Engineering and PLM Modernization for a Consumer Goods Manufacturer

We have transformed and modernized the R&D/Engineering and Product Lifecycle Management for the customer to efficiently manage the product’s lifecycle, engineer, and manufacture its products at the highest level while continuing to innovate.

Client and Challenge

A U.S.-based consumer goods manufacturer needed to modernize its R&D and engineering and its PLM environment to better leverage data across the product lifecycle. The client relied on an outdated CAD integration toolset to manage R&D and engineering data and integrate it with SAP, which created UI/UX limitations and reduced efficiency. Complex and time-consuming to use, the system supported only a narrow subset of R&D data and lacked critical functionality. This made it difficult to manage the product lifecycle efficiently, support engineering execution, and consistently manufacture high-quality products.

Solution

LeverX modernized the client’s R&D/engineering and PLM landscape by establishing a single, integrated environment for engineering data and comprehensive change management.

Key elements of the solution included:

• Managing documents, CAD data (SOLIDWORKS), and quality processes in a unified workflow
• Deploying SAP Engineering Control Center (ECTR) to create an engineering-friendly workspace and connect design and engineering data with business data in SAP
• Leveraging SAP 3D Visual Enterprise to generate lightweight 3D visuals for manufacturing planning and visual work instructions
• Implementing a flexible engineering change management approach using LeverX’s IPS (Integrated Process Solution) to enable configurable workflows without heavy custom development

Technology Stack

• PLM and CAD integration: SAP Engineering Control Center (ECTR)
  SAP ECTR provides a single, integrated workspace for managing engineering and PLM data in SAP and enables direct integration with SOLIDWORKS.
• 3D visualization: SAP Visual Enterprise Suite (SAP VES) / SAP 3D Visual Enterprise
  SAP 3D Visual Enterprise is used to create lightweight 3D visualizations that support manufacturing planning and the development of visual work instructions.
• Workflow and engineering change management: Integrated Process Solution (IPS)
  IPS is used to modernize engineering change management by enabling flexible, configurable workflows and supporting end-to-end change processes connected to the SAP-based PLM landscape.
• CAD authoring tool: SOLIDWORKS
  SOLIDWORKS is the primary CAD authoring tool and is integrated with SAP through SAP ECTR.

Results

LeverX successfully delivered a modernized R&D/engineering and PLM solution during a highly constrained period, starting in March 2020 and going live in September 2020, with delivery executed fully remotely.

The project was delivered on time and on budget at a critical moment for the client’s business. During the COVID-19 pandemic, the client experienced a surge in demand, and revenue increased by 40%. The implemented solution helped the client continue business operations without disruption while scaling engineering and manufacturing efforts to meet growing demand, including international expansion.

LeverX continues to support the client’s roadmap planning, including initiatives related to moving to S/4HANA.