MVGR COLLEGE OF ENGINEERING A.N.S.

PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1

PRODUCT LIFECYCLE MANAGEMENT

PROJECT-1

AIM:
To Select a product of your choice and provide detailed descriptions for the following
aspects:
1. Product Identifiers
2. Identification Standards
3. Product Classification
4. Versions, Variants, Options
5. Product Structure
6. Product Architecture.
PRODUCT SELECTED:
The product that was selected was Pulsar 150 cc.
INTRODUCTION:
The Bajaj Pulsar is a range of motorcycles manufactured by Bajaj Auto in India. This
iconic brand, launched in 2001, revolutionized the Indian motorcycle market by introducing a
new segment of performance-oriented bikes.
➢ Development and Launch:
The Pulsar was a product of Bajaj Auto's product engineering division, developed in
collaboration with Tokyo R&D and later with renowned motorcycle designer Glynn Kerr. The
project faced significant internal resistance and scepticism from external consultants like
McKinsey & Company, who doubted its potential impact on Bajaj's existing relationship with
Kawasaki. Despite these challenges, the project was completed in 36 months at a cost of ₹1
billion.
The Pulsar twins (150cc and 180cc) were launched in India on November 24, 2001.
Prior to this, the Indian motorcycle market was dominated by fuel-efficient, small-capacity
bikes. The Hero Honda CBZ had shown a potential for performance bikes, and Bajaj capitalized
on this opportunity with the Pulsar.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1
➢ Market Impact and Success
The Pulsar's launch marked a turning point for the Indian motorcycle industry. It
redefined the expectations of Indian youth, who began demanding higher power and advanced
features from their bikes. The model's immense popularity is evident from its sales figures:
Average monthly sales of around 86,000 units in 2011, capturing a 47% market share in its
segment.
Over five million units sold by April 2012.
Ten million Pulsar units sold by 2018, celebrated with a nationwide campaign.
The Pulsar's success can be attributed to its perfect blend of performance, style, and
affordability. It catered to the aspirations of the young Indian rider, offering a thrilling riding
experience without breaking the bank.

1. PRODUCT IDENTIFIERS:
Product Identifiers (PIDs) are unique codes or labels assigned to products to
facilitate their identification, tracking, and management throughout their lifecycle. In a
Product Lifecycle Management (PLM) system, PIDs are crucial for maintaining data
integrity, traceability, and efficient product development and management.
Types of Product Identifiers:
1. Internal Product Identifiers:
a. Part Number: A unique code assigned to a component or part within a
product assembly.
b. Item Number: A unique code assigned to a product or assembly.
c. Product ID: A generic term for any internal identifier used to track a
product.
2. External Product Identifiers:

a. GTIN (Global Trade Item Number): A standardized number format used to

identify trade items.
b. UPC (Universal Product Code): A barcode symbology widely used in retail
for product identification.
c. EAN (European Article Number): A barcode symbology used in Europe and
other countries.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1
d. SKU (Stock Keeping Unit): A unique identifier for a product variant.
e. MPN (Manufacturer Part Number): A unique identifier assigned by the
manufacturer to a product.

Product Identifiers in pulsar 150cc:

The basic product identifiers for an pulsar 150 cc is
• Model no
• Chassis no
• Trade mark logo
• Based on cc
• Based on colour

➢ Model no:

1. Pulsar 150 Single Disc

2. Pulsar 150 Twin Disc

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1

3. Pulsar 150 Neon

➢ Chassis no/Engine no:

A chassis number, also known as a Vehicle Identification Number (VIN), is a
unique code assigned to every vehicle. It serves multiple critical purposes:
Identification and Verification:
Unique Identification: Each vehicle has a distinct chassis number, making it possible to
identify a specific vehicle accurately.
Vehicle Verification: It helps verify the authenticity of a vehicle, preventing fraud and theft.

➢ Trade mark logo:

Bajaj is a well-known Indian multinational conglomerate with a distinct logo.
While the specific logo might vary slightly across different Bajaj Group companies, the
core elements remain consistent.
Typically, the Bajaj logo features:
• The word "Bajaj" in a distinctive font.
• A specific colour palette.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1
Sometimes, additional elements like a symbol or design.

➢ Based on cc:
the capacity(CC) of pulsar varies from 125cc to 220cc

➢ Based on colour:
While specific colour options might change over time, some common color
combinations include:
1. Sparkle Black Red
2. Sparkle Black Blue
3. Sparkle Black Silver
4. Sapphire Black Blue

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1

2. IDENTIFICATION STANDARD:
Identification standards are crucial in PLM to ensure accurate, consistent, and
efficient management of product data throughout its lifecycle. These standards provide
a common framework for identifying and tracking components, assemblies, and
products.
❖ Key Identification Standards in PLM are
1. Part Numbering System:
A structured approach to assigning unique identifiers to parts. Includes
elements like part type, material, design, and revision.
Examples: Alphanumeric, decimal, or hierarchical systems.
2. Item Numbering System:
Similar to part numbering but for finished products or assemblies.
Often includes product line, version, and configuration information.
3. Global Trade Item Number (GTIN):
An international standard for product identification used in supply chain
management. Includes UPC (Universal Product Code) and EAN (European
Article Number).
4. Stock Keeping Unit (SKU):
A unique identifier for a specific product variant, including size, color, and
packaging.
5. Manufacturer Part Number (MPN):
A unique identifier assigned by the manufacturer to a product.
In the context of motorcycles, the primary identification standard is the Vehicle Identification
Number (VIN).
The VIN
A VIN is a unique 17-character code assigned to every vehicle manufactured worldwide. It
contains information about the manufacturer, model, year, and other specific details of the
vehicle.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1
Structure of a VIN:
The VIN is divided into three sections:
1. World Manufacturer Identifier (WMI): The first three characters identify the country of
origin and manufacturer.
2. Vehicle Descriptor Section (VDS): Characters 4 to 9 describe vehicle attributes like
body type, engine, and restraint system.
3. Vehicle Identifier Section (VIS): Characters 10 to 17 provide specific information about
the vehicle, such as model year, plant code, and serial number.
Importance of the VIN:
Vehicle Identification: Uniquely identifies a specific motorcycle.
Theft Prevention: Helps in recovering stolen motorcycles.
Insurance Purposes: Required for insurance policies.
Regulatory Compliance: Used for vehicle registration and safety recalls.
Data Tracking: Essential for tracking vehicle production, sales, and service history.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1
3. PRODUCT CLASSIFICATION:
Product classification is a fundamental process in Product Lifecycle
Management (PLM) that involves organizing and categorizing products, components,
and assemblies into meaningful groups based on shared characteristics. This structured
approach enhances data management, search capabilities, and decision-making within
the organization.
Key Benefits of Product Classification:
Improved Search and Retrieval: Efficiently locate product information and assets.
Enhanced Collaboration: Facilitates communication and knowledge sharing across teams.
Data Consistency: Maintains uniform product data across the organization.
Effective Decision Making: Supports informed choices based on product attributes and
relationships.
Cost Reduction: Optimizes product development and manufacturing processes.
Classification Methods:
There are several approaches to product classification:
Hierarchical Classification: Creates a tree-like structure with broader categories at the top
and more specific ones at lower levels.
Faceted Classification: Allows multiple classification schemes to be applied simultaneously,
providing flexibility and granularity.
Rule-Based Classification: Uses predefined rules to assign products to categories.
Hybrid Classification: Combines multiple methods to achieve optimal results.

Product classification in pulsar is:

1. Primary classification:
• Model: Pulsar 150, Pulsar 180, Pulsar 220, etc.
• Segment: Sports, commuter, cruiser, etc.
• Engine Type: Single-cylinder, twin-cylinder, etc.
• Displacement: 150cc, 180cc, 220cc, etc.
2. Secondary Classification:
• Variant: Disc brake, drum brake, fuel injection, carburettor, etc.
• Colour: Black, red, blue, etc.
• Year of Manufacture: 2023, 2024, etc.
• Tertiary Classification (if applicable)
• Special Editions: Pulsar NS200, Pulsar RS200, etc.
• Market-Specific Variants: Pulsar for different regions or countries.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1

4. VERSION, VARIANT, OPTIONS:

In Product Lifecycle Management (PLM), understanding the distinctions
between version, variant, and option is crucial for effective product configuration and
management.
Version: A version represents a specific state or iteration of a product or component
over time.
Purpose: Tracks changes and evolution of a product, enabling comparison and rollback
if necessary.
Examples: Software releases (v1.0, v2.0), hardware revisions (Rev A, Rev B),
document updates (v1.1, v1.2).

Variant: A variant is a variation of a product that shares common characteristics with

other products but has specific differences.

Purpose: Represents different configurations or customizations of a product to meet

specific market segments or customer requirements.
Examples: Car models with different trim levels (base, luxury, sport), smartphone
models with varying storage capacities (128GB, 256GB).

Option:An option is a feature or component that can be added or removed from a

product to create different configurations.

Purpose: Offers flexibility in product customization and allows for different pricing and
packaging strategies.
Examples: Car options (sunroof, leather seats, navigation system), computer options
(additional RAM, hard drive size).

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1
IN PULSAR:
1. Version:
Concept: Represents a significant update or redesign of the Pulsar model.
Example: The transition from the original Pulsar 150 to the newer Pulsar NS150 could be
considered a version change.

2. Variant:
Concept: Represents different configurations of the same Pulsar model.
Example: Pulsar 150 Single Disc, Pulsar 150 Twin Disc, Pulsar 150 Neon are variants of the
Pulsar 150 model.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1
3. Option:
Concept: Represents additional features or components available for purchase with a Pulsar
bike.
Example: Anti-lock braking system (ABS), different colour schemes, or accessories like
windshields or saddlebags could be considered options.

5. PRODUCT STRUCTURE:
Product structure is the backbone of a Product Lifecycle Management (PLM)
system. It defines the hierarchical relationship between components, assemblies, and
the final product. Essentially, it's a digital representation of the physical product.
❖ Key Components of Product Structure:
Items: These are the basic building blocks of a product, such as parts, components, or
sub-assemblies.
Instances: Represent specific occurrences of an item within a product structure.
Relationships: Define how items and instances are connected (e.g., parent-child,
assembly-component).
Attributes: Provide additional information about items and instances (e.g., material,
quantity, weight).

Types of Product Structures:

1. Engineering Bill of Materials (EBOM): Focuses on design and engineering
aspects, including part numbers, specifications, and relationships.

2. Manufacturing Bill of Materials (MBOM): Reflects the structure required for

production, including manufacturing instructions and process information.

3. Service Bill of Materials (SBOM): Defines the components needed for product
service, repair, and maintenance.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1
Importance of Product Structure:
Efficient Product Development: Provides a clear overview of product composition.
Accurate Costing: Enables accurate cost estimation based on component costs.
Effective Supply Chain Management: Supports sourcing and procurement activities.
Improved Manufacturing: Facilitates production planning and scheduling.
Enhanced After-Sales Service: Aids in repair, maintenance, and spare parts
management.
IN PULSAR:
Level 1: Motorcycle Assembly
Engine Assembly
Chassis Assembly
Electrical System Assembly
Bodywork Assembly
Wheels and Tires Assembly

Level 2: Sub-Assemblies
Engine Assembly: Cylinder block, piston, connecting rod, crankshaft, camshaft, etc.
Chassis Assembly: Frame, swingarm, forks, shock absorbers, brakes, etc.
Electrical System Assembly: Battery, wiring harness, ignition system, lighting system, etc.
Bodywork Assembly: Fuel tank, fenders, fairings, seat, etc.
Wheels and Tires Assembly: Wheels, tires, tubes, brake discs/drums, etc.

Level 3: Components
Individual parts that make up sub-assemblies (e.g., bolts, nuts, screws, bearings)
Importance of Product Structure in Motorcycle Manufacturing:A well-defined product
structure is crucial for efficient motorcycle manufacturing. It helps in:
Bill of Materials (BOM) Creation: Accurately defining the components required for each
motorcycle.
Inventory Management: Tracking and managing stock levels of components and assemblies.
Assembly Process: Guiding the assembly line workers through the build process.
Quality Control: Identifying and addressing issues at different levels of the product structure.
Spare Parts Management: Efficiently managing spare parts inventory and distribution.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1

6. PRODUCT ARCHITECTURE:
Product architecture is the blueprint that defines how a product's functions are
allocated to its physical components. It's the strategic framework that guides the design,
development, and manufacturing of a product. In the context of PLM, it's how the
product structure is organized and managed to achieve optimal results.

❖ Key Components of Product Architecture

Functional Decomposition: Breaking down the product's functions into smaller,
manageable units.
Physical Architecture: Defining the physical components and their relationships.
Interface Definition: Specifying how components interact with each other.
Modularization: Dividing the product into independent modules for flexibility and
reusability.

Types of Product Architectures:

Integral Architecture: Tightly coupled components with high interdependence.
Modular Architecture: Loosely coupled components with high independence.

Role of PLM in Product Architecture:

Data Management: Stores and manages product architecture information.

Collaboration: Facilitates collaboration among design, engineering, and manufacturing
teams.
Configuration Management: Supports different product variants and options.
Simulation and Analysis: Enables virtual prototyping and performance evaluation.
Visualization: Provides visual representations of product architecture.

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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1
Benefits of Effective Product Architecture:
Improved Product Development: Faster time-to-market and reduced costs.
Enhanced Product Quality: Better product performance and reliability.
Increased Flexibility: Easier to adapt to market changes and customer requirements.
Facilitated Manufacturing: Optimized production processes and reduced waste.
Challenges and Best Practices
Complexity Management: Handling complex product architectures efficiently.
Trade-off Analysis: Balancing different design objectives and constraints.
Collaboration: Ensuring effective communication and coordination among teams.
Change Management: Managing changes to product architecture throughout the
lifecycle.
IN PULSAR:
we can discuss a general product architecture framework commonly employed in the
motorcycle industry:
Chassis: The backbone of the motorcycle, housing the engine, suspension, and other
components.
Engine: The powertrain, responsible for propulsion.
Electrical System: Powering the motorcycle's electrical components.
Braking System: Ensuring vehicle control.
Suspension System: Enhancing rider comfort and control.
Potential Product Architecture Considerations for Pulsar
Based on the general motorcycle architecture, we can speculate on potential architectural
considerations for Pulsar:
Modular Design: Bajaj might have adopted a modular approach to share components across
different Pulsar models, reducing development costs and improving efficiency.
Weight Optimization: Given the performance-oriented nature of Pulsar, weight reduction is
likely a key architectural consideration.
Cost-Effective Engineering: Balancing performance with affordability is a crucial factor.
Ergonomics: Designing the motorcycle to suit the target audience's riding posture and comfort.
Safety Features: Incorporating safety features like ABS, disc brakes, and reliable braking
systems.
Challenges in Detailing Pulsar's Architecture:
Complexity: Motorcycles are complex systems with numerous interconnected components.
Proprietary Information: Detailed architectural information is closely guarded by
manufacturers.
Continuous Evolution: Motorcycle designs evolve over time, making it difficult to provide a
static overview.
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MVGR COLLEGE OF ENGINEERING A.N.S. PAVAN KUMAR
MECHANICAL DEPARTMENT Regd no:22335A0302
PLM PROJECT-1

SUMMARY:
Key Concepts Covered:
Product Identification: The importance of unique identifiers (e.g., model number, serial
number) for tracking and managing products.
Product Classification: Organizing products into categories based on shared characteristics for
efficient data management and analysis.
Product Version, Variant, and Option: Distinguishing between different iterations, variations,
and customizable features of a product.
Product Structure: The hierarchical breakdown of a product into components and assemblies.
Product Architecture: The overall design and organization of a product's components and
functions.
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