

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MAHLE International GmbH

© MAHLE

Individualization

73% of the manufacturers will individualize their portfolio due to more differentiated customer requirements

Innovation speed

81% of the CEOs agree that innovation speed is a crucial factor for the business success

Smart Products

Until 2022 one trillion sensors will be connected with the Internet of Things

Cooperation

A success rate of development projects that is 4 times higher in the case of interdisciplinary co-operation

Production

Until 2022 the first car body and until 2025 5% of all consuming products will be manufactured by a 3D printing process

complexity time to market

costs

transparency mastering

reduce

Industrie 4.0

Global trends in the era of Digitization…

vari

ety

of

part

s

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MAHLE International GmbH

© MAHLE

Individualization

Configuration

Mastering the intern variation diversity

Innovation speed

Modularization

Reduction of development times by reutilization

Smart Products

Mechatronics

Differentiation by IoT-enabled products

Cooperation

Collaboration

Cross-domain cooperation between mechanics, electrics, software, purchasing, production planning, manufacturing and logistics

Production

Digital validation/ Industrie 4.0

Cost reduction by simulation and automation of the production

... and how the challenges can be overcome

complexity time to market

costs

transparency mastering

reduce

Industrie 4.0

vari

ety

of

part

s

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MAHLE International GmbH

© MAHLE

One PLM covers the addressed challenges enabling the

provision of innovative mobility solutions

11.000

PLM Users

~1.500

CAD Users

7.2 Mio.

Documents

Increasing

efficiency

Enabling

global

collaboration

Cross-BU

synergies and

Collaboration

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MAHLE International GmbH

ERP

© MAHLE

One PLM rough Architecture and Core Applications

Series Concept / Acquisition Product and Process

Development

Production

Preparation

Production

Ramp-Up

QG1 QG2 QG3 QG4 MS0 MS1 MS2

Concept / Acquisition Release

Quotation Approval

Product and Process Development Release

Start of Design Validation

Production Preparation Release

Parts out of Series Equipment

Production Ramp-Up Release

Series Production Support Release

Corporate

Research

Pre-Deve-

lopment

SP1 SP2

QG0

Project Templates

Project Documentation

Resources

Duration and Effort

Gantt Charts

Functions

PSM

Product eMat/

eBOM

mMat/m

BOM

CAD

2D

3D

Descr. Docs

EDB

VDB

Validation

IPD

TechDB

PPF

PSM

Polarion

Requirement

ReqMan

PR

OJE

CT M

AN

AG

EM

EN

T

MA

ST

ER

DA

TA M

AN

AG

EM

EN

T

Manage milestones &

Quality Gates

PR

OC

ES

S M

AN

AG

EM

EN

T

SOF/PAC

Process Templates

Tasks, Checklists

Commit

process & data readiness

Manage processes

for data creation,

update and release

Product Structure

Synchronisation

Status Management

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MAHLE International GmbH

© MAHLE

One PLM covers the optimization of all PLM processes

enabling the provision of innovative mobility solutions

Strengthen market position

in core business areas

Invest in growth areas and

technologies

Dual Strategy

Build the Basis

1

Consolidate to one

data backbone

From local to global

Enable

Collaboration

2

Use synergies

Enable collaboration

cross-BU

Enable

Digitization

3

Mechatronics

Big data analyses

Assistant systems

One PLM pillars

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MAHLE International GmbH

© MAHLE

IT empowers MAHLE to master the age of Digitization and Industry 4.0

…Digitization drives change

on the markets and at MAHLE

Market Needs

I

…IT is everywhere: IT is the key

driver and designer of digitization

Reorientation

II

…IT becomes partner "on the

same level" with the business

Integration

III

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Create Awareness Leave Comfort Zone Tear Down Silos

MAHLE International GmbH © MAHLE

MAHLE Change Processes – Case Example

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MAHLE International GmbH © MAHLE

The main advantage is the transparency on the change

process and associated levers

Transparency on process!

Reduction of change cycles and thus costs

Planning and approval of costs

Improvements in product and data quality

Manage and coordinate global projects

Audit safety and traceability

Benefits

MAHLE

CHANGE

TYPES

ENGINEERING

CHANGE

PRODUCTION

PROCESS

CHANGE

SUPPLIER

CHANGE COMMERCIAL

CHANGE

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MAHLE International GmbH

WORKFLOW SUPPORT FOR INTEGRATING THE PROCESS CHAIN (E.G. ECM PROCESS ON THE BASIS OF CENIT CONNECT APM)

INTEGRATED DIGITAL MASTER FOR MAHLE

© MAHLE

An integrated digital master ensures consistency on data

level and links IT and process level

Requirements Functions

PSM

Product

eMat/

eBOM

mMat/

mBOM

CAD

2D

3D

Descr. Docs optional

Client

Logistics Procurement

Engineering

Project Management

Management Services Distribution

Manufacturing

Controlling Quality

ECR Engineering Change Request

ECO Engineering Change Order

MCO Manufacturing Change Order

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MAHLE International GmbH © MAHLE

Case Example: ECM process MAHLE BU2 –

Brief explanation of video

ECR

ECO

MCO

Main process ECR Phase

Development-Sub process ( Split level 1)

Plant –Sub prozess (Split level 2)

Main process ECR Phase

Development-Sub process ( Split level 1)

Plant –Sub prozess (Split level 2)

Main process ECR Phase

Development-Sub process ( Split level 1)

Plant –Sub prozess (Split level 2)

Oil Air

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ECO

ECR

ECR process with 1 base material Starting

position

Due to high degree of reuse: Find

and select all affected products

136 products found

6 products selected

Objective

MAHLE International GmbH © MAHLE

Case Example: Cenit Connect APM User Interface –

Task Desk including MAHLE Split matrix

Split matrix Team

Checklist

Objects

Activity

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MAHLE International GmbH © MAHLE

Thank you

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