Satyam Computer Services Ltd by rih47632

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									      ROHS - PLM

        By Debraj Dhar



Satyam Computer Services Ltd.
                                         What is ROHS
Restricts use of the following substances:


•      Lead
•      Mercury
•      Cadmium
                                                             • EU & UK
•      Hexavalent chromium (Chromium VI or Cr6+)
                                                             • China
•      Polybrominated biphenyls (PBB)
                                                             • Japan
•      Polybrominated diphenyl ether (PBDE)
                                                             • USA

                                                      ROHS
                 The maximum concentrations in EU            •Directive, not a law
                 are 0.1% or 1000ppm (except for
                                                             •Does not apply to fixed plants and tools
                 Cadmium, which is limited to 0.01%
                 or 100 ppm) by weight of                    •Does not apply to anything that does not
                 homogeneous material.                       require an electrical power source
                                                             •Other exemptions
                   RoHS impact on the Supply Chain




Customer
                                                                            Compliance
                                                                             Reports
                  Environmental
                                                                               Recyclers
                  Affairs       Engineering

                                                                                           Certificate of
                                                                                           Destruction
                                               Quality
    Procurement


            Manufacturing     Marketing                     International                  International
                                                            Suppliers and                    Recyclers
                                                            Mfg Partners
                                  Material
                                                                                 Recovery
                                 Declaration
                                                                                 Declaration

                  Suppliers




                                                         Recyclers
                                 Environmental Compliance Processes
                                      Across a Product’s Lifecycle



             As Designed               As Manufactured /           As               As
             / As Planned                 As Shipped           Maintained        Recycled
  Material                                Track                 Waste          Disposal
                            BOM         Assemblies
   Data                                                         Stream        Confirmation
      Bill of                                                     Recovery
                                                                              Recycler
    Substances             WEEE           Shipments                          Certificate
                                                                                           Material
User Info                                Quality                Treatment                  Manifest
                            RoHS
                                         Control               Disposal      Destruction
   Legislation             ELV                                Operations     Certificate


              Material                                                                           Product
             Declaration                                                                         Lifecycle

                                               Product Mgmt
                          Issues




                              Higher cost
           Seller                due to
       responsible for        expensive
      ROHS compliance          re-tooling



                                        Multiple
   Ambiguity of
                                      variants due
 compliance based
                                      to phase out
on market segment
                                       of current
                                        products


             Product        Product
            Reliability     Quality
RoHS Functions




  ERP

CAD   PLM
                          The role of Vendor

Needs to provide the data for

    · ROHS analysis

    · Lifecycle Cost estimation of
        · original part
        · changed part

    · Impact on the design parameters as a result of change

    · CAE analysis results on changes
                  Cost impact evaluation


· Cost Estimation
   · Estimate lifecycle should cost of a part
   · Estimate lifecycle should cost of a configured product /
     variant of a product

· Cost Analytics
   · Compare/report manufacturing should cost for various
     manufacturing solutions of the same part / product
   · Estimate cost associated with a change or collection of
     changes (Change Management)
                  Manufacturing Cost estimation

S.No             Required Inputs                             Source

  1           Manufacturing Approach                    Manufacturing BoM

  2             Processing Technique                    Manufacturing BoM

  3            Manufacturing Features                   Manufacturing BoM

  4            Machine Specifications            Resource Manager & Classification

  5     Material Types, Handling Techniques                Material Data

  6    Cutting Conditions, Speed & feed, Stock        Manufacturing System

  7        Resources, Rates of Resources                   ERP System

  8       Tool setup, Part load/unload time          Operation & Activity data

  9               Quality Assurance                       Quality System
                              PLM Benefits

·   Easy search capabilities to find noncompliant parts

·   Easy management of variants caused by alternate parts

·   Easy calculation of costs needed for the compliance

·   Easy notification sending capabilities in case of non-compliance

·   Easy modification of workflow so as not to release non-compliant parts
    for production

·   Easy sharing and collaboration of knowledge in such cases
                               The role of PLM
                 PLM
                                                           Automatic
                                                            Design
                                                            Checker


      Assem                                  Test for                                     Release
                                             ROHS                      √                 process for
                                           compliance              X                    manufacturing
              Sub-Assem1

                            Part11 X
                             Part11 alt.                                   Not to be
BOM
                            Part12                    Add as               released
                                                  alternate part
                            Part13
                            Part14    X
                                                                                        Search
                                                 Evaluate Impact
               Sub-Assem2                                                                  for
                                                  of Alternate on
                                                                                       alternates
                             Part21                Design, Cost

                             Part22   X
                                                  Test Alternate                Send request to
                             Part23
                                                     Design                     vendor if needed
                 Alternate parts Management


·   Parts identified as alternates

·   Parts classification help in identifying alternates

·   Using the alternate in the dummy BOM before release for estimation
    and analysis

·   Tracking the changes made


All the above requirements are well met by PLM systems.
           Design Checker

                                                                 Material
                                                                 Library
 3D CAD    3D CAD     Exported to
                                         Design
assembly     part                      Checker tool


                        Contains
                        Material                       Calculate
                     definitions for                  mass of Part
                           the
                    parts/assemblies

                 Database
Vault           containing                Geometry               Form Data in
                Meta-data                   Data                 PLM System


PASS
                                                        Calculate %
                      Compare                           of Material
                                                         by weight
 FAIL
                       ROHS
                    Information
                       Library
                             The role of KBE


·   Create design templates for same design using different materials.

·   Create rules for using different material types.

·   Implementation of checks and balances that may be required if
    alternate material does not suit the total lifecycle cost.

·   Interface with Material Library for intelligent material assignment.

·   Quicker design time leading to faster creation of compliant products.
                              Satyam highlights

                                  Over USD 1 Billon in Revenues
 SEI-CMMI Level 5                                                          34,908 Associates




Market Capital about USD 5.78 B




                                      SATYAM



                                                     Among Top 5 IT service providers from
                                                     India. Provider of End to End IT Solution

              26 Global Solution Centers &
                    521 Customers
              Service Offerings


               Business
Engineering
              Intelligence
 Services
                Services
                             “ Satyam is best suited for all types and sizes
                                                  of SAP projects” Forrester
    BPO         Hi-Tech
               Solutions


 Strategic     Extended
Outsourcing    Enterprise
 Services      Solutions


 e-Business     Quality
  Solutions    Consulting
                  European Footprint
·   Branch operations in 12 countries
·   Business Footprint in more than 20 countries



                                                   Branch Operations

                                                   Business Footprint
                                                       Development
UK: 1500 +                                               Centres
                         Europe: 750 +




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     Thank You!

       Debraj Dhar
 debraj_dhar@satyam.com

Presented by Anand Thakar
 anand_thakar@satyam.com

								
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