Engineering Software

Plexus Online provides a powerful set of engineering modules that allow engineers to control Parts, Engineering Changes, Process Routings, Bills of Material, and the other building blocks of an integrated system. In addition to the standard engineering modules, the system can also be configured to support special information pertaining to your specific process. In other cases we have developed highly mathematical engineering analysis programs to help automate engineering theory and calculations.

  • Part List
    This module provides a master list of Parts, including all associated part data, such as Part Description, Part Type, and Revision. This modules also provides an easy-to-use mechanism to upload small digital photos of each part. The Part List also provides links to many other areas of the system, where applicable, such as Key Part Dates, Customer Part Numbers, APQP Checklist, Inventory, Shipment History, Problem History and so on.

  • Process Routings
    A process routing is the series of steps required to manufacture or process a given part. This module defines those steps. Includes the Operation Number, Operation Name, Approved Workcenters and Suppliers, Crew Size, Weight, Container Type, and other key routing data.

  • Bill of Materials
    This module defines the components that make up a part. Plexus Online supports infinite levels of BOM. It provides indented BOM, exploded BOM, drilldown BOM, and a variety of other methods for visualizing and editing BOMs. Plexus Online handles BOMs with just a few components, or many thousands.

  • Part Specifications
    This module is used to establish and maintain a detailed list of dimensions and characteristics on specific parts, including Dimension Name, Target Value and Tolerance.

  • Multi-Out Production
    Identifies and controls manufacturing processes where multiple different Parts are produced from a single Operation. This is a critical capability for stampers, multi-part die forgers, injection molders, and other manufacturing processes. Plexus Online also supports a die cavity status which allows machines to run some of the cavities, but not all the cavities.

  • Customer Part Numbers
    This module provides the ability to store and manage one or more Customer Part Numbers for each internal Part. Includes Revision Level, Revision Date, Customer Program, Estimated Annual Volume, and other pertinent data about each Customer Part No.

  • Manufacturing Masters
    This module is used to tie together and manage a long manufacturing process that involves a complex interconnection of parts, routings, BOM and Multi-outs. For example, this will schedule the component parts of an assembly.

  • CAD Integration
    Plexus provides a special feature within your CAD system to number and name each Dimension on the Part Drawing. Then, whenever the drawing is saved, it synchronizes the dimensions and their tolerances to the Part Specification List in Plexus Online, which in turn drives the Control Plan, Checksheet, and data collection systems. The CAD Integration subsystem saves you from having to type dimensional data into Plexus and adds a high-degree of advanced integration between Engineering, Quality and Manufacturing. Currently in use with AutoCAD 2004. Will also work with other CAD systems such as SolidWorks, CATIA, Unigraphics, Pro/Engineering, and so on.

  • Engineering Change Request
    The ECR module provides an online system for company personnel to submit change requests to engineering. The system tracks the ECR, manages the work flow, organizes and controls the drawings, and maintains on-going documentation of the change.

  • Engineering Drawing Management
    This module provides the Engineering Department a method for attaching CAD files and other important documents to Parts, Tools, Assemblies, and other key engineering records. Each drawing can be managed with a description, version, owner, format, electronic approvals, check in/out, and so on.

  • Document Control System
    The Document Control module provides the ability to store, edit, track and view documents on line. Includes full electronic approval and revision tracking system ideal for ISO/TS 16949. Supports many file types, including Word, Excel, Powerpoint, AutoCAD, PDF, HTML, and more. This module is usually used to control the Quality Manual, Procedures and Work Instructions. It is also used for the Employee Handbook, Supplier Handbook, and Technical Documentation.

  • Universal Attachment System
    The Attachment system allows you to attach files to records in the database. File attachments are used for Employees, Equipment, Gages, Orders, Problem Records, Customers, and many other areas. Attachments can be in any file type, including Word, Excel, Powerpoint, and digital photographs.

  • Specification Management (Documents)
    The specification module is used for managing and tracking Specification Documents, such as Engineering Specifications (E.S.), Material Specifications, and other external standards documents.

  • Heat Treat Parameters
    This module provides a formal structure for storing Heat Treat parameters and settings for each Part.

  • Option Configurator
    The Option Configurator provides a user-definable wizard for selecting various product options to generate a custom Build. Often used in Quoting, Order Entry, and Job Shops. It's ideal for one-off jobs with complex options, such as building machinery.

  • Temper
    This module provides a master list of Tempers, including Description. Tempers are integrated into the materials, inventory, parts, and other subsystems within Plexus Online.

  • Engineering Data
    Plexus can be configured to support custom, company-specific engineering data such as setup parameters, machine specifications, product dimensions, tolerances, process data and many other requirements.

  • Engineering Directives
    This module is used to track and control Engineering Directives to the shop floor, when specifications and instructions have changed.

  • Part Component Details
    For use when discrete inventory items of a Part are not identical. Allows tracking of distinct piece weights, values, etc. within a given Part.

  • Part Configurator
    The Part Configurator provides a highly-sophisticated and customized interface for designing and creating new parts within the constraints of your product lines, processes and capabilities. This module is especially useful for fastener manufacturers/distributors, steel distributors, and other organizations that have families of similar, type-driven part characteristics: nuts, bolts, screws, steel bars, tooling, etc.

  • Backward Extrusion Analysis
    This module helps metalforming engineers design backward extrusions. Calculates pressures, forces, and extruded wall heights.

  • Forward Extrusion Analysis
    This module helps metalforming engineers design safe and viable forward extrusions. Calculates forming pressures and forces, and recommends chevron-free taper angles. Engineering based on Upper Bound Elemental Technique.

  • Press Fit Tool Design
    This module enables experienced tooling engineers at forging and stamping companies to optimize die designs for cylindrical, axially-symmetric dies that have been press fit together. This module applies to a classic three-piece assembly model (Die, Sleeve, Case) which goes through the following sequence: 1)Die is pressed into a sleeve 2)Die-Sleeve Cartridge is pressed into a case, and 3)Assembly is used in forming. It serves as both a design and training tool and facilitates quick “what if” scenario-evaluation. The underlying theories rest on well-known mechanical engineering principles such as thick-walled cylinder analysis, Hooke’s law, stress/strain, maximum-normal-stress theory, elastic/plastic failure behavior, ductile/brittle failure behavior and Mohr’s theory.

  • Weight Calculator
    Calculates mass and weight of various shapes and material types. Especially useful for generating quotes.

  • Raw Material Specification
    This module is used to define detailed chemical and physical specifications for materials, such as steel, aluminum and other metals. Includes user-definable specification templates. Provides capability to link multiple materials to a part, and multiple parts to a material.

  • FMEA
    The Failure Mode & Effects Analysis module provides the ability to create, edit and view QS-9000-compliant FMEA's on screen, including Design and Process FMEA's. FMEA's are developed at the beginning of the project to address the following questions: 'What can go wrong? What will happen if it does? What controls do we have in place to detect it if it does? How should we improve the part or process?' Some companies use 'Common FMEAs' that cover a whole range of processes in a generic fashion. Other companies establish one or more FMEA's for each part. FMEA's are a requirement of QS-9000.

    (Design, Process, and System)
  • Control Plans
    The Control Plan module provides the ability to create, edit and view Control Plans and detailed Inspection Instructions on screen. Some companies create one or more "Common Control Plans" to cover a whole range of processes in a generic fashion. Other companies establish a detailed Control Plan, breaking down each dimensional Specification at each operation. Control Plans include the Sample Frequency, Gage, type of Control chart, and other quality-oriented data. Control Plans are a requirement of QS/ISO-9000. The Control Plan is highly integrated with the Part Specification system.

  • Checksheets & Process Instructions
    Powerful subsystem for authoring process instructions and checksheets. Fully integrated with and driven from the Control Plan system.

  • Deviation Tracking
    A module for tracking approved deviations from engineering dimensions/specifications during the manufacturing process.

  • APQP Overview
    The APQP overview module is used for coordinating all the various tasks by individual across checklists. APQP and Team Feasibility Checklists are a requirement of QS-9000.

  • Program Manager
    This module provides capabilities for tracking and managing internal programs, product launches and major product revisions.

  • Tool Management System
  • Master Tool List
    This module is used to establish a master list of tool numbers, and the pertinent data about each tool number, including Revision, Material, Supplier(s), Min Quantity, Order Quantity, and so on. The Master Tool List is the foundation of the overall tooling system. It also provides links into Tool Inventory, Tool Manufacturing, and the other tooling-related modules.

  • Tool BOM / Assemblies
    A List of the tools required to produce each production part at each operation and workcenter. Distinguishes machine-specific tools (adapters) from the tools used regardless of machine (forming tools). Provides the foundation for the Tool Sets module, which tracks the physical instances of each assembly. This module also provides the foundation for tool-staging reports, which compare available inventory to the tooling required to fulfill the production schedule.

  • Workcenter List
    This module is used to establish a master list of Workcenters or Machines within the company. Provides the foundation for Production Tracking, Scheduling and other modules.