End-to-end Digital PLM transformation for a leading global Discrete Manufacturer

A global discrete manufacturing company, targeting significant revenue growth through 2030, faced critical challenges in scaling innovation and operational efficiency. The organization operated with fragmented tools, manual processes, and disconnected systems across the product lifecycle. Key issues included: 

• Manual interfaces to SAP for material mastering and EBOM creation   

• Disconnected MCAD/ECAD data and document management   

• Engineering change management handled via Microsoft Office tools   

• No centralized platform for requirements or project management   

• High manual effort in SBOM creation and service documentation   

• Lack of integration with third-party tools (e.g., BomCheck, iPoint)   

• Misaligned BOM structures impacting material flow and traceability   

• Limited collaboration across R&D, manufacturing, quality, and service   

These inefficiencies led to increased quality risks, slower time-to-market, and reduced responsiveness to customer and regulatory demands. 

Hitachi Digital Services led a comprehensive Digital PLM transformation initiative, structured around a Walk–Run–Fly roadmap to enable phased value realization. The solution included: 

• Deployment of a unified Global One PLM platform   

• Seamless integration with SAP S/4HANA, MES, CRM, and LIMS   

• End-to-end BOM management (Design, Engineering, Manufacturing, Service BOMs)   

• Closed-loop change, quality, and regulatory controls   

• MCAD/ECAD integration and document lifecycle management   

• Traceable requirements management and digital collaboration across functions   

• Supplier collaboration and environmental compliance integration   

• AI/GenAI enablement for knowledge management, BOM assistance, and zero-touch service desk   

• Standardization using out-of-the-box PLM capabilities tailored via configuration   

This transformation enabled a digital thread across the product value chain, improving traceability, compliance, and innovation velocity. 

The PLM transformation delivered measurable business impact across the enterprise: 

• 20–45% improvement in product quality through integrated design, reuse, and change control   

• 20–40% reduction in operational costs via automation, reduced rework, and optimized inventory   

• 35–55% improvement in delivery performance through streamlined collaboration and traceability   

• Enhanced regulatory compliance and reduced warranty claims   

• Improved supplier efficiency and purchasing effectiveness   

• Accelerated innovation across product management, engineering, and service functions