Project of the Month


"Preparation for the implementation of an Engineering Configurator"

A structured three‑phase methodology to reduce risk and complexity before implementing an engineering configurator.

KEY FIGURES

  • 36% reduction of configuration logic through structured analysis and validation
  • Reduced the number of required engineering models by 59% by consolidating product catalog sections into parametric engineering models.

INITIAL SITUATION

The customer planned to introduce an engineering configurator to handle automated production requirements, such as machine data generation and increasing product variety. However, the existing configuration and engineering data landscape was fragmented, undocumented, and distributed across multiple systems and individual knowledge holders.


Key challenges included:

  • Inconsistent engineering data between CAD drawings, CNC programs, and ERP logic
  • Hidden and redundant configuration logic accumulated over time
  • Lack of standardized documentation for construction rules and dependencies
  • High risk of transferring inconsistencies directly into the new configurator environment



Without structured preparatory work to assess configuration complexity and validate engineering logic, the implementation risked misaligned configurator rules, costly rework, extended timelines, and limited scalability.


APPROACH

Three‑Phase Preparatory Methodology

Phase 1 – Engineering Data Preparation

  • Identification of representative product types based on usage analysis (ABC-Analysis)
  • Structuring parts into clearly defined part families
  • Systematic collection of configuration‑relevant engineering data using developed standardized checklists
  • Validation of construction data across CAD drawings, CNC programs, and expert knowledge
  • Application of modularity principles for interface standardization to reduce future rule complexity


  • Outcome:
    Validated engineering documentation templates for hinging logic, doweling patterns, edgebanding, and material‑surface logic, forming a reliable baseline for future system setup.


Phase 2 – Configuration Logic Structuring and Validation

  • Extraction and analysis of legacy ERP‑based configuration logic
  • Identification of frequently used configuration features
  • Feature modeling to make dependencies and constraints transparent
  • Verification of configuration logic
  • Elimination of redundant, overlapping, or inconsistent option codes


  • Outcome:
    Reduction of configuration logic by 36% while preserving the existing configuration scope and output behavior.


Phase 3 – Engineering Model Grouping and Feasibility Validation

  • Definition of three alternative engineering model grouping strategies
  • Evaluation based on model flexibility, maintainability, scalability, robustness, and complexity
  • Utility analysis involving multiple stakeholders
  • Selection of the best engineering model grouping strategy
  • Conceptual prototype to validate feasibility without full system rollout


  • Outcome:
    Reduced the number of engineering model groups by 59% through consolidation of product catalog sections, creating a scalable and maintainable foundation for future implementation.

CUSTOMER BENEFITS

The project demonstrated that structured preparatory work significantly reduces implementation risk and long‑term maintenance effort:

  • Engineering and configuration knowledge became transparent, documented, and verifiable
  • Redundant and inconsistent logic was eliminated before system setup
  • Future engineering model complexity was reduced while maintaining flexibility
  • The methodology enabled informed decisions on configurator scope and structure

By separating preparation from implementation, the configurator rollout could now proceed with validated data, and reduced risk.