"In terms of cost, mass and BoM–CAD alignment, we are miles and miles ahead of any other Programme at this stage, and the difference is we have QR_ running PDM." - UK Director.
Case study: Establish and operate a new PDM function
Managing and maintaining an accurate BoM is a challenging task for many manufacturers. When managed well, a centralised BoM can accelerate development processes. But when the data is disparate, it can have a profound and costly impact on manufacturing operations. QR_ were bought in to analyse a client's existing data landscape and transform it into an asset that would improve production efficiency.
Case study: Establish and operate a new PDM function
Our client, a leading high-performance EV manufacturer, approached us to help connect the disparate, siloed data that were impeding their mission of creating a fully electric performance car to rival Tesla.
Previously operating within a global OEM before branching out as a standalone brand, the newly independent company faced the challenge of bringing its first full-scale production model to life. However, designing and engineering a vehicle at a speed to rival established incumbents with highly evolved processes presented immediate obstacles. From a lack of detailed processes to disparate data, it was clear developing and implementing a robust PDM function would be the key to success.
1. Challenge
With each function head recording data offline and in their own unique way, these multiple sources of truth led to little or no visibility for programme management to make informed business-critical decisions. Consequently, the programme experienced a CAD-BoM separation - a misalignment resulting in low confidence around maturity of design and part attributes, as well as poor insight into cost and weight. Knowing the solution lay in enabling data-aligned decision-making, QR_ sought to develop processes and methodology that would do just that.
2. Approach
QR_ took a three-pronged approach to improving communication between systems. First was the design of a standardised, central BoM, to act as an accurate guide and shopping list for the final product. Creating a BoM that balanced flexibility with structure to meet the requirements of engineering teams, programme management and the wider business. But a BoM is only as good as the data fed into it. To remedy the previous CAD-BoM misalignment, QR_ devised a method for comparing CAD data with the latest BoM model to identify part and data discrepancies. Once identified, these could be flagged to relevant teams for resolution, and the status tracked. With a successful CAD-BoM alignment in place, accurate part-level cost and weight tracking against comparison targets was also possible.
3. Outcome
This approach is already showing lasting value, which is sufficiently embedded for the client to not require a long-term QR_ presence. CAD-BoM alignment improved from 63 to 75 percent and is still climbing. Visibility and accuracy of programme KPIs, including cost and weight reporting, are enhanced and have enabled data-led strategic decision making. Moreover, there have been valuable ~20% week on week time-savings from the QR_ approval tool, signalling a step-change in efficiency.
4. Feedback
"In terms of cost, mass and BoM–CAD alignment, we are miles and miles ahead of any other Programme at this stage, and the difference is we have QR_ running PDM." - UK Director.