Turning vision into reality: Configuring over designing

The goal

Working with an external partner from the region, KNOLL Maschinenbau introduced SAP for its finance and logistics departments at the end of 2016. Once the logistical processes were in place, MAIT implemented SAP PLM. MAIT's task was to transfer the more than 270,000 design files and 3D models that existed as CAD files into the new, more powerful SAP PLM. What convinced KNOLL was MAIT’s strategic PLM concept of connecting the CAD system directly with SAP.

The project

When installing the new PLM system, MAIT was able to build on the SAP platform that had already been installed in the first step. Upon analyzing the process, however, it quickly became clear that KNOLL's large variety of products and their modular structure meant that the team would have to work with order BOMs (bills of materials). At KNOLL, the models are created in "SOLIDWORKS", then CAD Desktop (CDESK) transfers them to SAP together with the structural data as a BOM. To ensure the best possible support for the design engineers, the existing CDESK was first extended so that the structured lists of individual parts and assemblies could be transferred smoothly from "SOLIDWORKS" to SAP. CDESK is an interface within SAP PLM that gives design engineers access to the important features and views of a product, including its structure. The main advantage of the CK extension is that the design engineers can transfer their order-related BOMs directly and automatically from CAD to SAP on the basis of the model structures. This posed a particular challenge during installation. The different product variants and their modules are now taken into account. A huge relief for the developers at KNOLL.

There were also a number of other tasks to master, including the previously inconsistent approvals management. This was not standardized, and numerous exceptions made it confusing and time-consuming. Based on the customer's prerequisites and the potential for improvement, MAIT developed a concept for consistent approvals management in "SOLIDWORKS", CDESK, and SAP. Here too, the result is a faster and better workflow. The designs are now approved for production through what is known as neutral format generation in the PLM system and transferred to the workshop for manufacturing via SAP.

The neutral format is generated using software from SEAL Systems, which is standard in the industry. After approval, the software generates a 2D PDF from a 3D model in order to "freeze" the approved status of the preliminary drawing or model. An additional approval PDF is generated for SAP. Data migration also posed a considerable challenge. All CAD models and metadata had to be extracted from the previous PLM system into a corresponding exchange directory. After defining the naming conventions and renaming the files, two test runs were carried out before the data were successfully transferred to SAP in a third step. Once the data had been transferred, MAIT focused on supporting the go-live. This involved integrating the new software into everyday operations as smoothly as possible. MAIT applied a "train the trainer" approach here, with KNOLL’s key users then training all other users. Once the system had gone live, the MAIT consultants provided intensive support. "Our trainers were always there to help when the KNOLL design engineers had any questions about the system, and there was always someone on hand to show them how things worked or how to go about doing something. This marked the end of the first step in integrating SAP PLM," explains Frank Zimmer, Head of Sales SAP at MAIT.

In a further step, in response to a request from the customer, MAIT replaced the initially installed "CAD-DESKTOP" interface with the new Engineering Control Center (ECTR). Both interfaces provide data exchange between "SOLIDWORKS" and SAP. In 2017, ECTR was ready to go to market as the successor to CDESK. Being an innovator, KNOLL analyzed the new solution to see what benefits it could bring to its own operations, despite the fact that CDESK had only been in use for a short time at that point. In a series of tests over a number of weeks, advantages over CDESK were identified as being better performance and a more intuitive and modern interface for the design engineers—one that they know and that does not have the SAP "look & feel” about it.

What ultimately clinched the deal in favor of switching to ECTR was its deeper integration into "SOLIDWORKS" and the flexibility of the user interface. After weighing up the economic aspects, KNOLL decided to switch to ECTR as soon as possible, even though CDESK had only recently been introduced. The necessary transfer of the "SOLIDWORKS" configurations from CDESK to ECTR also took place at the same time. Since then, ECTR has reached a level of maturity that represents a real alternative to "CAD desktop", which has so far been the most widely used solution. SAP will continue to support "CAD desktop" until 2025, but innovations and enhancements will only take place in ECTR. This now makes ECTR SAP's standard solution. Managing versions, approving them, and keeping track of changes is mandatory. Using ECTR keeps all product data up to date and consistent throughout the company in order to link up the various MCAD and ECAD authoring tools and make all product data available company-wide throughout their entire lifecycle.