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Challenges in Apparel PLM Implementation And How To Overcome Them


 

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Product lifecycle management (PLM) is a strategic process that manages the entire journey of a product from the initial idea to its disposal. PLM can help apparel companies reduce costs, improve quality, accelerate time to market, and boost innovation. However, implementing PLM is not a simple task. It requires careful planning, clear objectives, effective communication, and organizational buy-in. In this blog post, we will discuss some of the common challenges that apparel companies face when implementing PLM and how to overcome them.


Challenge 1: Choosing the right PLM system

One of the first and most important decisions that apparel companies need to make is which PLM system to use. There are many PLM solutions available in the market, each with different features, functionalities, and prices. Choosing the wrong system can lead to frustration, inefficiency, and wasted resources.


How to overcome it: To choose the right PLM system, apparel companies need to conduct a thorough analysis of their business needs, goals, and processes. They need to identify the key pain points that they want to solve with PLM, the main workflows that they want to streamline or automate, and the data that they want to manage and share. They also need to evaluate the PLM systems based on their industry relevance, customization options, integration capabilities, user-friendliness, scalability, and customer support.


Challenge 2: Integrating PLM with other systems

Another common challenge that apparel companies face when implementing PLM is integrating it with other systems that they use, such as ERP, CRM, CAD, or e-commerce platforms. Integrating PLM with other systems can help improve data quality, visibility, and consistency across the product lifecycle. However, integration can also pose technical difficulties, compatibility issues, and data conflicts.


How to overcome it: To integrate PLM with other systems smoothly, apparel companies need to have a clear understanding of their data sources, formats, and flows. They need to map out how data will be exchanged between different systems and what rules or standards will be followed. They also need to choose a PLM system that has built-in or easy-to-use integration tools or APIs. Moreover, they need to test the integration thoroughly before going live and monitor it regularly for any errors or glitches.


Challenge 3: Managing change and resistance

Implementing PLM is not only a technical project but also a cultural one. It involves changing the way people work, communicate, and collaborate across the product lifecycle. However, not everyone may be willing or ready to embrace these changes. Some people may resist PLM because they fear losing control, authority, or familiarity. Others may resist because they lack the skills, knowledge, or motivation to use PLM effectively.


How to overcome it: To manage change and resistance when implementing PLM, apparel companies need to involve their stakeholders from the beginning. They need to communicate the benefits and expectations of PLM clearly and frequently. They need to provide adequate training and support for their users to learn and adopt PLM. They also need to solicit feedback and suggestions from their users and address any issues or concerns promptly.


Challenge 4: Measuring and demonstrating ROI

Implementing PLM can be a significant investment for apparel companies. Therefore, they need to measure and demonstrate the return on investment (ROI) of their PLM project. However, measuring and demonstrating ROI can be challenging because PLM impacts various aspects of the product lifecycle that may not be easy to quantify or attribute. For example, how do you measure the improvement in product quality or customer satisfaction that PLM brings?


How to overcome it: To measure and demonstrate ROI of their PLM project, apparel companies need to set clear and realistic goals and metrics for their PLM strategy. They need to establish a baseline for their current performance and compare it with their expected performance after implementing PLM. They also need to track and report their progress and results regularly and transparently.


Challenge 5: Keeping Up with Evolving Technology

In the fast-paced world of technology, staying current is a challenge in itself. As apparel companies implement PLM, they may find that the landscape is ever-evolving, with new features, tools, and methodologies surfacing regularly.


How to overcome it: Stay in the loop! Keep an eye on industry trends and advancements in PLM technology. Establish a system for ongoing training and updates for your team to ensure they are well-versed in the latest developments. Foster a culture of continuous improvement, encouraging your team to explore new features that could enhance your PLM implementation.


Challenge 5: Replacing Excel as the go-to tool

Many apparel companies still rely on Excel as their main tool for managing product data and information. Excel is familiar, flexible, and easy to use. However, Excel also has many limitations when it comes to product lifecycle management. Excel files are prone to errors, inconsistencies, duplication, and corruption. Excel files are also difficult to share, update, and secure across different teams and locations.


How to overcome it: To replace Excel as the go-to tool for product lifecycle management, apparel companies need to show their users the advantages of using a dedicated PLM system instead. A PLM system can help eliminate manual tasks such as copying data across different files or systems, double-checking data for inaccuracies or missing information or searching for data in multiple places. A PLM system can also help automate workflows, enforce data standards, and provide real-time visibility and collaboration across the product lifecycle.


Challenge 6: Aligning with manufacturing

One of the main goals of PLM is to improve the alignment and communication between design and manufacturing. However, many PLM systems can create a gap or a barrier between these two functions. This is because many PLM systems are not designed to meet the specific needs and preferences of manufacturers. Manufacturers may have their own processes, formats, and systems for managing product data and information. They may also be reluctant to adopt a new system that they perceive as complex, expensive, or intrusive.


How to overcome it: To align with manufacturing when implementing PLM, apparel companies need to involve their manufacturers from the start. They need to understand their manufacturers' requirements, expectations, and challenges. They need to choose a PLM system that can accommodate their manufacturers' needs and preferences, such as supporting different languages, units, or currencies. They also need to provide their manufacturers with adequate training and support to use the PLM system effectively.


Challenge 7: Dealing with complexity and user interface issues

Many PLM systems are complex and sophisticated, offering a wide range of features and functionalities. However, this can also make them difficult and cumbersome to use. Many PLM systems have a cluttered and confusing user interface that can overwhelm or frustrate the users. Many PLM systems also require a lot of customization and configuration to fit the specific needs and processes of each apparel company.


How to overcome it: To deal with complexity and user interface issues when implementing PLM, apparel companies need to focus on the user experience. They need to choose a PLM system that has a simple and intuitive user interface that can guide the users through the product lifecycle. They also need to customize and configure the PLM system only as much as necessary, avoiding unnecessary features or functionalities that can add complexity or confusion.


Challenge 8: Learning curve and investment

Implementing PLM is a learning process that requires time, effort, and resources. Apparel companies need to invest in acquiring, installing, and maintaining the PLM system. They also need to invest in training their users on how to use the PLM system effectively. Moreover, they need to invest in monitoring and evaluating the performance and impact of the PLM system.


How to overcome it: To reduce the learning curve and investment when implementing PLM, apparel companies need to plan ahead and budget accordingly. They need to assess their current situation and identify their gaps and opportunities for improvement. They also need to prioritize their needs and goals and select the most suitable PLM system for their business. Furthermore, they need to leverage the expertise and support of their PLM vendor or partner who can help them with the implementation process.


Conclusion

Implementing PLM can bring many benefits to apparel companies, such as increased productivity, decreased costs, enhanced product quality, faster time to market, and improved innovation. However, implementing PLM also comes with many challenges. To overcome these challenges, apparel companies need to follow some best practices, such as conducting a thorough analysis of their business needs and goals, evaluating the PLM systems based on their industry relevance and integration capabilities, involving their stakeholders from the beginning and providing adequate training and support, and setting clear and realistic goals and metrics for their PLM strategy. By doing so, apparel companies can ensure a successful PLM implementation that delivers value and results.

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