Client Overview

Leidos is a Fortune 500 technology, engineering, and science company serving defense, intelligence, civil, and health markets. Their aerospace and defense division needed to modernize manufacturing process management to improve efficiency, maintain data consistency across enterprise systems, and enable concurrent engineering and manufacturing planning.

The Challenge

Leidos faced critical manufacturing process challenges:

No connection between engineering and manufacturing BOMs. Engineering designed products in Windchill PLM using engineering BOMs (eBOMs). Manufacturing planned production in Costpoint ERP using manufacturing BOMs (mBOMs). Manual transformation between the two created errors, delays, and version control issues.

Sequential engineering and manufacturing planning. Engineering completed designs before manufacturing could begin process planning. This sequential approach delayed time-to-market and prevented manufacturing input during design phase.

Data consistency across enterprise systems. Multiple systems (Windchill PLM, Costpoint ERP, Solumina MES) needed synchronized data. Manual updates created discrepancies and required constant reconciliation.

Training and adoption concerns. Previous system implementations had struggled with user adoption. Leadership needed proof that MPMLink would deliver ROI before full investment.

The Element Approach

Element Consulting implemented PTC MPMLink within Leidos's Windchill SaaS PLM environment to enable seamless eBOM-to-mBOM transformation and concurrent planning.

Phase 1: Requirements and Planning

• Documented current state workflows for engineering and manufacturing teams

• Defined future state with concurrent engineering and manufacturing planning

• Created business requirements document aligned with Costpoint ERP integration needs

• Established success criteria and ROI metrics

Phase 2: MPMLink Configuration

• Installed MPMLink on Dev/Test environments (Windchill 12.0.2.16)

• Configured BOM Transformer to automate eBOM-to-mBOM conversion

• Set up Process Plan Browser for manufacturing process definition

• Created decision matrix for when manufacturing data lives in Windchill vs. Solumina

• Defined options and variants strategy for product configurations

Phase 3: Integration and Testing

• Established connectivity between Windchill MPMLink and Costpoint ERP

• Ensured single revision control across PLM and ERP systems

• Provided technical assistance for eQube integration middleware

• Developed comprehensive test cases for BOM revision flow

• Verified associativity between eBOM and mBOM structures

• Validated that changes in engineering automatically update manufacturing plans

Phase 4: Training and Knowledge Transfer

• Delivered SME (Subject Matter Expert) training to Leidos engineers

• Conducted live walkthroughs of MPMLink capabilities

• Created training materials for sustained adoption

• Equipped internal team to demonstrate ROI to leadership

• Provided ongoing support during transition from legacy systems

Implementation Timeline

• Sprint 1: August 19 - September 2 (Requirements and initial configuration)

• Sprint 2: August 30 - September 13 (System configuration and testing)

• Configuration & Test Migration: September 16-20 (Move to production)

• Ongoing support through multi-year implementation

The Results

Improved process efficiency. Concurrent engineering and manufacturing planning reduced time-to-market. Manufacturing can now provide input during design phase, catching producibility issues early.

Enhanced data quality. BOM Transformer eliminated manual eBOM-to-mBOM conversion errors. Single source of truth maintained across Windchill and Costpoint.

Integration success. Digital thread established across PLM, ERP, and MES systems. Engineering changes automatically flow to manufacturing and procurement.

Knowledge transfer achieved. Leidos SMEs trained and equipped to sustain MPMLink adoption internally. Internal team can demonstrate ROI and expand usage.

Key Outcomes:

• Enabled concurrent design and manufacturing planning

• Automated eBOM-to-mBOM transformation (eliminated manual conversion)

• Maintained single revision control across PLM and ERP

• Reduced discrepancies between engineering and manufacturing data

• Established foundation for digital thread across enterprise systems

• Trained internal team for sustained adoption

Project Challenges Overcome

Data migration complexity. Existing mBOMs and routings were not in scope, requiring manual alignment during transition period. Element developed interim workflows to bridge legacy and new systems.

Revision control synchronization. Ensuring single revision consistency between Windchill and ERP required careful business rules definition and testing. Team developed comprehensive test scenarios to validate all edge cases.

Demonstrating value to manufacturing engineers. Initial skepticism about MPMLink value required early wins and clear ROI demonstration. Element focused on quick pilot wins to build credibility.

Lessons Learned

Early stakeholder engagement is critical. Bringing manufacturing, engineering, and IT together from day one prevented misalignment and ensured buy-in.

Test case rigor ensures smooth transition. Comprehensive testing of BOM flows, revision control, and integration points caught issues before production impact.

Continuous training accelerates adoption. Ongoing support and training (not just initial sessions) built confidence and sustained usage.

Project Details:

• Industry: Aerospace & Defense Contracting

• Systems Integrated: Windchill PLM (MPMLink), Costpoint ERP, Solumina MES

• Project Type: Manufacturing process management implementation

• Users Trained: 50+ engineers and manufacturing planners

• Status: Ongoing multi-year expansion