Securing market competitiveness through a complete product lifecycle management approach
Collaboration is key factor in realizing significant, quantifiable benefits across operations
A leading automotive parts supplier
Founded in 1974, Pungkang Co., Ltd. (Pungkang) is a leading manufacturer of parts for the automobile and general machinery industries. Pungkang specializes in nut products, including wheel, lock, conical, weld, castle, flange and hex. Under the company’s corporate maxim, “Clean & Clear,” Pungkang is recognized as one of the best manufacturers in Korea and, in fact, currently holds second place in its niche globally with total annual revenues of 9.5 billion won. The company established its high-value reputation based on credibility, creativity and business acumen. With more than 230 engineers, Pungkang recently launched a fully automated production factory in Hwasung to further establish its competitive foothold.
Critical need to update development through manufacturing
According to Jae Yoon Seo, who manages Research and Development at Pungkang, the company was badly in need of an effective, systematic method to more efficiently produce new products. He explains, “The company felt an increasing need to more effectively manage, share and re-use data. However, with its existing product data management (PDM) process based on using spreadsheet software, it felt that significant gains could only be made by changing to a complete product lifecycle management (PLM) approach. Moreover, in order to maintain and further expand the company’s increasing market presence, it had to update its development-through-manufacturing environment, including addressing a key issue: effectively converting 2D-based computer-aided designs (CAD) to 3D.”
To address its challenges, Pungkang evaluated a number of PLM solutions, and ultimately adopted Solid Edge® software (CAD technology for accelerated design, faster revisions and better data re-use) and Teamcenter® software (preconfigured for rapid deployment and fast return on investment). Pungkang felt that the Siemens PLM Software products would best enable it to increase profitability and meet its corporate vision: “Best Product and Best Technology.”
With Solid Edge, company engineers could promptly collaborate and come to a precise decision since they would be able to search and connect to any CAD data, as well as quickly and easily utilize computer-aided engineering (CAE) with Solid Edge Simulation and forging analysis software. With Teamcenter, company management saw strategic value in terms of raising overall production capacity and creating additional competitive value. Management was especially impressed with the capabilities of Teamcenter for part library management/knowledge re-use, explicit control of existing and new data, and quick verification of high volumes of data in real-time on a daily basis.
In addition, Pungkang introduced NX™ software, a highly integrated product design, engineering and manufacturing solution, also from Siemens PLM Software, to improve its collaboration with its major partner General Motors (GM). With NX, Pungkang and GM would be able to minimize errors in both their design and production processes, in notable part through exceptional data compatibility.
Pungkang successfully improved its 3D modeling strengths in a short order by utilizing components, such as Mate and Alignment, from the system library of Solid Edge. By doing so, key-ins are automatically set when making features.
Pungkang also uses Solid Edge for drawing sketch elements by entering simple dimensions (without the need for complex instructions), and by choosing a domain for projection and rotation to calculate basic shapes. This saves significant time in producing individual parts and complex assemblies.
The rapidly built models then go through a 3D-simulation test, enabling an efficient review of the entire product concept for performance and potential errors/defects. The data generated using Solid Edge is then managed with Teamcenter, which serves as the central information source for engineers. This boosts data re-use while reducing the time and effort required for error inspections and rework.
In addition, Pungkang has established highly effective collaboration with GM through the use of NX, which is GM’s technology platform for design, engineering and analysis. “Pungkang’s big gains with NX are productivity and agility, as geometric data sharing is smooth and engineers from both companies are highly proficient in utilizing the software’s capabilities for fast and efficient product development,” says Seo.
Quantifiable results: productivity, speed and business value
Pungkang has realized significant benefits using Solid Edge and Teamcenter. Seo points out, “This includes a 30 percent decrease in both design errors and development costs thanks to Solid Edge.” Seo notes that engineers like the software for a number of reasons, including ease of use, interference checking capabilities, bill of materials (BOM) calculation, weight calculation, speed in converting 2D-based designs to 3D, and compatibility with NX.
“The use of Teamcenter has generated particular synergy across operations, because the company uses the software as its single system for managing product information,” says Seo. “The common data platform has helped prevent repurchasing the same components, markedly increased the data re-use rate and enabled the company to efficiently collaborate with its partners. With Teamcenter, we have increased our overall business productivity substantially, and in fact, now move our products to market approximately 30 percent faster. As an open PLM platform, the use of Teamcenter has been especially effective in providing a stable collaboration environment, regardless of solution type, thanks to its interoperability and compatibility.”
Seo concludes, “The adoption of Siemens PLM Software solutions has ultimately boosted Pungkang’s productivity by more than 30 percent across operations. Pungkang’s customers note that the company has gained the upper-hand on its competition, estimating that it delivers, on average, 50 percent greater efficiency in design and data management.” That, in part, explains the company’s success. Seo explains, “Since introducing Siemens PLM Software solutions, we have realized a 30 percent increase in sales. Commensurately, we have dramatically improved our edge in our marketplace by bolstering the value of our products and services to our customers.”