What is product lifecycle management (PLM)?

Whether it’s a pair of sneakers or a component for a satellite, every manufactured product is actually the culmination of thousands of small decisions made by hundreds of different people. Each item is its own little story, written collaboratively across engineering desks, production floors, and conference rooms. But without the right approach, the narrative can quickly become jumbled, inconsistent, and full of costly mistakes. That’s the power of product lifecycle management (PLM): It provides a unified space where all these product decisions come together. PLM aligns teams, streamlines collaboration, and gives clarity at every step of the journey – from the first spark of inspiration through to final product delivery and beyond. Ultimately, PLM helps companies not just create products, but craft coherent, compelling stories that resonate with customers, reduce complexity, and inspire lasting success.

Product lifecycle management (PLM) is the process of managing a product through every stage of its lifecycle – from initial concept and design, through manufacturing and usage, to final disposal. It integrates data, processes, and people involved, ensuring seamless collaboration and efficient product development.

PLM software is the technological foundation for the many processes within product lifecycle management. It’s the place where people and information intersect, to bring your products to life. PLM software:

• Centralises product data: PLM software serves as a unified hub for all product-related information. Engineers can access precise measurements quickly, designers can retrieve the specs they need, and suppliers can view exact part requirements. This eliminates outdated files or conflicting information and prevents costly mistakes.
• Connects cross-functional workflows: PLM software lets your teams manage workflows from end to end. When an engineering change is finalised, procurement gets automatic alerts to order necessary components, and manufacturing teams receive updated assembly plans, ensuring everyone knows precisely what the next step will be.
• Facilitates collaboration: If you want effective product development, you need smooth collaboration. PLM software invites all stakeholders – including internal departments and external suppliers – to work together early and often. Teams share ideas, review designs, and incorporate feedback within the system, preventing late-stage surprises and costly delays.
• Ensures traceability and compliance: Every decision, change, or approval made within a PLM system is carefully documented. This audit trail is invaluable, especially for companies in highly regulated industries like aerospace. If compliance issues arise, teams can quickly identify exactly what changed, when, and why – simplifying audits and improving overall accountability.

While exploring PLM, you might also hear about enterprise resource planning (ERP) and manufacturing execution systems (MES). These three systems each serve distinct roles but work closely together.

• PLM focuses specifically on managing the entire end-to-end lifecycle of a product. It organises product-related data, tracks changes, ensures compliance, and supports cross-departmental collaboration.
• Enterprise resource planning (ERP) systems have a broader scope. ERP software manages overall business operations like finances, procurement, inventory, and human resources. It takes product data from PLM and uses it to schedule production, purchase materials, and manage resources effectively.
• Manufacturing execution systems (MES) operate specifically on the manufacturing floor. MES controls real-time production activities, tracks quality, and manages detailed manufacturing data. It ensures products are built correctly, efficiently, and traceably.

How they work together:

• PLM → ERP: PLM provides detailed product data and designs to ERP
• ERP → MES: ERP schedules and dispatches production orders to MES
• MES → ERP and PLM: MES feeds real-time manufacturing data back to ERP (for inventory updates) and to PLM (for ongoing design improvements)

In short, PLM defines what needs to be made, ERP plans when and how to make it, and MES ensures it's built correctly on the shop floor. Together, these systems create an efficient, integrated product lifecycle from start to finish.

Back in the 1900s, Henry Ford said that if you ask people what they want, they won’t say cars, they’ll say faster horses. When it comes to innovation and new technologies, there’s always a bit of resistance to change – even if those changes will make everyone’s lives a whole lot easier in the long run. So it is with digital tools like PLM.

What can be learnt from the most successful companies over the past 50 years is that it’s important to manage technological change with openness and clarity. Don’t spring new systems on your people overnight. Don’t forget to take wise counsel from the shop floor – not just the C-suite. Don’t leave communication and change management as an afterthought. Get out in front of digital transformations. Show your teams hands-on, concrete examples of how PLM solutions can help them with everyday tasks. Demonstrate the real-time features with actual test runs. Set an example with a top-down commitment to training, listening, and establishing a concise and transparent rollout plan.

Today’s smartest PLM solutions

With the speed of advancement in AI and machine learning, and the growing ubiquity of cloud-based solutions, PLM – like all enterprise software – is advancing at a rapid pace.

• Cloud-based PLM: Traditionally, PLM software has lived on local servers within companies. But now there's a total shift toward cloud-based solutions. Cloud PLM offers easier scalability, lower upfront costs, and quicker updates, making it accessible to companies of all sizes. With teams increasingly remote and globally dispersed, cloud solutions ensure seamless collaboration, anytime and anywhere.
• Integration with IoT and digital twins: As products become smarter and connected through the Internet of Things (IoT), PLM is leveraging this trend by integrating real-time data from devices in the field. This gives rise to "digital twins" – virtual replicas of physical products that update continuously with real-world performance data. Teams can proactively monitor performance, test new ideas virtually, and even predict when maintenance will be needed.
• Artificial intelligence and automation: AI-powered PLM systems introduce intelligent features that help teams work smarter. Machine learning algorithms can predict potential bottlenecks, suggest design improvements based on historical data, or automate routine tasks like data entry or standard approvals. By reducing manual workload, smart systems let product teams focus on innovation rather than repetitive tasks.
• Sustainability as a core focus: Today, sustainability isn't just a nice-to-have – it's a critical business priority. PLM systems increasingly help companies design greener products by tracking sustainability attributes throughout a product's lifecycle. Teams can quickly assess environmental impacts, choose sustainable materials, and ensure compliance with evolving environmental regulations. PLM thus becomes a vital tool in creating more sustainable, eco-friendly products and processes.

Conclusion

In the end, product lifecycle management is really about connection – connecting people, ideas, and processes in a way that brings clarity to complexity. When done right, it turns good intentions into great products, helping teams move smoothly from imagination to reality. In an increasingly crowded market, PLM isn't just practical; it's essential for making your best ideas thrive.