Rootstock Product Lifecycle Management Integration, using common Rootstock APIs and file downloads, automates the process of transferring current product configuration data from a company’s Product Lifecycle Management (PLM) system to Rootstock, avoiding manual entry errors and ensuring that manufacturing configuration data is always up to date and fully synchronized.
Rootstock and the PLM solutions work together to provide a flexible solution for manufacturers that face constantly changing products combined with ever shortening product life cycles. Together, they deliver up to date product configuration information resulting in improved visibility and more efficient manufacturing operations. These joint Software as a Solution (SaaS) offerings provide mid-market manufacturers with shorter implementations, lower costs, and quick return on investment. Requiring dramatically less resources, the PLM solutions and Rootstock allow you to recoup your investment quickly, while delivering a robust manufacturing solution that enables you to be more responsive to changing customer needs.
Shared Product Information
The Rootstock PLM integration synchronizes the latest product configuration data, ensuring efficient and accurate production planning and operations. This downloaded data generally includes:
How the Integration Works
The Rootstock PLM integration is triggered when product-related information, such as Items, Item Revisions and Bills of Materials, are changed via an approved Engineering Change Order (ECO) within a PLM System that provides its own standard APIs as effective interfaces to ERP systems such as Rootstock. The Rootstock APIs and standard download software receives the changes, processes them, and takes the product data to create the Rootstock engineering item master, inventory item master, and other detailed product records.
The PLM system revision information is used to create Rootstock engineering item revision records. The engineering change information is also used to create the Rootstock ECO master and detail records. Rootstock can log exceptions. The system administrator is notified of exceptions, such as revisions of more than 6 characters, unrecognized division or commodity codes, or invalid change numbers.
It has been Rootstock’s experience that there is no such thing as a standard interface, per se, between a PLM System and an ERP system, and for each installation would ‘borrow code’ from prior engagements to create a custom solution for each organization. It should be noted that a PLM system has a number of features and capabilities to manage and control Item, Bill, and Engineering changes. But, because of the flexibility provided within a PLM system, organizations that build their processes around such systems often take different approaches and use different features. Some even add vendor and cost information within the PLM system which would ordinarily be found in Rootstock’s ERP module. The downloaded data that Rootstock requires includes Items, Item Revisions, Bill of Materials (BOMs), and Engineering Changes. This data is received and used by Rootstock to perform up-to-date manufacturing planning and shop floor operations. Cost and vendor information is one example of information that might have been stored in a PLM system prior to the implementation of an ERP system. Rootstock cannot use nor depends upon vendor and cost information contained within the PLM system, as that is part of the Rootstock ERP system and is maintained within the ERP system.
Rootstock Production Engineering includes the following capabilities: Item Master Maintenance, Bill of Material Maintenance, Item and Bill of Material Revision Control, and Engineering Change Control.
Item Master Maintenance
Within Item Master Maintenance, the Direct Material Item Characteristics are maintained. Key information, such as Item Description, the Commodity Code, Responsible Engineer, Lot or Serial Tracking within Inventory, Part Status and Part Type is recorded. Additionally, Inventory attributes such as lead times and MRP policies, and purchasing policies such as vendor lead time and Responsible Buyer, are noted as well.
Of importance is the identification as to how the supply of an item is ‘sourced’. Rootstock supports manufactured, purchased and subcontract sourcing. The assignment of the Commodity Code for the item is of key consideration because the item can inherit many of the Commodity Code attributes, thus reducing the need for users to enter every field on the Item Master.
Bill of Material Maintenance
The Manufacturing or Subcontract Assemblies are identified within Bill of Material Maintenance. Each Component contains a separate record. Standard information associating the component to the assembly can be kept on the Rootstock Bill of Material. Required information, such as the quantity per assembly and add and delete effectivity data, is maintained on each component link. Required Add and Delete effectivity information includes status and date with optional information, including revision and engineering change order. Additional capabilities include a scrap factor, ‘issue to’ work centers on the Shop Floor, and lead time offset for planning purposes.
Bills of Material are also used in a Standard Cost Rollup to compute the material cost and the subcontract material cost of the purchased (or subcontract purchased) item.
Item and Bill of Material Revision Control
All items are added with a revision (zero). If Revision Control is desired, then the user can maintain status (planned, released, implemented) as well as effectivity date, which can facilitate the setting of effectivity status and date information on multiple bill of material component links. Additional revisions to the part (drawing changes, bill of material structures and even routing changes) can be maintained by the user and referenced to the appropriate bill of material and/or routing operations.
Another capability of maintaining an item revision is that a work order’s demands can be generated by specifying the appropriate revision on the work order. This enables the system to copy the correct bill of material in generating the work order’s demand records.
Engineering Change Control
Engineering Change Control is the process that ‘manages’ the related items’ revisions that are associated with an Engineering Change Order. Revision Control denotes the change, and Engineering Change Control denotes the process that manages the revisions to the bill of material and the routings. Since the management of item revisions can be accomplished by the Engineering Change Control process, Engineering Change Control therefore enforces discipline and management control over modifications to bill of materials and shop floor routings, based on revision control.
Component and operation changes can be tracked through an authorization and approval process and are logged into an ECO history database. MRP and Work Order Bill of Material Explode will retrieve component records, based on correlating the work order’s scheduled pick date to the add and delete effectivity dates associated with a revision. Work Order Routing Operation Extract will extract those Routing operations using similar add and delete effectivity comparisons.
All Rootstock programs that use bill of materials and routing master records to ‘explode’ or ‘extract’ components and operations contain ECO capabilities. Material Requirements Planning explodes bill of materials to create the component demands for each work order and subcontract PO requisition. These configurations are based on the scheduled pick date of the orders compared with the ECO effective dates on the bills.
Rootstock Product Management includes the following capabilities: Product Maintenance, Item Master Maintenance and Bill of Material and Kit Maintenance.
Product Master Maintenance
Within Product Master Maintenance the Product’s Characteristics are maintained. In Rootstock, a Product number identifies something that is sold and it may or may not be the same identification number used to identify Items kept in inventory. Key information such as Product Description, the Product Commodity Code, Pricing, Direct Ship parameters and Product Part Type (e.g.: Stock, Configured, Kit, Service, Miscellaneous) is recorded.
The assignment of the Product Commodity Code for the product is of key consideration because the product can inherit many of the Product Commodity Code attributes, thus reducing the need for users having to enter every field on the Product Master.
Item Master Maintenance
Direct Material Item Characteristics are maintained within Item Master Maintenance. Key data points, such as Item Description, the Commodity Code, Lot or Serial Tracking within Inventory, Part Status and Part Type, are recorded. Additionally, Inventory attributes such as lead times and Replenishment Planning (RP) policies, and purchasing policies such as vendor lead time and Responsible Buyer, are noted as well.
Of importance is the identification as to how the supply of an item is ‘sourced’. For Distributors, Rootstock supports manufactured, purchased and subcontract sourcing. The assignment of the Commodity Code for the item is of key consideration because the item can inherit many of the Commodity Code attributes, thus reducing the need for users having to enter every field on the Item Master.
Bill of Material Maintenance
The Manufactured or Subcontract Assemblies are identified within Bill of Material Maintenance. Each Component contains a separate record, and standard information associating the component to the assembly can be kept on the Rootstock Bill of Material. Required information, such as the quantity per assembly and add and delete effectivity data, is maintained on each component link.