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PLM Transformation in Developing MarketsBerlin, February 27th 2017
Kirsten Gottschling, Dr. Adrian Reisch
@PITVtweets #PIBerlin
1 About Nordex and Acciona Windpower
2 Challenges
3 PLM Transformation
4 Lessons Learned
Agenda
2/28/2017PLM Transformation in Developing Markets 2
Nordex and Acciona Windpower cover the entire windpark value chain with core business solutions & products
About Nordex and Acciona Windpower
2/28/2017PLM Transformation in Developing Markets 3
Project Development, Marketing, Financing
Wind FarmSystem Planning
Production and Tech-nical Implementation
Wind FarmOperations
Services and Maintenance
Selection of location
Ownership
Optimal siting
Wind measurements
Soil survey
Noise / shade emission
Economic viability
Grid connection
Special purpose registration
Environmental permitting
Building permitting
CIVIL WORKS
ELECTRICAL INFRASTRUCTURE
INSTALLATION & COMMISSIONING SERVICE
TURBINE DELIVERY
PROJECT DEVELOPMENT
Expected 2016 key performance indicators (as of Q3/2016)
Order intake (EUR bn) 3.4 EBITDA margin (in %) 8.3
Sales (EUR bn) 3.4 Employees 5.200
The comprehensive product portfolio covers very different markets to globally serve individual customer needs
About Nordex and Acciona Windpower
2/28/2017PLM Transformation in Developing Markets 4
Individual customer needs and a highly differentiated product portfolio increase the complexity for a project-driven company
Focus: Sophisticated WTG solutions
Typical project:Noise restricted sites
Dealing with RESTRICTIONS
& LAND CONSTRAINTS
Focus: Low capexWTG solutions
Typical project:100 MW in
emerging markets
Projects with NO LAND
CONSTRAINTS
TOGETHER Winning in very different markets
IEC Class I IEC Class II IEC Class III
3MW+
N100/3300 N117/3000
AW100/3000 AW125/3000 N131/3000
AW116/3000 N131/3300
AW132/3000
2MW N90/2500 N100/2500 N117/2400
1MW AW1500 series ( AW70, AW77, and AW82)
Solutions to serve customer need around the globe
LCOE=CAPEX+OPEXLife
AEPLife
2/28/2017PLM Transformation in Developing Markets 5
Low Cost of Energy (COE) are key to adress price pressure and ensure competitiveness in the wind energy market
Challenges
Levelized Cost of Energy (LCOE)
Compensate the price pressure
COE Target
Levers
OPEX
Cost Down
Yield
LCOEnow
CAPEX
Value up LCOEfuture
Cost Down
EBITDAnow
Price EBITDAfuture
COEEBITDAdrivers
Nordex confirms 18% COE reduction through 2018 (vs 2015)
Ongoing price pressure in the market renewables energy market
Global trends and challenges in the wind energy market drive the need for efficient product development and lifecycle mgt.
Challenges
2/28/2017PLM Transformation in Developing Markets 6
Enable the project-driven
company
Increase CTO, decrease ETO
Reduce time-to-market
PLM@Nordex as enabler for future revenue growth and efficiency
Time
Profit
PLM@Nordex
Individual customer
needs
Low cost of energy
Digitalization
PLM Strategy
The enormous growth over the past years caused challenges in the engineering organization and over the entire Product Lifecycle
Challenges
2/28/2017PLM Transformation in Developing Markets 7
Replace customized tools and processes without losing productivity
Harmonize various legacy systems into one global solution
Ensure an understanding, acceptance and responsibility for end-to-end processes with a very limited capacity of inhouse resources
Manage product complexity & align mechanical, electrical, software engineering
Ensure high business performance immediately
after project go live
Challenges are managed in an integrated approach to guarantee the success of PLM@Nordex
PLM measures are divided into work packages for stepwise transformation without losing productivity
PLM Transformation – Strategic Direction Setting
2/28/2017PLM Transformation in Developing Markets 8
Long-termMid-termShort-term
PLM Strategy
Integrated BoM management
Master data harmonization
Classification
2016
PLM-ERP-Integration
Release management
Configuration
Document management
Master data management
CAD methodology
Integrated PLM IT architecture
Product structure
2017
Change management
Implementation of small work packages in several releases one after the other
Product configuration in early phases improves time-to-market and better risk evaluation of ETO modules
PLM Transformation – Processes & Organization
2/28/2017PLM Transformation in Developing Markets 9
Sales Configuration Execution Service
Conception of end-to-end processes with involvement of all stakeholders
Tender
Pre-Configuration
Contract
CTO
ECN
Planning
Long-lead items
Service operations
Logistics & Commissioning
ECR
Production order CTO
Purchase order CTO
Production order ETO
Purchase order ETO
Sales
Project Mgt.
Engineering
Purchasing
Production
Service
The end-to-end process is reflected by functional building blocks across the PLM-ERP IT landscape
PLM Transformation – IT & enabling technologies
2/28/2017PLM Transformation in Developing Markets 10
PLM
Product Structure
150% eBoM, technical
configuration
Product data & document
management
Mechanic, Electronic, Software
Bill of Material Management
eBoM, mBoM, sBoM
It is crucial to proof the concepts for smaller building blocks fast in the system landscape with an agile or rapide protoyping approach
Engineering Change
Management
PR, ECR, ECN
Requirements Management
Requirements, specifications
PLM – ERP Interface
Field mapping, document exchange, status transfer,…
ERP
Manufacturing, Production and Service management
Supply Chain and Vendor management Project management
Finance and Accounting processes Customer relationship management
Improved performance enabled by new processes and IT landscape hast to be established in the organization
PLM Transformation – Performance Management
2/28/2017PLM Transformation in Developing Markets 11
In addition to the project communication, knowledge build-up and transfer has to be managed to fully benefit from the performance improvements
1
2
3
4
5
7
Denial
Learning
Knowledge Expertise
Pe
rce
ive
d In
div
idu
al C
om
pe
ten
cy
tInformation/
Communication
Shock
Rational
Perception
Acceptance
Training Hypercare &
Coaching
Operationalization/
Continous Improvement
Go Live
Improved end-to-end process performance
6
min
min
PLM is a cross-functional approach that requires collaborative ways of working across departments
PLM Transformation – Management of Change
2/28/2017PLM Transformation in Developing Markets 12
Sales
Prod.Develop.
ElectricalEng.
SystemIntegration
Project Mgt.
Purchasing.
Production
Standards
MechanicsEng.
Service
Product Mgt.
Product Structure
SoftwareEng.
• Generic modules• Specific variants• Part
The product structure serves as main enabler to support the new way of cross-department work in product development & lifecycle management
The new way of working is based on the modular product structure
PLM Transformation – Management of Change
2/28/2017PLM Transformation in Developing Markets 13
Create/ Adapt 3D
Model
Update tracking
sheet
Copy BoM from old
tracking sheet
To
day
Create Mat/ BoM
CREO ExcelExcel SAP ERP
Create/ Adapt 3D
Model
Create materials &
detail eBoMProduct structure
Fu
ture
Transfer Mat/ BoM
CREO PLM WindchillPLM Windchill SAP ERP
Focus
Focus Transform
Modular product structure-based development and lifecycle management processes are key levers for complexity and COE reduction
The PLM journey at Nordex and what we achieved so far
Lessons Learned
2/28/2017PLM Transformation in Developing Markets 14
IT Landscape
and CREO 3D CAD
Team Data Management
in PTC Windchill PDMLink
PLM Scan:
Strategic Direction Setting
and PLM Business Case
PLM Conception:
End-to-end process
& IT concepts in
PLM and SAP ERP
PLM Release 1:
Product structure,
document and release
management
PLM Release 2:
PLM-ERP integration,
BoM and change
management
2017
2016
2015
2014
2013
2012
PLM Release 3:
Project configuration,
modular document and
windparc management
Factors for success
Lessons Learned
2/28/2017PLM Transformation in Developing Markets 15
Replace customized tools and processes without losing productivity
Harmonize various legacy systems into one global solution
Ensure an understanding, acceptance and responsibility for end-to-end processes with a very limited capacity of inhouse resources
Manage product complexity & align mechanical, electrical, software engineering
Ensure high business performance immediately
after project go live
Challenges are managed in an integrated approach to guarantee the success of PLM@Nordex
Implement small pieces one after the other
Swift communication between high
performing teams
Agile project work: Proof concepts fast in the system
Structured and clear test cases for business acceptance
Intense communication for successful Management of Change
Transparent decision making process and governance
End-to-end process conception
Your contact
2/28/2017Title of presentation 16
Kirsten GottschlingVice President
Head of Standards and
Commercial Engineering
Nordex Energy GmbH
Hamburg
Dr. Adrian ReischSenior Manager
PLM Leader
Ernst & Young GmbH
Wirtschaftsprüfungs-
gesellschaft
Berlin
Thanks foryour attention
Togetheron the same course
Nordex SELangenhorner Chaussee 60022419 HamburgGermany
Tel: +49-40-30030-1000Fax: +49-40-30030-1101Email: [email protected]: www.nordex-online.com
Acciona WindpowerPolígono IndustrialBarásoain, parcela 231395 BarásoainNavarra, Spain
Tel: +34-948-720535Fax: +34-948-720531Email: [email protected]: www.acciona-windpower.com