Breaking Down Data Silos: The Role of PLM in Industrial Machinery

Manufacturing companies often face a significant challenge: isolated pockets of data spread across different departments, systems, and locations—commonly known as data silos.

Named after the cylindrical storage towers traditionally used in agriculture, these silos block communication, slow down production, and make it harder to innovate. For industrial machinery manufacturers, the impact runs deep—from delayed product launches to quality control issues.

In this article, we examine how Product Lifecycle Management (PLM) can eliminate data silos and bridge the gap between all your manufacturing systems.

Short on Time? Here’s a Brief Overview

• Data silos occur when information gets trapped in separate systems or departments, making it inaccessible to others who need it.

• PLM systems create a central source of truth by connecting design, engineering, production, and supply chain data.

• Modern PLM platforms integrate with existing software to preserve investments.

• Breaking down silos leads to faster product development, better quality control, and improved data.

  
  

Understanding Data Silos in Industrial Machinery Manufacturing

First, let’s examine why data silos happen in industrial machinery manufacturing.

For one, manufacturing companies adopt specialized tools based on what each team needs to excel at their work. Design teams, for example, use sophisticated computer-aided design (CAD) systems for product development. Production managers, meanwhile, rely on manufacturing execution system (MES) software to run their operations, and maintenance teams track equipment through dedicated management platforms. 

This autonomy can result in isolated systems that can’t easily share data, otherwise known as data silos. 

System age adds another layer of complexity. Many manufacturers use a combination of old and new technology, and legacy systems from decades ago often can’t connect with modern cloud platforms.

Why break down data silos?

Data silos negatively affect every aspect of manufacturing operations:

• Design teams may work uninformed: Engineers waste hours searching multiple systems for needed information. A designer working on a new machine component might never learn about maintenance problems with similar parts simply because that data lives in another system.

• Production can fall behind: Manufacturing teams often build products using outdated information because they can’t see the latest design changes. Even minor modifications can take days or weeks to reach the shop floor.

• Quality issues often take longer to fix: When defects occur, quality teams must search through disconnected systems to find the cause. They might notice patterns in their quality data but lack access to the design specifications or production parameters needed to solve the problem quickly.

• The supply chain loses efficiency: Supply chain managers can’t optimize inventory without a complete picture of demand, engineering changes, and production capacity. They may end up with too much stock of some items while running short of others.

  
  

How PLM Systems Break Down Data Silos

Modern PLM systems can connect disparate systems and create a unified flow of information. PLM capabilities specifically address common data silo challenges in several ways:

Centralized data management

PLM systems create a single information source for product-related information, making it accessible to all authorized users regardless of their department or location. This solution works through a combination of the following:

• Version control and change management: PLM tracks all changes to product data, maintaining a complete history of who made what changes and when. Everyone works from the current version while maintaining access to historical information when needed. For example, if a design change affects manufacturing processes, the system automatically notifies relevant team members and updates related documentation.

• Structured data organization: Instead of scattered files across multiple servers, PLM organizes product data in a logical structure that mirrors the product lifecycle. Finding information is intuitive—from initial concept sketches to final manufacturing instructions and service manuals.

• Access control and security: While making data accessible, PLM systems maintain tight control over who can view and modify different types of information. Engineers might have full access to design files, while manufacturing teams get view-only access to approved production documents.

Enhanced collaboration

PLM platforms provide tools that actively promote collaboration across departments. These include:

• Visual collaboration tools: Modern PLM systems include built-in visualization capabilities that let non-CAD users view and mark up 3D models and technical drawings. A production supervisor can quickly review a new design and add comments about manufacturability without needing specialized software.

• Automated workflows: PLM workflows automatically route information and approvals to eliminate manual handoffs. When an engineer submits a design change, the system automatically notifies affected departments, collects necessary approvals, and updates related documentation.

• Cross-functional project spaces: Digital workspaces within PLM systems let teams collaborate on specific projects. For example, a new product development team might include engineers, manufacturing specialists, quality experts, and supply chain managers with the same up-to-date information.

Integration with legacy systems

PLM doesn’t replace existing software—it connects systems. Changes in one system automatically update connected systems. When engineering updates a design in CAD, for example, production systems receive the new information immediately. Production data flows back to engineering, creating a continuous feedback loop.

Modern PLM platforms can connect to other systems, including legacy systems, in multiple ways. There can be direct links to common engineering and manufacturing software, open connections for custom software integration, basic file sharing for older systems, and web connections for cloud applications.

This way, each department can keep the tools that work best for them while gaining access to information from other teams.

Practical Applications in Industrial Machinery Manufacturing

PLM’s connected data approach delivers measurable improvements, including: 

Faster design and engineering

PLM changes how engineering teams work by giving them direct access to real-world feedback. Engineers can then see how their designs perform in production without leaving their desks. They can access quality data, operator feedback, and production metrics right next to their design tools, leading to better designs with fewer revisions.

PLM also links between product requirements, design decisions, and manufacturing results. Teams can trace the reasons for changes and understand their impact, simplifying compliance and speeding up future improvements.

Smarter production

Connected data through PLM is part of smart manufacturing. Production teams work from up-to-date documents, and if engineering makes a change, work instructions and quality checks update automatically.

Then, if production spots quality issues, they can send feedback to engineering immediately. Teams can see the complete picture—design specifications, production parameters, and quality data—to fix problems quickly.

Better supply chain management

PLM extends data connections beyond company walls. Through secure online portals, suppliers can directly access the specific product data they need. They can see design requirements and changes immediately, reducing errors and speeding up the supply chain.

When designs change, PLM helps you assess the impact on parts and suppliers. Procurement teams can quickly identify affected components and work with suppliers on updates.

Steps to Breaking Down Silos with PLM

Breaking down data silos through PLM typically happens in three stages: planning, implementation, and monitoring.

Assessment and planning

To get started, map out where your product data lives, from design files and engineering specifications to production records and quality reports. Note which teams create and use different data types, and pay special attention to gaps where information gets stuck or lost between systems.

Next, talk with your teams about their daily data challenges. These pain points help identify which data silos cause the most problems and should be first in line for attention.

With a clear picture of your current state, set specific objectives for your PLM implementation. Pick one or two high-impact areas rather than trying to solve every data challenge at once. For example, you might focus first on connecting engineering data with production systems to eliminate manual file transfers and reduce errors.

When selecting a PLM system, focus on how well it integrates with your existing software. The right solution connects to both modern and legacy systems, scales to handle your data volume, and provides appropriate security controls.

Implementation

Start small with implementation, choosing one department or product line for your pilot project. You can test your approach, work out integration issues, and demonstrate value before expanding.

For the pilot to succeed, invest time in training your teams. Show them how to use the PLM system and explain how it makes their work easier. Create quick reference guides for everyday tasks and identify power users who can help their colleagues. When users see tangible benefits in their daily work, adoption follows naturally.

Continuous improvement

Monitor the system's performance and how teams use it. Are people finding information faster? Are there fewer errors from outdated data? Use these metrics to fine-tune your approach and build support for a wider rollout. As your teams get comfortable with the basic functionality, you can add more advanced features and integrations.

Think of PLM implementation as a continuous journey rather than a one-time project. Your needs will evolve as your business grows and technology advances. Build flexibility into your implementation plan, and keep communication channels open with your teams.

Final Thoughts

Breaking down data silos through PLM implementation delivers tangible benefits for industrial machinery manufacturers. From accelerated product development to improved quality control, connected data drives better outcomes across the organization. Working with experienced partners can help navigate common challenges and accelerate time to value.

For additional insights and practical steps, explore CLEVR’s “Extending PLM Capabilities with Low Code” whitepaper.

Research Methodology

We combined an analysis of industry research and case studies with practical implementation experience. We also examined data from manufacturing organizations across multiple sectors to identify common challenges and successful approaches to breaking down data silos through PLM adoption.

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