Product Lifecycle Management (PLM): Mapping value creation processes holistically

At Fraunhofer IPT, we focus on the digital design and optimization of cutting tools, cutting processes and complete process chains: Systematic Product Lifecycle Management (PLM) makes it possible to record and manage design, production and usage data along the entire life cycle of a component. We are particularly interested in the optimization of design and manufacturing processes.

Faster product development and better collaboration between all parties involved in the manufacturing process

From the product planning stage onwards, production generates huge amounts of data from which important information can be derived. PLM uses various processes, tools and methods to collect and prepare such data. The information obtained is not only used to detect and minimize errors, but can also accelerate product development. The targeted preparation and dissemination of data and associated information also improves collaboration between different teams and stakeholders.

Our services at a glance

  • Individual PLM projects – from conception to the procurement of suitable machine tools
  • Acquisition of machine and sensor data
  • Model-based interpretation of component states
  • Visualization of process and quality data
  • Digital process planning and production
  • Process simulation and process optimization

Tools for Product Lifecycle Management

In conventional manufacturing, knowledge about the product life cycle is often spread across numerous stakeholders, making it difficult to identify optimization potential. At Fraunhofer IPT, we have the tools that facilitate a holistic view and make it possible to systematically improve costs as well as quality, time and sustainability along the entire process chain.

The digital twin: the heart of PLM

A central component of our PLM approach is the digital twin. For the digital twin of a component, we collect and process data from design, process layout and production and enrich it with CAD/CAM, sensor and machine data as well as simulation results. This enables us to systematically reduce manufacturing errors and optimize our machining strategies. In this way, we reduce manufacturing costs for prototypes and post-processing costs, for example for highly complex and costly components such as those for turbomachinery.

3D models reduce errors

3D models with additional manufacturing information help to minimize or even completely avoid errors. In design, we have been using model-based definition (MBD) for many years to create 3D models. We enrich these with all relevant product manufacturing information (PMI), for example tolerances, surface quality and a range of other important data. This enables us to reduce ambiguities and misinterpretations and simplify communication between all parties involved. The models also serve as a data source for creating digital twins of the component.

Machine and sensor data

Systematic processing of sensor and machine data creates more transparent production processes: To this end, we have equipped our machine tools with modern sensor technology that provides information on pressure, temperature, vibrations and other production parameters. Machine data from the numerical control (NC) or programmable logic controller (PLC) provides additional information about the performance, status and operation of the machine, such as motor currents of the drive axes and spindle performance. The systematic processing of this data contributes to more transparent, less error-prone and more sustainable manufacturing processes and promotes higher product quality.