In the fast-evolving world of digital product development, companies are increasingly turning to Windchill for its powerful Product Lifecycle Management (PLM) capabilities. However, to truly unlock Windchill’s potential, it’s essential to understand the various services that support its implementation, performance, and long-term success. From installation and configuration to ongoing maintenance and support, Windchill services ensure your PLM system is optimized, secure, and aligned with business objectives.

Why Windchill Services Matter

Implementing and maintaining a PLM system like Windchill isn’t just a one-time task—it’s an ongoing commitment to system reliability, efficiency, and performance. Without expert support and regular maintenance, businesses risk facing system downtimes, data inaccuracies, and delays in product development. Windchill services are designed to minimize these risks while maximizing the return on your PLM investment.

Core Components of Windchill Services

Windchill services are made up of several core components that work together to ensure your PLM environment is strategically implemented and continuously optimized. Each of these services plays a crucial role in supporting the success, scalability, and security of your Windchill system.

1. PLM Implementation Planning

Successful PLM implementation starts with a solid strategy. Services in this stage focus on aligning Windchill capabilities with your organizational goals, ensuring a smooth rollout that meets your technical and business requirements.

2. Installation & Configuration

Whether you choose an on-premise or cloud deployment, professional Windchill services ensure that your environment is installed correctly and configured to support scalability, security, and performance from the beginning.

3. Windchill System Maintenance & Support

System maintenance involves routine health checks, patch updates, bug fixes, and performance optimization. Regular maintenance reduces system disruptions and ensures ongoing compliance with evolving industry regulations.

Why IT Departments Shouldn’t Go It Alone

Many companies rely on their internal IT teams to manage PLM systems like Windchill. While IT is essential to infrastructure, managing PLM requires specialized knowledge in product development, CAD integrations, and lifecycle management. Overburdening IT with Windchill responsibilities often leads to delayed upgrades, missed opportunities for optimization, and increased total cost of ownership.

By leveraging dedicated PLM service providers, companies gain access to expert-level support, faster problem resolution, and proactive system management.

Advanced Windchill Services for Growth and Innovation

Beyond foundational implementation and maintenance, advanced Windchill services enable businesses to fully capitalize on their PLM investment. These services focus on enhancing system capabilities, user adoption, and integration across the digital enterprise—driving long-term growth and innovation.

Data Migration & System Integration

Merging legacy data into Windchill and integrating with systems like ERP or CAD requires technical precision. Professional services ensure clean, accurate data transitions and seamless integrations that support end-to-end digital thread visibility.

User Training & Change Management

A successful Windchill deployment hinges on user adoption. Windchill services often include customized training programs, documentation, and change management strategies to help teams fully utilize the platform.

Customization & Extension Development

Businesses often need to tailor Windchill to meet specific industry or organizational needs. Expert services can create custom extensions, dashboards, and workflows that enhance usability and functionality.

The Business Value of Professional Windchill Services

Beyond maintaining system performance, professional Windchill services contribute directly to business outcomes. With the right partner, organizations can achieve better product quality, faster release cycles, and streamlined regulatory compliance.

Utilizing expert Windchill services leads to significant business advantages:

  • Reduced downtime and increased system performance
  • Faster time-to-market for new products
  • Lower costs through automation and optimized processes
  • Improved product quality through better collaboration and control
  • Enhanced compliance with regulatory requirements

Windchill support services also ensure your PLM system evolves with your business, rather than holding it back.

How to Choose the Right Windchill Services Provider

Choosing the right Windchill services provider is critical to achieving a high-performing and future-ready PLM system. The ideal partner not only brings technical expertise, but also understands your industry-specific challenges, business objectives, and internal workflows. Look for a provider who offers flexibility, proactive communication, and a proven track record of success with organizations similar to yours.

When evaluating a service provider, consider:

  • Their experience with Windchill and PLM implementations
  • Industry-specific expertise
  • Flexibility of support plans (on-demand, ongoing, or project-based)
  • Availability of training and user support
  • Track record of successful deployments and satisfied customers

A good Windchill partner doesn’t just keep your system running—they help you get the most out of your investment.

Next Steps with Windchill

Windchill services are a critical component of any successful PLM strategy. From implementation and maintenance to integration and training, these services ensure your PLM system is reliable, scalable, and delivering maximum value to your organization. Whether you’re just beginning your Windchill journey or looking to optimize an existing deployment, partnering with experienced professionals can transform your digital product development environment.

Ready to get more from your Windchill system? Learn how EAC services can help you meet your business needs.

monitor displaying CAD file evoking ERP / MRP / PLM

In today’s increasingly digital and interconnected manufacturing environment, understanding the relationship and differences between ERP, MRP, and PLM systems is critical. Companies that rely on modern product development and supply chain management must know how these systems fit together to drive innovation, efficiency, and profitability.

This blog explores what ERP, MRP, and PLM systems are, how they differ, and why integration between them is essential for business success.

What is ERP (Enterprise Resource Planning)?

ERP stands for Enterprise Resource Planning. It is a business management software that helps organizations automate and integrate core business processes. ERP systems typically handle a wide range of business functions, including finance, human resources, procurement, inventory, order management, and manufacturing execution.

ERP software acts as a centralized system where data flows across departments, allowing for real-time visibility into operations and enabling better decision-making. A well-implemented ERP system improves productivity, reduces costs, and ensures better compliance across departments.

Key ERP functions include:

  • Financial management and reporting
  • Supply chain and logistics management
  • Human resources management
  • Order fulfillment and production scheduling
  • Procurement and inventory control

What is MRP (Material Requirements Planning)?

MRP, or Material Requirements Planning, is a subsystem often found within ERP platforms. It focuses on production planning, scheduling, and inventory control. MRP ensures that the right materials are available at the right time to support production without overstocking or understocking.

Originally developed as a standalone system, MRP has evolved into MRP II (Manufacturing Resource Planning), which includes broader manufacturing processes like capacity planning and shop floor control. Today, MRP is generally integrated within ERP platforms to offer a comprehensive solution for manufacturing management.

Core functions of MRP systems:

  • Inventory management and materials tracking
  • Production scheduling and planning
  • Demand forecasting
  • Order management for raw materials

What is PLM (Product Lifecycle Management)?

PLM stands for Product Lifecycle Management. Unlike ERP and MRP, which are focused on executing and managing business operations and manufacturing, PLM is centered on innovation, product development, and the lifecycle of a product from concept through end-of-life.

A PLM system manages everything related to the product record: engineering data, design documents, CAD models, BOMs (Bills of Materials), change orders, and product configurations. It enables design teams, engineers, and product managers to collaborate efficiently across the entire development lifecycle.

Key PLM capabilities include:

  • Centralized management of product data
  • Version control and engineering change management
  • BOM creation and synchronization
  • Collaboration tools for cross-functional teams
  • Compliance and quality assurance documentation

ERP vs. PLM: What’s the Difference?

Many companies search for “ERP vs PLM” or ask, “What’s the difference between ERP and PLM?” These systems serve distinct but complementary purposes.

ERP is about executing business processes: ordering materials, producing goods, shipping products, and managing financials. PLM, on the other hand, is about developing the right product: designing it correctly, managing revisions, and collaborating across teams.

Think of PLM as managing the recipe and ERP as executing it. PLM creates and maintains the product definition, while ERP uses that information to manufacture and deliver the product.

FunctionalityERPPLM
FocusBusiness executionProduction innovation
Primary UsersOperations, finance, logisticsEngineering, R&D, Product Dev
Data ManagedFinancials, orders, inventoryCAD files, BOMs, Product Data
Lifecycle StageProduction through shipmentConcept through design

ERP vs. MRP: Understanding the Relationship

MRP is not a competitor to ERP or PLM; rather, it’s a foundational component within many ERP systems. MRP handles the materials and scheduling side of manufacturing, ensuring production has what it needs, when it needs it. ERP uses MRP outputs to coordinate operations and resources across the entire business.

While ERP covers broader business management, MRP narrows in on ensuring supply meets demand efficiently. In other words, MRP supports the production plan, and ERP supports the entire organizational plan.

ERP / MRP / PLM: How They Work Together

When integrated properly, ERP, MRP, and PLM systems create a powerful digital ecosystem. PLM manages the ideation and design process, MRP ensures material and production readiness, and ERP orchestrates the delivery, resource allocation, and financials.

This integration leads to better data accuracy, smoother handoffs between departments, and shorter time-to-market. With a digital thread connecting all systems, companies can eliminate silos, reduce manual errors, and respond faster to market demands.

Benefits of Integration:

  • Real-time synchronization of product changes across departments
  • Streamlined collaboration between engineering, production, and procurement
  • Greater visibility into product costs and timelines
  • Easier compliance with industry standards and audits

Choosing the Right Systems for Your Business

Selecting ERP, MRP, and PLM solutions should be based on your company’s size, industry, product complexity, and operational needs. Some companies may need robust PLM features for complex product development, while others prioritize ERP for financial and operational efficiency.

Modern platforms increasingly offer pre-integrated solutions or connectors to ensure seamless data flow. Look for systems that support scalability, open architecture, and proven integration frameworks.

Questions to Ask When Evaluating Solutions:

  • Can the system handle our current and future product complexity?
  • How easily does it integrate with our existing tools?
  • Does it support our compliance and traceability needs?
  • Is the user interface intuitive for different teams?

ERP, MRP, and PLM: Next Steps

Understanding ERP, MRP, and PLM is key to building a streamlined, responsive, and competitive organization. While each system serves a different purpose, together they support the full journey of a product — from concept to customer delivery.

Whether you’re modernizing legacy systems or building a digital infrastructure from the ground up, the integration of ERP / MRP / PLM platforms should be at the core of your strategy.

By aligning people, processes, and technology, businesses can accelerate innovation, improve efficiency, and deliver products that meet market and regulatory demands.

Looking to learn more about PLM or how to integrate your ERP and PLM systems? Reach out to the experts at EAC for a personalized consultation.

In a competitive, fast-paced world where innovation is key, businesses need better tools to manage the growing complexity of product development. That’s where PLM comes in. But what is PLM really, and why is it becoming a must-have for organizations across industries?

PLM, or Product Lifecycle Management, is more than just software. It’s a business strategy and digital solution that supports a product from its initial idea all the way through retirement. In this guide, we’ll explore what PLM is, how it works, and why it’s transforming the way companies design, build, and support their products.

What is PLM?

PLM stands for Product Lifecycle Management. At its core, PLM is a systematic approach to managing the entire lifecycle of a product, from inception, through engineering design and manufacturing, to service and disposal.

Think of PLM as the digital backbone of your product information. It connects people, processes, and data across the organization, ensuring that everyone is working with the latest, most accurate information. Unlike standalone systems that manage specific functions, PLM offers a unified solution across the lifecycle.

The Stages of the Product Lifecycle & How PLM Applies

Every product goes through a journey—from a rough idea sketched on a whiteboard to a physical item in a customer’s hands, and eventually, retirement. At each stage, there are critical decisions, documents, and data that must be captured and connected. PLM helps orchestrate that journey by creating a consistent, collaborative framework to manage everything from concepts to compliance.

1. Concept & Requirements Gathering

This is the earliest phase of product development, where new ideas are born based on market demands, customer feedback, or internal innovation. PLM systems help capture all these inputs in a centralized location. With PLM, stakeholders can manage initial concepts, define high-level requirements, track voice of the customer (VoC) insights, and ensure alignment with corporate strategy.

2. Design & Development

During this phase, engineering teams create detailed product designs using CAD tools integrated within the PLM system. PLM enables real-time collaboration between cross-functional teams, ensuring that every component and sub-assembly is properly documented and reviewed. It facilitates the creation and control of Bills of Materials (BOMs), technical specifications, and digital mockups. Version control ensures that everyone is working with the most up-to-date information, reducing costly errors and design rework.

3. Prototyping & Validation

Before full-scale production, companies often build physical or virtual prototypes to validate the product design. PLM tracks test results, simulation data, and validation reports. It helps manage issues that arise during testing and supports closed-loop feedback mechanisms to drive design improvements. This stage may also include regulatory validation, and PLM ensures that all required documentation and traceability records are maintained for audit-readiness.

4. Manufacturing & Production

PLM plays a critical role in bridging the gap between engineering and manufacturing. Approved designs and specifications are transferred seamlessly to ERP and MES systems. PLM ensures that shop floor instructions, tooling data, and assembly procedures are accurate and consistent with the final design. It also helps manage change orders, track supplier compliance, and maintain cost-effective production schedules.

5. Service & Support

After a product hits the market, PLM continues to provide value by storing service documentation, maintenance manuals, parts catalogs, and technical bulletins. Field data and service reports can be fed back into the PLM system, enabling organizations to track product performance, identify recurring issues, and proactively manage warranties or recalls. This feedback loop is essential for improving future product generations.

6. Retirement/Disposal

Eventually, products reach end-of-life. Whether due to obsolescence, regulatory shifts, or market changes, PLM helps manage the retirement process responsibly. This includes tracking final product revisions, archiving compliance documentation, and ensuring proper disposal of components per environmental standards. It also supports historical audits and knowledge reuse for next-gen products.

By supporting each of these stages, PLM provides a continuous thread of digital information that enhances decision-making, streamlines workflows, and drives product success across its entire lifecycle.

Benefits of Using PLM Software

Adopting a PLM solution doesn’t just optimize product development—it transforms the way your entire organization works. From faster innovation cycles to better compliance and collaboration, PLM delivers measurable improvements that impact your bottom line. Below are some of the most significant benefits businesses experience when implementing PLM software:

  • Faster Time-to-Market
    PLM automates workflows and approvals, reducing time spent on manual tasks and accelerating product launches. Streamlined collaboration allows teams to quickly iterate on designs and bring new innovations to market faster.
  • Improved Product Quality
    With centralized data management and real-time access to product information, PLM reduces the likelihood of errors, inconsistencies, or outdated documents. This results in fewer design flaws, improved manufacturing outcomes, and higher-quality end products.
  • Enhanced Collaboration Across Departments
    PLM breaks down silos by enabling cross-functional collaboration between engineering, manufacturing, procurement, and quality assurance. Everyone works from the same source of truth, which improves communication, alignment, and decision-making.
  • Better Regulatory Compliance
    Especially critical in industries like medical devices, aerospace, and automotive, PLM ensures full traceability of design changes, audit trails, and documentation. Compliance with standards like ISO 13485 and FDA 21 CFR Part 11 becomes easier and more consistent.
  • Cost Reduction
    PLM minimizes costly rework, scrap, and delays by improving design accuracy and change control. It also reduces the overhead associated with managing product data manually, leading to long-term operational savings.
  • Innovation Enablement
    By fostering a digital environment where ideas can be easily captured, shared, and iterated upon, PLM supports continuous innovation. Features like simulation, digital twins, and advanced visualization allow companies to test ideas without physical prototypes.
  • Increased Data Visibility and Governance
    PLM provides structured access to product data across departments and geographies. With user roles and permissions, it ensures that the right people have the right access at the right time, supporting data integrity and security.
  • Improved Change and Configuration Management
    PLM simplifies how teams handle engineering changes, ensuring that all impacted documentation and processes are updated and approved. It also allows easy management of product variants and configurations.
  • Stronger Supplier and Partner Collaboration
    Through secure portals and integrations, PLM allows companies to extend product data access to suppliers and external partners, improving coordination, reducing lead times, and increasing trust throughout the value chain.
  • Sustainable Product Lifecycle Decisions
    PLM can support environmental compliance and sustainability efforts by tracking materials, assessing lifecycle impacts, and helping organizations meet evolving regulatory and ethical requirements.

By adopting PLM, companies are not just investing in a software tool—they are building a more agile, connected, and competitive business.

What does PLM (Product Lifecycle Management) mean in manufacturing?

The manufacturing industry is one that benefits most from PLM. PLM consolidates data and improves design control. Engineers no longer waste time looking for data or wondering if it’s up to date. Teams gain a central location for managing revisions and BOMs. Additionally, PLM strengthens change management, compliance, and scalability. As products become more complex, the ability to manage variants and configurations is essential. PLM ensures consistency, even across global teams.

PLM vs ERP: Understanding the Difference

From time to time, people can confuse PLM and ERP. While they work together, these are different systems that serve different purposes.

  • PLM (Product Lifecycle Management) manages product development data—designs, requirements, documents, and changes.
  • ERP (Enterprise Resource Planning) manages business operations—inventory, procurement, finance, HR, and logistics.

So, where does PLM end and ERP begin? PLM comes first. It feeds accurate product data into ERP systems so that manufacturing, purchasing, and logistics can act on it.

You can think of PLM as the brain of product innovation; ERP is the muscle that gets things made and delivered. Looking for better understanding of the differences between PLM and ERP… and MRP? Check out our blog, ERP / MRP / PLM: Understanding the Differences and How They Work Together.

Who Uses PLM?

PLM is used across departments and roles within organizations, including design engineers, project managers, compliance officers, quality managers, and manufacturing engineers—all of whom benefit from centralized access to accurate product data.

Industries using PLM include:

  • Aerospace and Defense: To manage complex compliance requirements, configurations, and long product lifecycles.
  • Automotive: To streamline design iterations, ensure quality standards, and manage global supply chains.
  • Medical Devices: For strict regulatory compliance, traceability, and quality control throughout the product lifecycle.
  • Industrial Equipment: To manage large assemblies, engineer-to-order products, and after-market service support.
  • Consumer Products: To bring innovative products to market faster, manage seasonal SKUs, and align with branding.
  • Electronics: To handle rapid product refreshes, component obsolescence, and global collaboration among teams.

Today’s PLM platforms are evolving rapidly to support digital transformation. These solutions are becoming more intuitive, scalable, and tailored to fit a variety of industries. Companies are moving toward cloud-first approaches and integrating advanced technologies to drive better decisions and faster innovation.

  • Cloud-Based PLM: Faster deployment, lower IT overhead, and easier updates.
  • IoT Integration: Real-time performance data from connected products.
  • AR/VR Support: Advanced visualization for design and training.
  • AI-Driven Insights: Predict quality issues or suggest design improvements.
  • Digital Thread: Seamless flow of information across the lifecycle.
  • Model-Based Engineering (MBE): Single source of truth for all stakeholders.

Common Challenges Without PLM

Without a Product Lifecycle Management system in place, companies often face several critical challenges that hinder productivity, innovation, and product success:

  • Data Silos
    Teams store product data in disconnected systems or local folders, making collaboration difficult and increasing the risk of working with outdated or inconsistent information.
  • Lack of Version Control
    Without automated version tracking, it’s easy for teams to overwrite each other’s work or rely on incorrect designs, leading to costly errors and rework.
  • Manual Workflows
    Processes such as approvals, change requests, and document management are handled manually, slowing down product development and increasing the likelihood of human error.
  • Poor Collaboration
    Disconnected departments struggle to stay aligned, resulting in communication gaps, duplicate work, and misinformed decision-making across the product lifecycle.
  • Compliance Risks
    Without centralized documentation and traceability, companies may fail audits, fall out of regulatory compliance, or miss required certifications.
  • Delayed Time-to-Market
    The inefficiencies caused by data silos, manual tasks, and miscommunication lead to slower product development cycles and delayed product launches.
  • Higher Costs
    Errors, inefficiencies, and rework increase operational costs and reduce profitability, especially when products require frequent changes or updates.
  • Limited Visibility
    Managers and executives lack real-time insights into product status, making it difficult to identify bottlenecks or make data-driven decisions.

By addressing these challenges, PLM empowers organizations to streamline operations, enhance collaboration, and ensure successful product outcomes from start to finish.

Getting Started with PLM

Not sure if your organization needs PLM? Ask yourself:

  • Are product launches delayed?
  • Do you struggle with version control?
  • Is compliance documentation a nightmare?
  • Are design and manufacturing teams out of sync?

If you answered yes to any of these, a PLM system can help. The next step is assessing your current product development processes and identifying pain points that PLM could solve. Then, engage cross-functional stakeholders—including engineering, IT, operations, and executive leadership—to define goals and secure buy-in.

Start small by implementing PLM in a focused area, such as engineering change management or BOM control, to prove value and demonstrate ROI. From there, scale gradually by expanding features, integrating with ERP systems, and digitizing more of your product lifecycle processes. Partnering with a trusted PLM solutions provider, like EAC, can also accelerate success through expert guidance, user training, and customized implementation services.

Introducing PTC Windchill

PTC Windchill stands out as a leading PLM solution because it offers a powerful combination of robust functionality, scalability, and user-friendly design—making it ideal for organizations looking to streamline and modernize their product development processes. As a comprehensive digital backbone, Windchill enables real-time collaboration across global teams, secures a single source of truth for product data, and supports everything from design and change management to compliance and quality control. With its out-of-the-box capabilities, flexible deployment options (including cloud-based), and seamless integration with tools like Creo and ThingWorx, Windchill empowers companies to innovate faster, reduce costs, and stay competitive in today’s fast-paced market.

Next Steps with PLM

So, what is PLM? It’s more than just software. It’s a strategy that empowers organizations to manage product complexity, accelerate innovation, and ensure product success across every stage of the lifecycle. If you want to improve efficiency, enhance collaboration, and stay competitive in a digital-first world, implementing PLM is a critical step forward. Learn more in our post “what is PTC Windchill?”

Windchill is a mission-critical enterprise system with multiple components and touch points across an entire enterprise. Because of this complexity, you might recognize the need for Windchill Managed Services. EAC has created a managed services program for your Windchill system: the EAC Alliance Program. The Alliance Program provides PTC Windchill managed services such as Windchill administration and support.

Our team of expert system administrators help improve system performance, optimize server and license configurations, and maintain a stable PLM environment for your organization. Looking to understand what we deliver? Below are some frequently asked questions.

Frequently asked questions around Windchill Administration

When manufacturing and engineering leaders evaluate their PLM strategy, they have a lot of critical questions. Decision-makers need clear answers on what Windchill administration involves, when they should consider outsourcing, and what risks unmanaged environments pose. Below we provide focused answers to frequently asked questions to help you evaluate whether a Windchill managed services program is right for your organization.

What does Windchill administration involve and why is it important?

Windchill administration encompasses the full set of tasks required to keep your PLM system healthy, secure and aligned with organizational processes—such as user and license management, system configuration, performance tuning, and lifecycle/workflow definitions. Effective administration ensures data integrity, minimizes downtime, and keeps product data flowing smoothly across engineering, manufacturing and service operations. For example, administrators will manage user access, define roles/teams, configure workflows, administer object types and versioning, and monitor system logs to identify issues before they escalate.

Without dedicated administration, companies risk slow performance, inconsistent processes, and lost productivity—making this role foundational for any serious Windchill deployment.

When should a company consider outsourcing Windchill administration instead of managing it in-house?

Outsourcing Windchill administration makes sense when internal resources are limited, the system has become complex, or you want access to specialist expertise without hiring full-time staff. Many companies turn to managed services when they lack sufficient Windchill-specific knowledge in-house, or when maintaining uptime, performance, patching and monitoring become too burdensome for their IT/engineering teams. According to recent program data, partnering with a managed services provider can deliver high-availability environments and relieve internal teams to focus on strategic PLM usage rather than just maintenance.

If your Windchill system is integral to product development and you can’t afford extended downtime or degradation in performance, outsourcing can be the smarter and more scalable choice.

What are the typical risks of poorly managed Windchill environments?

When Windchill systems are under-managed, organizations face risks such as unplanned downtime, degraded system performance, data inconsistency, version misalignment, and security vulnerabilities from delayed patching. These issues can slow engineering workflows, hamper collaboration between teams, increase support costs, and even result in compliance or audit failures if product data is uncontrolled. For instance, if workflows or lifecycles aren’t properly configured, teams may inadvertently work on the wrong version of a part or document—leading to errors that propagate downstream. In highly regulated or competitive manufacturing sectors, these problems compromise innovation speed and product quality, making adequate administration essential rather than optional.

What types of administrative tasks are included in a Windchill managed services program (patching, system tuning, replication, license optimization)?

A Windchill managed services program typically includes proactive system tasks such as regular patching and updates, server and application performance tuning, license usage tracking and optimization, data cleanup, replication site management, CAD worker configuration and environment monitoring. For example, administrators will monitor system logs for error patterns, manage replication sites to support multiple locations or disaster recovery, and alert you when license groups or worker scripts need attention. Additionally, managed service offerings may include scheduled health checks, junior to expert support tiers, shared service dashboards and continuous improvement planning so your Windchill environment evolves rather than stagnates. Outsourcing these tasks ensures consistent support for your PLM environment and often delivers performance gains and uptime improvements beyond what internal teams achieve alone.

 

What can customers expect from our Windchill managed services?

Here’s what customer’s see with our Windchill Managed Services and what you can expect.

Windchill Managed Services Percent of Uptime

95.1% of our EAC Alliance Program customers achieve 100% Windchill uptime. Our customers that do not have 100% Windchill uptime still maintain over 99% availability.  This is an overall average of 99.95% or more uptime.

Windchill Managed Services Predictive Maintenance

Our Alliance program executes planned (weekly, monthly, etc) Windchill maintenance.  Predictive maintenance is more efficient and the preferred approach to system maintenance. Roughly 1/4 of Alliance customers choose to implement PTC System Monitor (PSM) as a way to bolster EAC’s already rigorous proactive maintenance.

Speed/Performance of Windchill with Managed Services

100% of EAC’s Alliance Program customers see an improvement in the speed and performance of their Windchill system.  Out of the box, Windchill leaves a lot of room for performance tuning and server optimization. Our EAC Alliance Program Team are skilled in analyzing  and optimizing system resources to suit your individual needs

Windchill Managed Services Security/Patches

100% of our EAC Alliance customers receive (or are notified) of patches.  This way you can be assured that your system is running with maximum security at all times. 

 

Next Steps: Optimize Your Windchill System with Confidence

Your Windchill system is the backbone of your product development process. Don’t let preventable performance or maintenance issues slow down your innovation. Whether your team needs help managing system uptime, planning proactive maintenance, or optimizing your PLM environment for scalability, EAC Product Development Solutions is here to help.

Our Windchill Managed Services give you direct access to certified PLM experts who monitor, maintain, and continually optimize your environment, so your engineers can stay focused on product design, not system administration.

If you’re ready to improve your system’s reliability, performance, and ROI, connect with us to help your organization achieve:

  • Secure, compliant, and future-ready Windchill environments
  • Predictable uptime and proactive system maintenance
  • Improved performance, speed, and data integrity
  • Optimized license management and reduced total cost of ownership

Product development is becoming more complex, fast-paced, and globally distributed than ever before. As a result, businesses can no longer afford to rely on outdated tools or fragmented systems to manage the product lifecycle. That’s where Product Lifecycle Management (PLM) comes in.

PLM is a strategic solution that helps organizations manage everything from initial concept to retirement. But when a PLM system is missing, poorly maintained, or improperly implemented, the consequences can be costly, chaotic, and even catastrophic. This blog explores the top risks companies face without a robust PLM system and why investing in the right tools, processes, and support is essential.

Here is a list of the common problems you could face if you choose to manage your engineering data management and PLM systems in-house.

  

The Growing Demand for Centralized Product Data Management

In the absence of PLM, teams often resort to spreadsheets, local files, and email chains to manage critical product data. These disconnected tools may work temporarily, but they quickly become unmanageable as product complexity increases.

Without centralized data management, teams lose time hunting for information, risk using outdated files, and duplicate work. PLM offers a single source of truth that connects engineering, manufacturing, quality, and procurement teams with real-time access to product information.

 

Consequence #1: Product Delays & Missed Market Opportunities

One of the most immediate consequences of no PLM system is slower product development. Without structured workflows, version control, and digital collaboration tools, approvals take longer and communication breaks down. This delay not only increases development costs but also results in lost revenue from missed market opportunities.

Implementing PLM accelerates time-to-market by streamlining design iterations, automating change approvals, and enabling cross-functional collaboration from day one.

Consequence #2: Quality and Compliance Risks

Companies without PLM often struggle to maintain audit trails, proper documentation, and consistent processes across teams. This is especially risky in regulated industries like medical devices, aerospace, and automotive, where compliance is non-negotiable.

Manual systems leave room for error and increase the chance of delivering products that fail to meet safety or quality standards. PLM ensures that traceability, validation records, and required documents are captured and managed systematically.

Consequence #3: High Costs from Inefficiencies and Errors

Without PLM, inefficiencies build up across the product development lifecycle. Design teams may use incorrect versions, resulting in rework or scrapped parts. Change requests can be lost or ignored, causing costly delays or customer dissatisfaction.

A well-maintained PLM system mitigates these risks by automating data updates, linking CAD models with BOMs, and ensuring that teams are always working with accurate, up-to-date information.

Consequence #4: Poor Collaboration Across Departments and Suppliers

In companies without PLM, departments often operate in silos. Engineering, manufacturing, and procurement teams each rely on their own systems or documents, making it difficult to stay aligned.

This fragmentation leads to poor communication, misunderstandings, and decision-making based on outdated or incomplete data. PLM bridges these gaps by providing a collaborative platform where internal and external stakeholders can access and contribute to a unified product record.

Consequence #5: Lack of Long-Term Scalability

As products become more complex and markets more competitive, scalability is essential. Manual processes and disconnected systems simply don’t scale with growing demands.

Without PLM, organizations struggle to support product line expansion, manage global operations, or respond to evolving regulatory standards. PLM systems are designed to grow with the business, supporting new products, processes, and geographies over time.

Overlooked Risk: Not Hiring PLM Admin Support

Even companies that implement PLM systems may face challenges if they don’t hire dedicated admin support. As outlined in this article, the absence of skilled PLM administrators can lead to poor system performance, low user adoption, and reduced ROI.

PLM admin services ensure your system stays optimized, configurations remain aligned with your processes, and users are properly supported. Regular PLM maintenance prevents system failure and ensures your investment continues to deliver value.

Training the Workforce for Successful PLM Adoption

Technology alone isn’t enough. Even the most powerful PLM solution will fall short if your workforce isn’t trained to use it effectively. Without proper onboarding and continuous learning opportunities, employees will fall back on old, inefficient methods.

Ongoing training and change management initiatives help teams embrace new workflows and get the most out of your PLM implementation. It’s the difference between a tool that collects dust and one that transforms your business.

The Flip Side: What You Gain with a Strong PLM System

While the consequences of no PLM system are serious, the rewards of successful PLM implementation are equally powerful. A strong PLM foundation enables organizations to operate more efficiently, respond faster to change, and innovate with confidence. When done right, PLM implementation delivers measurable business benefits:

  • Long-term scalability that supports business growth and transformation
  • Faster innovation cycles with streamlined collaboration
  • Higher product quality through digital traceability and control
  • Reduced costs by eliminating errors and rework
  • Improved supplier integration and external collaboration
  • Data-driven decisions based on real-time product insights

By integrating PLM into your core operations, you position your organization for future success. You gain not only operational efficiency but also strategic agility that lets you outpace competitors and exceed customer expectations.

Don’t Wait for the Pain Points to Pile Up

Many companies don’t recognize the consequences of no PLM system until they’re already struggling. Delays, quality issues, compliance failures, and high operational costs creep in quietly but compound quickly.

Investing in PLM implementation, ongoing PLM maintenance, user training, and admin support is not just a technology upgrade—it’s a competitive advantage. Don’t wait for these challenges to derail your product development. Let EAC help you build a strong PLM foundation that fuels innovation, efficiency, and growth. Learn more about what we can do for you! Check out our services today.