Modern product development moves fast. Designs evolve, supply chains shift, and regulatory requirements grow more complex. In this environment, managing product changes effectively isn’t just an operational necessity. It’s a strategic advantage.
Change management in PLM (Product Lifecycle Management) ensures that design modifications, manufacturing updates, and field adjustments happen in a controlled, traceable, and efficient manner. Without structured change control, teams face duplicated work, misaligned data, and costly errors that ripple throughout production.
That’s where PTC Windchill comes in. As one of the industry’s most powerful PLM platforms, Windchill provides the digital framework companies need to handle change systematically, connecting people, processes, and data across the product lifecycle.
What Does Change Management in PLM Encompass?
At its core, change management in PLM refers to the process of capturing, evaluating, approving, implementing, and tracking all product design and manufacturing changes. In Windchill, these are managed through a structured hierarchy of change objects, including Problem Reports, Change Requests, Change Notices, and Change Tasks. These govern every stage of a modification.
This structured approach ensures every alteration, no matter how small, is properly evaluated for impact before it reaches production. Engineers can trace how a change affects CAD models, bills of materials (BOMs), documentation, and service content—all within the same environment.
By embedding change management into the PLM platform, Windchill provides traceability, accountability, and visibility. This is the foundation of a connected digital thread across engineering, manufacturing, and service.
Common Challenges Companies Face with Change Management
Implementing change management in PLM isn’t just about adding new tools. It’s about changing habits, workflows, and expectations across the organization. Many companies start strong but struggle to maintain consistency as teams, systems, and product complexity grow. Recognizing these common challenges early helps organizations plan smarter and avoid costly missteps that can slow progress or derail adoption.
Many organizations recognize the importance of change management but struggle to execute it effectively.
Here are some of the most common pain points:
- Inconsistent workflows: Changes are handled differently across departments or regions, leading to confusion and rework.
- Disconnected systems: Engineering, manufacturing, and supply chain teams rely on separate tools with limited visibility into one another’s changes.
- Undefined roles and responsibilities: Without clear ownership, approvals stall or critical details fall through the cracks.
- Compliance and audit issues: Unrecorded changes or incomplete documentation increase risk, especially in regulated industries.
- Change fatigue: Teams overwhelmed by unstructured processes lose efficiency and confidence in their tools.
These challenges highlight why many organizations turn to Windchill change management: to replace fragmented manual processes with a single, automated source of truth.
How Windchill Enables Effective Change Management
PTC Windchill simplifies and strengthens the change management process by integrating it directly into the product lifecycle. With configurable workflows and standardized change objects, companies can capture, evaluate, and implement changes with full visibility across teams.
Key Windchill capabilities include:
- Configurable workflows: Tailor approvals and tasks to fit your organization’s engineering, manufacturing, or service requirements.
- Linked data and impact analysis: Automatically identify which parts, documents, or assemblies are affected by a change.
- Complete audit trails: Every change is recorded, time-stamped, and traceable for full accountability.
- Digital thread connectivity: Ensure downstream teams—like manufacturing and service—receive accurate updates from engineering in real time.
With Windchill, change control becomes proactive rather than reactive—keeping your operations agile, compliant, and aligned.
Practical Best Practices for Implementing Change Management in PLM
Turning change management from theory into practice requires a structured, intentional approach. The goal is to create repeatable processes that everyone—from engineering to manufacturing—can follow with confidence. These best practices for Windchill change management will help your organization build a framework that’s scalable, transparent, and ready to evolve with your business needs.
To build a resilient and effective change management process, organizations should follow a structured roadmap:
- Assess your current state. Audit your existing change-control processes and identify bottlenecks or inconsistencies.
- Define your process owners and participants. Clarify who submits, reviews, approves, and implements changes.
- Standardize workflows. Configure Windchill change templates to align with your business structure and industry standards (such as CM2).
- Pilot before scaling. Test new workflows in one product line to validate results and gain user feedback.
- Engage cross-functional teams. Involve engineering, manufacturing, sourcing, and service early to ensure holistic adoption.
- Train and communicate. Equip teams with training and documentation to understand the “why” behind structured change control.
Successful change management in PLM requires both governance and culture—clear processes supported by consistent adoption and continuous improvement.
Benefits of a Well-Structured Change Management Process
A mature, well-designed PLM change management process doesn’t just make engineering changes easier—it transforms how teams collaborate and make decisions. By embedding structure, accountability, and visibility into every stage of the product lifecycle, organizations can move from reactive problem-solving to proactive innovation. The benefits extend beyond efficiency—they directly impact product quality, compliance, and customer satisfaction
When implemented properly, Windchill change management delivers tangible business value at every level of the organization.
1. Faster Decision Making
Standardized workflows reduce approval bottlenecks and allow for parallel review processes—accelerating design-to-production cycles.
2. Improved Data Accuracy
By managing all change data in a single PLM environment, teams minimize duplication and eliminate version confusion.
3. Enhanced Compliance and Traceability
Windchill automatically records every decision and approval, ensuring full documentation for audits and regulatory reporting.
4. Reduced Rework and Waste
Controlled processes prevent errors and miscommunication, saving time and material costs.
5. Stronger Collaboration Across Functions
With shared visibility, engineering, manufacturing, and service teams can align faster—closing the loop on the digital thread.
A mature PLM change control process isn’t just about efficiency—it’s about building trust in your data and confidence in every decision.
Frequently Asked Questions Around Change Management in Windchill
When evaluating change management in PLM platforms like Windchill, decision makers often want clear, practical answers about change control, collaboration, and compliance. The following answers address key considerations, helping teams see how Windchill creates a more structured, traceable, and efficient approach to product change management.
Does Windchill support change management and configuration control?
Yes, Windchill provides a complete framework for managing both change and configuration control across the product lifecycle. It uses structured change objects (Problem Reports, Change Requests, Change Notices, and Change Tasks) to ensure all updates are tracked, reviewed, and approved before implementation. Configuration control within Windchill links product data, CAD files, and BOMs so every stakeholder works from the latest, approved version. This structured governance helps prevent errors, improve data consistency, and ensure all teams stay aligned as designs evolve.
How does Windchill handle engineering change management?
Windchill’s engineering change management process captures, evaluates, and implements design changes through configurable workflows and standardized approval steps. Each change is linked directly to the affected parts, assemblies, drawings, or documents, creating a complete digital audit trail. Automated notifications keep engineering, manufacturing, and quality teams informed throughout every stage. This ensures changes are implemented efficiently, accurately, and with full visibility into downstream impact.
What are the benefits of using Windchill for change control?
Using Windchill for change control eliminates manual hand-offs and disconnected approvals that often slow production and introduce risk. The system accelerates decision-making with standardized workflows and automated routing, while maintaining full traceability for compliance and audits. Teams gain a single, authoritative view of each change, reducing duplication and version confusion. Ultimately, Windchill helps organizations respond faster to market demands without sacrificing quality or control.
How does Windchill improve collaboration between design and manufacturing teams?
Windchill bridges the gap between engineering and manufacturing by giving both teams real-time access to accurate, up-to-date product data. When a design change is approved, updates automatically flow downstream to manufacturing and service teams, minimizing miscommunication and rework. Shared visibility into BOMs, change status, and impact analysis keeps all stakeholders aligned. This seamless collaboration enables faster launches, fewer production delays, and stronger overall product quality.
Can Windchill track and document product revisions automatically?
Yes, Windchill automatically tracks every product revision and records who made the change, when it was made, and why. Version control is built into the platform, ensuring that only approved and released data is available for use in production or service. Historical versions are preserved for reference, enabling full traceability across the product’s lifecycle. This not only improves accountability but also supports compliance with industry and regulatory standards.
How does Windchill reduce manual work in the change approval process?
Windchill automates much of the change approval process through configurable workflows, notifications, and digital sign-offs. Instead of relying on spreadsheets or email approvals, teams can manage and approve changes directly within the PLM environment. Automated routing ensures each step moves efficiently to the right reviewers based on defined roles and business rules. This reduces administrative workload, shortens approval cycles, and eliminates bottlenecks caused by manual oversight.
How can Windchill help ensure product and regulatory compliance?
Windchill embeds compliance into everyday workflows by maintaining complete, time-stamped records of all engineering and manufacturing changes. It supports audit readiness through controlled documentation, approval tracking, and built-in reporting capabilities. Regulatory standards such as ISO 9001, FDA 21 CFR Part 820, and AS 9100 can be mapped directly to Windchill’s processes. This traceable, documented approach helps manufacturers meet quality requirements and demonstrate compliance with confidence during audits or inspections.
Getting Started: A Roadmap for Success
Building a successful change management in PLM foundation doesn’t happen overnight, but it starts with a clear plan. Whether you’re new to Windchill or looking to refine existing workflows, having a roadmap helps you move from disorganized change control to a well-governed, repeatable process. These key steps will guide you toward smoother adoption, stronger alignment, and long-term PLM success.
If your organization is still relying on email threads, spreadsheets, or informal approvals to manage engineering changes, now is the time to modernize. Here’s how to begin:
- Conduct a Change Management Readiness Assessment. Evaluate your current processes, tools, and team structure.
- Start with a Pilot. Implement change management in Windchill for one product or department before scaling enterprise-wide.
- Define Governance. Establish process owners, KPIs, and escalation paths.
- Integrate Systems. Connect PLM with CAD, ERP, and quality systems to maintain data consistency.
- Partner with Experts. Work with PLM specialists—like EAC Product Development Solutions—to configure, optimize, and sustain your Windchill environment.
EAC’s Change Management Workshop helps organizations document their current state, identify process gaps, and build an actionable roadmap to success.
Turning Change Into a Competitive Advantage
In today’s fast-moving manufacturing environment, change management in PLM is the cornerstone of operational excellence. It ensures that your organization doesn’t just react to change—but leads it with confidence, precision, and speed.
With Windchill, companies gain the tools and structure to manage change across the entire product lifecycle—creating a connected, compliant, and future-ready digital ecosystem.
Looking to streamline your engineering change process and strengthen your PLM foundation, but not sure exactly where to start? Check out our webinar Preparing for Change Management in Windchill to learn more!
If you’re wondering how to get effective and long-term PTC Windchill Support, look no further.
We partner with PTC and are a Top Solution Provider because our experts truly believe PTC products are the best in the industry for the Digital Thread and improving the complete product development process. Our company would like to address some of the pain points you may experience while using your Windchill PLM platform. As well as inform you about the steps we are taking to enhance your overall user experience and boost efficiency across your enterprise.
As with any complex software system, there can be a number of frustrations that users may experience when working with Windchill. Here are some common Windchill complaints that we hear in the industry:
- Complex User Interface especially for infrequent users
- Cumbersome Navigation
- Slow Performance & Speed
- Customization Limitations
- Limited Task Support & Access for departments outside of Engineering
- Lack of Workflow Synergy between multiple departments
Overall, these frustrations can make it difficult for users to work efficiently and effectively with Windchill. Read on to learn how Windchill Navigate works FOR you, not against you.
Windchill Support: User Interface
We understand that the complexity of the PTC Windchill user interface can sometimes be overwhelming. Windchill’s user interface can often be cluttered and difficult to navigate. The system has a lot of options and features based on how complex an integrated product database must be. In response to this feedback, we created EAC Productivity Apps.
Our goal is to simplify and streamline the interface, making it more intuitive and user-friendly across teams and departments while keeping security high. By reducing clutter and improving navigation according to different job titles and roles, we aim to enhance your productivity and reduce the learning curve.
Quick Search App
For example, the Quick Search App provides a simplified way for users to enter a number or attribute into a single search bar to find the data results within the context of their job role. This removes the need for users to apply an understanding of how Windchill objects are related and eliminates unwanted, irrelevant data for the task at hand.
Report Viewer App
Our Report Viewer app gives individuals outside the engineering department the ability to view and run Windchill reports with ease. Within the Report Viewer app, you can easily:
- Run pre-configured reports and saved reports
- Save new reports
- Access pre-built report dashboards that utilize the Windchill search engine
Part Associations App
This app provides a “shortcut” for users (especially shop floor employees) to access critical CAD files and documentation, and it consolidates results onto a single screen. Quickly access drawings, parts, assemblies, and other documents associated with CAD and part data.
For users who are in Windchill every day, we strongly suggest seeking out adequate training and support as a first step towards solving some of these frustrations. Even the most seasoned users may find tips and tricks that can simplify their workflows on a day-to-day basis.
BoM Compare App
Pro Tip: Did you know that Windchill BoM comparisons exist in Windchill?
They do! Now with our BoM Compare App, this feature is easier to find and leverage. View a side-by-side comparison of two Windchill bills of materials and select which attributes to compare, all with the click of a button.
Streamline PTC Windchill Navigation
Easy navigation is a huge factor that plays into workflow productivity. Windchill has many menus, screens, and options, making it difficult for users to navigate the system and find the information they need. This can be especially frustrating for infrequent users who are not familiar with the system.
Our EAC Apps are purposefully designed with easier navigation in mind. Instead of constant mouse clicks and multiple new windows opening across your screens, our developers created an ideal workflow. And significantly reduces how long it takes for you to get the info you need based on your job role.
Another challenge we hear from Windchill users is how long it takes to search for and find the data they need. We acknowledge that searching and finding documentation in Windchill can take way too long and cause a lot of frustration. This is especially true for people who only need to go into Windchill once in a blue moon. EAC Apps gets users to the data or drawings they need in just a few mouse clicks.
Below is a timetable that compares the number of mouse clicks it takes in the standard Windchill interface (a user with Windchill experience and skill) versus how many it takes using our productivity apps with little to no training needed.
Support Windchill Performance and Speed
Windchill can be slow to load, especially when working with large amounts of data or performing complex operations. This can lead to delays and frustration for users who need to work quickly and efficiently.
Additionally, optimizing the platform’s performance with maintenance on the back end is critical to ensure smoother operation, faster response times, and improved overall stability.
As a start, we highly recommend checking out the infographic, “6 Ways to Check and Maintain Your Windchill System” to support a healthy Windchill environment.
If your Windchill system continuously crashes or freezes, there is a serious issue that needs attention. For additional help, our managed services team is dedicated to resolving these issues and providing you with a more efficient and seamless experience. Our managed services, EAC Alliance, takes the heavy lifting off of your system admins so they can focus on their core responsibilities.
Learn more about the EAC Alliance program for Windchill. In regards to system crashing or freezing, that does NOT have to be your “normal”. In fact, 99.5% of our Alliance customers see a 100% in Windchill uptime and over 99% in availability. And 100% of our customers say they experience a significant improvement in speed and performance.
For most apps, you don’t even have to log into Windchill at all to get the info you need quickly and securely whether you’re a finance team member in your home office, or a builder on the manufacturing shop floor using your phone or tablet.
Quick Access App
More specifically, the Quick Access App eliminates the need to go into Windchill at all. Shop floor personnel can submit a problem report, a change request, or a new variance directly within the app. The Quick Access app improves user adoption and streamlines access to critical data sets.
The Quick Access app enables team members to quickly view a product’s structure, supporting information, and digital content. It also facilitates rapid issue capture to ensure quality and speed time to market.
Help with Effective Windchill Customizations
Another pain point that has been highlighted is the limited flexibility for customization within PTC Windchill. We understand that different organizations have unique requirements, and we are committed to empowering you with the ability to tailor the platform to your specific needs.
We are actively working on expanding the customization options and offering more flexibility to adapt PTC Windchill to your workflows and processes. Each EAC App allows for ample customization based on what your team or department wants or needs! We’ll set you up for success.
The best part is, even if you upgrade your Windchill version, you don’t have to start over with custom code like you do with ThingWorx! Our apps help administrators maintain the user portal after ThingWorx Navigate upgrade releases.
Windchill Security and Task Support
Need to give Purchasers access to only specific assets? Our EAC Apps allow you to share critical data securely with those who need it based on particular permissions and settings.
Give your shop floor access to the latest drawings, and design changes with easy-to-find and digestible data without having to email busy engineering teams. By expanding access to users in multiple departments with just a few clicks supports your Windchill investment.
Task Management App
Meet the Task Management App. Task Management helps users complete multiple tasks within one window! Streamline your workflows, filter by team assignment, and finish your to-do list. This app will fuel your efficiency, user adoption, and time management.
The Task Management App was designed to enable stakeholders to review and act on assigned Windchill change tasks. It provides visibility into important open tasks and their status.
Additionally, we have a robust knowledge base, user mentoring, and tutorials to assist you in leveraging the full potential of PTC Windchill. Our training and mentoring team is always available to address your queries and provide timely assistance.
Support for Windchill Collaboration and Integration
Is your engineering team the only department accessing Windchill data? If so, your company is not maximizing your technology investment. Our experts stress the value of collaboration and integration with other tools and systems for seamless workflows and processes surrounding your current tools and technology environment.
Our intuitive role-based apps make it easy for stakeholders in other departments to get the data they need from Windchill in a matter of seconds – instead of constantly having to ask the engineering team for answers!
Each app can be tailored to a specific role in your organization. Plus our PLM Apps integrate with any 3rd party system and expand Windchill’s integration capabilities, allowing you to connect with a broader range of applications and enabling smoother collaboration across different teams and departments.
Windchill Support for BoM Reports
For example, a healthy manufacturing BoM report requires input from multiple departments including design, procurement, manufacturing, and sales, and even more stakeholders need access.
The BoM Reports App allows all departments across the enterprise to accurately see the BoM data they need in real-time in the context of their job role. Within the app, you can view lists of unreleased products, created or modified parts in real-time (Cheers to supporting the digital thread strategy!)
Windchill Support for Change Management
Furthermore, Change Management is a core operational asset that can make or break processes across the enterprise. Our Change Management App aims to automate the critical flow and hand-off of information between teams and departments.
Enable excellent project management with an app that provides graphical views of problem reports, change requests, change reports, change variances, promotion requests, and more. This app is highly customizable based on the department and role of each user for maximum efficiency.
Bonus PTC Windchill Support: Implementation & Upgrades
Without experts who have the adequate time and capacity to do so (it’s seriously a full-time job), Windchill may not always be implemented properly in a timely fashion. This leads to data inconsistencies and errors. Errors that almost all manufacturers just can’t afford to be making.
The right approach matters, especially with PLM. To mitigate risk and save your IT team from a heavy burden, check out our service offerings for advanced Windchill support including Windchill implementations, upgrades, installs, and migrations.
Why Windchill is Still Critical for Success
Your feedback and input have been invaluable in shaping the direction of our efforts to improve your experiences with the complex yet powerhouse that is Windchill. We want to assure you that we are committed to continuously enhancing the platform with EAC Apps to serve your needs better and exceed your expectations.
The amount of power and robust capabilities of Windchill is the best investment a company can make on its digital transformation journey and implementing the digital thread. Connecting your data is critical. Finding and accessing your data with user-friendly PLM apps expands Windchill usage and amplifies your Windchill investment.
EAC Apps is the practical solution for PTC Windchill support by increasing Windchill usage and user satisfaction across the enterprise.
If you have any further pain points or suggestions, we would love to hear from you. Your insights are vital in driving our ongoing improvements.
Discover more info in the EAC Apps Brochure.
JR Automation, a Hitachi Group Company, leveraged EAC Productivity Apps to solve Windchill PLM frustrations, scale their business operations and improve the shop floor experiences of their engineers. Discover how JR Automation implemented PLM Apps to gain ROI, bring efficiency and clarity for builders on the manufacturing floor, and achieved scalable digital transformation.
Business Initiatives
JR Automation knew the company needed to update operational processes in order to meet and exceed customer expectations. Their goal was to reduce the time it was taking builders and engineers to manage print packages by 80%.
Additionally, they wanted to increase efficiency by 5% or more during the assembly phase. Including enhanced communication on the shop floor. As well as saving time on machine assembly and tactical coordination. As such, was estimated to be taking up 30% of a builder’s day.
Business Challenges
With an increase of workers on the shop floor, builders had no choice but to walk back and forth to shared kiosks in order to visualize and assemble designs. These complications only intensified as products became more complex. With manual error-prone operations, redline quality, and accuracy were at stake.
Similar to many other manufacturing organizations, challenges arose when it came to searching for the correct prints, managing paper booklets, and updating print designs.
Rework stemming from incorrect designs, and file management complications were growing. Also, misplaced product information (needed for closed-loop change processes) had never been greater. JR Automation was seeking a simple way for low-tech machine builders to get last-minute design changes to engineering. Ross Walters, Director of Engineering, knew that builders required a solution that was highly intuitive.
The Solution: EAC Apps
JR Automation looked at PTC Windchill Navigate. Windchill Navigate does offer a single view to multiple enterprise systems like ALM, MRP, ERP, SLM, CRM, Accounting, and PLM (Windchill). It also gives users universal access to the latest most accurate product information when they need it.
However, it was clear to JR Automation that what they really needed was a customized app that made things easier. EAC’s experts knew the solution and streamlined processes that allow builders to get drawings, CAD files, and other related documents in a single portal. With EAC Apps they could also see role-based reports and make redlines.
By providing all the information needed on a single screen, with user-friendly workflows and easy-to-submit redlines, EAC apps improved operational efficiency as well as customer satisfaction.
A Custom Solution with Major Impact
After evaluating cost, functionality, implementation time, training, and other considerations, JR Automation unveiled they would gain an ROI of $1.4 million from EAC Productivity Apps.
EAC Apps benefited JR Automation with:
- 80% efficiency increase in print management for mechanical engineers
- 60% efficiency increase in builder print management
- 60% increase in digital efficiency gains
In conclusion, JR Automation’s builders no longer need to share a kiosk. Working with EAC enabled efficiencies for more than 200 workers who use Redline Apps today. They have eliminated the need for paper, print supplies, and additional booklets saving them additional costs. EAC Apps have continued to provide benefits such as improved accuracy with customer shipment orders, product designs, onboarding, and training efficiencies.
I’m sure at least once in your life you’ve heard the saying, ‘Work smarter, not harder.’ But what a cliche, right?! Well, for those of you managing your Bill of Materials (BOMs) in Excel, it’s time to step away from the cell block prison (pun intended).
In this article, we’re going to break down what it actually means to revitalize your BOM strategy with the Digital Thread to start seeing the results you want.
What Is The Digital Thread?
First of all, let’s start with the basics. The Digital Thread is a term used to describe the seamless flow of information throughout the manufacturing process. From design and engineering to production and after-sales support. It provides a way to connect all the data and information generated at different stages and from systems of the product lifecycle.
Generally, the Digital Thread provides value by enabling better visibility and control of any processes that require or produce product data. It enables manufacturers to collaborate more effectively, automate and optimize workflows, and quickly respond to changes. All while adjusting quickly to customer needs.
Bill of Materials (BOM)
Next, let’s break down the concept of a Bill of Materials. A complete Bill of Materials (BoM) list usually contains all of the parts and components needed to create or manufacture an end product. You might think of a BoM as a recipe ingredient list. The information about each part can include details such as part names, part numbers, quantity required, and cost per unit. Not to mention, BoMs contain other relevant part details such as material type, color, or size if applicable; supplier information; serial numbers, etc.
By consolidating and organizing all the pertinent information product information, the BoM becomes a centralized resource. A critical resource that facilitates the manufacturing processes of specified products.
Ultimately, the goal of the BoM is to help track inventory and verify missing parts during assembly. Equally as important, BoMs are critical to support a healthy supply chain, as well as help with purchasing decisions and more.
The Digital Thread and Bill of Materials Working Together
Balancing a plethora of product information – it’s no surprise, the best BoM management strategy used within the industry does not leverage solely Microsoft Excel. Nor does it rely upon one Enterprise resource planning (ERP) system. Instead it works to unite data from multiple systems into a single source of truth.
Sounds great doesn’t it? But, if you’re like most – your product data lives all over the place in different systems from different departments. This situation tends to create data siloes resulting in time-consuming manual tasks using outdated operational processes. Generally, these are some of the biggest problems that inhibit manufacturers from achieving their business initiatives.
Oftentimes, during our EAC Assessments, we hear multiple teams across the enterprise and different management levels are frustrated by broken processes. In short, there is a lack of key information employees need to do their jobs right, at the time they need it most.
Meanwhile, the digital thread uses advanced technology (such as product lifecycle management systems as well as the Internet of Things) to connect critical disparate processes. This, in turn, helps minimize manual tasks, and breaks down data siloes. Implementing the digital thread to your BoM strategy creates a major impact for all stakeholders involved. For instance, design teams, engineers, manufacturing, assembly, operations, finance, purchasing, and even marketing.
How The Digital Thread Supports Engineering
Furthermore, the Digital Thread plays a crucial role in supporting engineering and bill of materials (BOM) management by providing seamless connectivity and accessibility to relevant data throughout the product lifecycle. Here’s how the digital thread benefits these areas:
1. Engineering Collaboration
Firstly, the digital thread allows engineers to collaborate effectively by providing a centralized platform for sharing and accessing engineering data. This facilitates cross-functional collaboration, enables real-time communication, and reduces errors or miscommunications during the design and development process.
2. Design Consistency
Secondly, the digital thread ensures design consistency by maintaining a single source of truth for engineering data. Changes made in the design phase are automatically propagated throughout the digital thread, ensuring that all related documents, models, and specifications remain synchronized.
3. BOM Accuracy and Visibility
The digital thread integrates BOM management, configuration management, and BoM transformation capabilities. This enables accurate and up-to-date BOMs, as the data will automatically reflect changes. Additionally, it provides real-time visibility into the BoM status, including component availability, sourcing information, and cost implications.
4. Change Management
Next, the digital thread streamlines change management processes. By automating change notifications, approvals, and tracking. Essentially, it ensures that engineering changes are effectively communicated, documented, and implemented across the relevant stages of the product lifecycle, minimizing errors and delays.
5. Manufacturing Process Optimization
By connecting engineering data with manufacturing process management, the digital thread enables better coordination and optimization of production processes. By in large, system and data integration allows for improved manufacturing planning, efficient resource allocation, and reduced lead times.
6. Enhanced Visualization and Analysis
Another example includes leveraging augmented reality (AR) design sharing to provide visual representations of designs. In detail, enabling stakeholders to view and analyze products in a virtual environment. It’s recommended to use AR to enhance design reviews, simplify communication, and facilitate better decision-making.
Overall, the digital thread improves engineering and BoM management. Markedly, by streamlining processes, enhancing collaboration, ensuring data consistency, and providing visibility across the product lifecycle. It promotes efficiency, accuracy, and agility in engineering and BoM-related activities. Leading to improved product quality and faster time to market in the long run.
How A Digital Thread BoM Strategy Streamlines Manufacturing
Simultaneously, the digital thread plays a significant role in enhancing the bill of materials (BoM) management for manufacturing, assembly, and quality control processes. In sum, here’s how the digital thread benefits these areas:
1. Manufacturing and Assembly Planning
The digital thread enables seamless integration between the BoM and manufacturing planning systems. It provides real-time visibility into the BoM, ensuring accurate and up-to-date information for manufacturing and assembly operations. This allows for efficient production planning, optimized resource allocation, and improved scheduling in all.
2. Supply Chain Integration
By connecting the BoM with supply chain management systems, the digital thread enhances supply chain visibility and collaboration. It enables better coordination with suppliers, accurate tracking of component availability, and improved procurement processes. As a result, it minimizes the risk of production delays and ensures timely delivery of materials.
3. Work Instructions and Assembly Guidance
Thirdly, the digital thread facilitates the creation and dissemination of detailed work instructions and assembly guidance based on the BoM data. This ensures that assembly operators have access to accurate and step-by-step instructions, reducing errors and improving productivity on the shop floor.
4. Quality Control and Traceability
The digital thread enables better quality control and traceability throughout the manufacturing process. By integrating the BoM with quality management systems, it ensures that quality requirements and specifications are adhered to during production. It also enables traceability of components and materials, making it easier to identify and address any quality issues or recalls.
5. Continuous Improvement and Feedback Loop
Additionally, the digital thread supports continuous improvement initiatives by capturing data and feedback from manufacturing and quality control processes. It enables the analysis of production data, identifies areas for improvement, and facilitates data-driven decision-making to enhance manufacturing efficiency and product quality.
6. Post-Market Monitoring
Finally, the digital thread extends beyond the manufacturing phase to support post-market monitoring and quality assurance. Integrating BoM data with field service management systems and customer feedback enables organizations to identify and address product issues, initiate product improvements, and provide timely support and maintenance.
All in all, the digital thread enhances BoM management for manufacturing and assembly processes by ensuring accurate and up-to-date information, facilitating supply chain integration, enabling effective work instructions, improving quality control, supporting continuous improvement efforts, and enabling post-market monitoring. Concurrently, it streamlines operations, improves product quality, and enhances customer satisfaction.
The Polaris Story
Polaris utilized PTC Windchill, an advanced product lifecycle management system, to transform their Bill of Materials into a reliable new business model backbone. As a result, it allowed them to create a connected enterprise.
Windchill PLM combines the digital thread framework with a maximized BoM and change management strategy. This powerful product lifecycle management platform organizes all information associated with the development of its products, allowing every stakeholder to access the latest up-to-date information in a dynamic format.
Once it was clear to Polaris that they had outgrown certain tools and processes, they coordinated and synchronized a digital thread of data throughout the enterprise by leveraging PTC Windchill.
As of today, Polaris’ Windchill PLM system enables them to manage and organize the bill of materials (BoM) and implemented configuration management practices. This helped transform their BoMs as needed, effectively managing changes, overseeing manufacturing processes, and utilizing augmented reality (AR) design-sharing capabilities.
By orchestrating these elements, the digital thread ensured seamless connectivity and flow of information across different stages and departments within Polaris. This enabled improved collaboration, streamlined workflows, effective change control, and enhanced manufacturing processes. On top of giving the ability to share and visualize designs using AR technology.
Conclusion
To sum it up, it’s time to put Excel away and start working smarter, not harder. Successful BoM management derives from a single source of truth throughout the enterprise in regard to all the data contained in the Bill of Materials. The Digital Thread allows for the seamless automated flow of the BoM information to create a truly connected enterprise, working in sync along every step of the manufacturing process.
Not sure where to get started? We created our EAC Assessments to help. Click here to learn more or have a conversation with our experts.
