Windchill PLM Architecture & Development
Interval supported a global manufacturing leader in transforming its product lifecycle management (PLM) landscape - designing a modular Windchill architecture to balance local flexibility with global consistency. The result: improved integration, data quality, and productivity across regions.
Situation
A multinational automotive parts manufacturer required implementation of a new version of Windchill to streamline its product lifecycle management (PLM) across multiple regions. The company had a highly customised PLM environment with complex interfaces linking its engineering, supply chain, and production systems in Europe, North America, and Asia. Over time, these systems had been tailored with bespoke integrations to regional ERP platforms, CRM tools, and factory management software, including SAP, SupplyOn and more. The challenge was to upgrade and integrate Windchill into this intricate setup without disrupting operations.
To address the complexity, the Windchill implementation had to support extensive customisations while maintaining global consistency in product data management. Each region needed specific workflows to comply with local regulations and processes, while ensuring central visibility for global stakeholders. Additionally, a key goal set by the client’s management was to achieve increased user friendliness and productivity.
In order to deliver the right level of expertise on this highly complex engagement, the client and its consulting partner engaged Interval to provide Windchill consulting.
Approach
Interval deployed two dedicated Windchill consultants to deliver the project scope. The initial work involved fixing issues in the existing Windchill implementation. A unique architecture and design was developed, based on a modular approach, maintaining flexibility to support regional customisations and centralised data management. A phased rollout was planned, starting with carefully-chosen regions to minimise disruption.
Middleware interfaces were developed for real-time data exchange with existing customised systems, ensuring seamless integration and compliance with local requirements. Each phase was rigorously tested to maintain centralised control of product data while supporting global operations. The consultants’ 20+ years’ combined experience and deep knowledge of the newest Windchill innovations meant they could advise the client with high precision.
All technical work was fully documented, enabling the client’s IT team to continue operating the PLM system beyond the consultants’ tenure.
Outcomes
The first project phase was delivered successfully within twelve months, ahead of schedule and within budget. The next project phase began immediately thereafter and is currently in progress.
The client was previously running Windchill 12. This project enables them to upgrade to Windchill 13 and deepen integration across the IT/OT landscape, providing strong foundations for better business processes, workflows and ultimately performance.
The programme is expected to take several years, but deliver significant efficiency, process and security improvements. The PLM system has over 5,000 active users, who will benefit from increased automation, data quality, availability of real-time information and reduced manual action to perform day-to-day tasks, thus increasing productivity and user satisfaction.