Windchill PLM Architecture & Development
Interval supported a global manufacturing leader in transforming its product lifecycle management landscape by designing a modular Windchill architecture that balanced local flexibility with global consistency. This delivered improved integration, stronger data quality and higher productivity across regions.
Background
A multinational automotive parts manufacturer needed to implement a new version of Windchill to streamline PLM processes across Europe, North America and Asia. The organisation operated a heavily customised PLM environment with interfaces connecting engineering, supply chain and production systems, including links to SAP, SupplyOn and various regional ERP and factory management platforms.Upgrading Windchill without disrupting operations required deep expertise in complex integrations, tailored workflows and global product data management.
The client needed a solution that could:
Support extensive customisations while ensuring global consistency
Accommodate regional workflows and regulatory requirements
Improve usability and productivity for thousands of users
Strengthen data governance and visibility for global stakeholders
Interval was engaged to provide specialist Windchill advisory and delivery support.
The Challenge
The project required:
Designing a scalable architecture capable of supporting diverse regional needs
Maintaining a consistent global data model while enabling local flexibility
Integrating Windchill with numerous customised legacy systems
Avoiding operational disruption across multiple regions
Delivering improved user experience and system performance
Our Solution
Interval deployed two senior Windchill consultants to lead architecture, development and integration activities.
Architecture and Design
Developed a modular PLM architecture supporting regional customisations
Designed centralised data management with controlled local variation
Planned a phased rollout to minimise operational disruption
Technical Integration
Built middleware interfaces for real-time data exchange with regional ERP, CRM and factory systems
Ensured alignment with regulatory and operational requirements across all regions
Rigorously tested each phase to maintain data consistency and system stability
Delivery and Knowledge Transfer
Resolved issues in the existing implementation before initiating the upgrade path
Fully documented all technical work for seamless handover to the client’s IT team
Provided advisory support based on over 20 years of combined Windchill expertise
Results
First project phase delivered within twelve months, ahead of schedule and within budget
Programme enabled the client to progress from Windchill 12 to Windchill 13
Stronger integration across IT and OT systems, improving workflows and data flow
Expected multi-year programme delivering major efficiency, process and security benefits
Over 5,000 active users will benefit from increased automation, better data quality and reduced manual effort, driving higher productivity and user satisfaction
Client Testimonial
“Interval’s consultants brought deep Windchill expertise, strong architectural thinking and a practical understanding of how to balance global standards with regional needs. They helped us stabilise our existing setup, design a scalable new architecture and deliver the first phase ahead of schedule. Their contribution has been central to the success of our PLM transformation.” - Global Team Lead PLM Solutions
Conclusion
Interval’s Windchill expertise allowed the client to modernise a highly customised PLM landscape, improving consistency, integration and usability across global operations. The modular architecture and phased delivery approach created a scalable foundation that will continue to support efficiency, quality and performance improvements for years to come.