In today’s world, it’s not uncommon for companies to be rich in data but poor in insights. Despite having access to a wealth of information, organizations struggle to properly analyze performance and drive transformational improvements. This is where ThingWorx Digital Performance Management (DPM) steps in to bridge the gap.

This week in your factory, you’ve applied maximum effort, pouring countless hours into perfecting your product. As the work week ends, a feeling of slight disappointment remains.

Could you have accomplished more? Where did it go awry? You may not be able to find the answers on your own, leaving your factory inefficient and operating below its full potential.

If this is you, look no further. With the capabilities of Thingworx Digital Performance Management, you will unleash an untapped potential of data and boost your manufacturing processes.

What is Digital Performance Management?

ThingWorx Digital Performance Management (DPM) is a cutting-edge solution designed to help organizations identify, prioritize, and improve production issues.

By capturing lost production hours and their causes, DPM indicates where to focus for the most critical impact. Also, it optimizes the finite time available, allowing organizations to reclaim lost hours and increase effective time by 20% or more. Thus, directly impacting the bottom line.

How Does DPM Work?

Consider a manufacturing facility that can produce one unit per hour. In a week with 88 hours worked, the facility manages to manufacture only 44 units. Let’s say 12 hours are lost through planned downtime and 14 hours are lost due to changeovers.

That leaves about 18 hours unaccounted for. Where did those come from? With ThingWorx DPM, you can quickly identify issues, and why they happened, and then take appropriate actions to fix them.

Moreover, DPM calculates and analyzes discrepancies, providing valuable insights to improve productivity. DPM is a comprehensive toolset that propels organizations towards peak performance by tracking performance, conducting in-depth analysis, planning, and validating improvements.

The Production Dashboard

One feature included with DPM is the Production Dashboard. The visual dashboard is a crucial tool for supervising shift performance and gathering vital data to inform reporting and analysis. It is designed for supervisors and line managers to track productivity across various production lines.

Some key features of the Production Dashboard include:

• Provides insights into shift progress at the production block level

• Allows for automated and manual data entry, including reason codes to capture all losses

• And offers a simplified interface to minimize disruption

Bottleneck Analysis

The Bottleneck Analysis tool is designed to automatically detect and monitor the most significant bottlenecks in your factory, providing valuable analysis and insights into OEE and OLE.

One of the challenges that customers face is a lack of visibility into bottlenecks, which leads to a disconnect between continuous improvement efforts and their impact on the business. However, bottlenecks are often dynamic and complex.

To address these challenges, DPM offers key capabilities to help identify and resolve:

• Automatically identifying and tracking bottlenecks.

• Systematic identification of the top constraints, which can significantly increase factory efficiency by 5-20%.

• Management of the dynamic nature of competing bottlenecks.

Overall, DPM works relentlessly, making up for lost time by tracing the root cause of issues and providing precise remedies to ensure smooth and efficient functionality. Consider DPM an invaluable employee, working tirelessly around the clock without additional overtime costs!

Accelerate Problem Solving with DPM

DPM’s capabilities extend beyond surface-level analysis. By combining Pareto analysis and time loss analytics, DPM users can uncover and address a significant percentage of production problems.

Additionally, with the further integration of AI and machine learning, DPM streamlines the identification of patterns in data, resulting in faster problem-solving and decision-making.

For instance, a DPM user noticed quality losses between 3 p.m. and 4 p.m. Thanks to DPM’s automated analysis, the manufacturing team quickly determined that the issue was caused by a glare from the sunset, making the inspection camera unreliable.

All in all, DPM helped accelerate the problem-solving process saving valuable time and resources.

Reap the Benefits

Digital Performance Management is as remarkable as it sounds. DPM holds the secret to your production improvements and is ready to share them with you. Discover the plethora of benefits that are tied to DPM:

• Standardized Measurement: DPM provides a consistent and standardized approach to measure losses, ensuring accurate evaluation of bottlenecks, and their impact on performance.

• Efficient Root Cause Analysis: Leveraging AI technology, DPM identifies the root causes of bottlenecks and facilitates their permanent resolution, eliminating recurring issues.

• Automated Problem Identification: DPM’s powerful AI algorithms automate the process of surfacing common issues, exponentially reducing the time spent on problem-solving.

• Real-time Insights: What once took months to identify critical insights now becomes easily accessible through DPM’s intuitive interface, providing teams with immediate access to actionable insights.

Get Started with DPM Today!

In conclusion, if you want to revolutionize your performance management and take your organization to new heights, it’s time to embrace Digital Performance Management.

Remember, in today’s fast-paced world, those who leverage technology to gain insights and make data-driven decisions are the ones who thrive.

Are you ready to unlock the true potential of your organization with Digital Performance Management? Talk with an expert now to take your first steps toward success.

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.

• Creo Illustrate for AR Developers
• Minimum Windchill Implementation to Achieve Significant ROI
• Augmented Reality and Expert Capture
• Model-Based Definition
• Assessing Your Business Practices to Find Optimization Opportunities
• Rapid Prototyping Made Simple with Creo Additive Manufacturing
• Simulation-Driven Design with Creo Simulation Live

LiveWorx 2023 Photo Recap:

The benefits of digital transformation include:

• Improved customer experience: Digital transformation can help you better understand and meet the needs of your customers. With the use of data analytics and other digital tools, you can gather insights into customer behavior and preferences, and tailor your products and services accordingly.
• Increased efficiency and productivity: Digital transformation can automate many processes, reducing manual labor and freeing up staff to focus on higher-value tasks. This can lead to increased efficiency and productivity across your organization.
• Competitive advantage: By embracing digital technologies, you can stay ahead of your competitors and differentiate yourself in the marketplace. This can help you attract new customers and retain existing ones.
• Cost savings: Digital transformation can help you reduce costs by streamlining processes and eliminating unnecessary steps. This can lead to significant savings over time.
• Innovation: Digital transformation can open up new opportunities for innovation and growth. By embracing new technologies and ways of working, you can develop new products and services that better meet the needs of your customers.

Adopting the Right Technology

The first step in digital transformation is choosing the right technology. You’ll want to consider:

• Software: What are your current needs and how will they change over time? Will you need additional features or functionality?

• Hardware: Do you have enough computing power and storage space for all of your data, or does it need to be scaled up or down depending on usage patterns at different times of day/year/etc.? Do you have sensors to track data that you need for production insight?

• Tools: What tools do developers use to build applications on top of this platform (e.g., Creo vs. Solidworks)? How easy is it for them to integrate their code with existing systems like databases and messaging queues? Are there any security issues with using these tools – and if so, how can they be mitigated by using another tool instead (e.g., switching from MySQL database server software to Microsoft Azure).

Implementing the Digital Transformation Plan

• Develop a timeline. The first step in implementing your digital transformation plan is to develop a timeline with milestones that will help you track progress.

• Set goals and objectives for each milestone. Once you’ve established your milestones, it’s time to set goals and objectives for each one of them so that everyone involved knows exactly what needs to be done at any given time during the project.

• Track progress regularly by reviewing dashboards or reports generated from data collected during testing phases of development projects (if applicable). It’s important not only for managers but also employees on lower levels within organizations who may not have access

Monitoring and Evaluating Performance

Monitoring and measuring performance is an important part of the digital transformation process. It allows you to identify areas where you are successful, and areas that need improvement.

Monitoring can be done using a variety of tools, including:

• Data Analytics Dashboards (e.g., Thingworx Analytics)

• Real-time Data Share (e.g., Windchill, EAC Productivity Apps)

• Digital Twin Performance (e.g., Augmented Reality)

Communicating the Benefits of Digital Transformation

In order to communicate the benefits of digital transformation, it’s important to understand who your stakeholders are and what they want.

If you’re working in an organization with a large number of stakeholders (such as a government agency), then there may be multiple groups that need convincing. For example:

• The board wants to see results from their investment in IT infrastructure. They’ll likely be interested in metrics such as ROI and cost savings.

• Executives want quick wins that will help them achieve their goals, but they also need proof that this new approach will work before they can commit time and resources to implementing it throughout the organization.

• Employees want something tangible they can hold onto when explaining why this change is important for them personally (and why it matters).

IoT has a plethora of benefits for manufacturers that overall saves companies time and money, and solves frustrations with outdated processes and siloed data.

Bellow are different ways the IoT solutions could benefit your production process:

Asset Monitoring & Utilization (AMU) & Real-Time Production Performance Monitoring

• Gain real-time insights from connected assets and legacy systems such as your PLM and ERP systems to align your IT and OT systems

• Make more informed decisions faster

• Increasing flexibility and agility

• Monitoring the status of inventory in real-time

• Quality Control

• Monitoring Distributed and Outsourced Processes

• Spare parts management

• IoT sensors allow organizations to gauge the specific use and deploy practices for more effective usage of resources.

Machine Learning & Predictive Analytics

By integrating machine-learning capabilities there is a whole new level of predictive intelligence brought to the factory floor – identified problems and resolved issues with minimal impact on operational performance. Other benefits include: 

• Detect problems before they occur

• This helps to maximize factory production utilize data analytics to perform predictive maintenance

• Optimizing Maintenance Schedules

Automation & Connected Work Cells (CWC)

In manufacturing, many processes are streamlined with IoT technology. For example, one IoT strategy is to use Automation. With IoT, using sensors allows you to automate certain tasks such as temperature monitoring or product tracking.

This means less time spent on manual labor and paper-based processes while increasing productivity simultaneously!

Safety & Compliance

Making sure that machines are running at a safe capacity and within the compliance standards creates a well maintained work area that brings employee satisfaction and confidence in a safe workspace.

All these things can be tracked through IoT technology, along with others: 

• Increasing energy efficiency of machines

• Reduce human errors

• Ensuring Products Comply with Set Standards

• Increased employee and customer satisfaction

OEE Visibility & Productivity

A factory enhanced by IoT solutions offer complete visibility into all of your factory operations. You can see all of your work orders, lines, and all critical KPIs through dashboards that pull together 

IoT sensors allow organizations to gauge the specific use and deploy practices for more effective usage of resources.

• Cost reduction

• Increase bottom line

• Decreased Machine Downtime

• Optimizing Factory Production

• Reduced lead time

• Improved efficiency

• Improvement of Operational Performance

These are just some of the many ways companies can reach their goals with Industry 4.0. With out-of-the-box solutions or even custom IoT apps, the possibilities are endless.