From engineering data to production control: aligning Windchill and ERP in high-growth manufacturing
In Barcelona, Stark Future is redefining performance in the electric motorcycle industry. With more than 100 engineers and operating in one of the fastest-growing segments of the global EV market, the company combines engineering excellence with an ambitious growth strategy. But in high-velocity manufacturing environments, innovation alone is not enough. Without structural control, growth quickly exposes weaknesses in data management and system integration.
At a critical stage of its expansion, Stark Future faced a challenge that is common in fast-scaling industrial companies: how to transform engineering data into production-ready structures without losing accuracy, traceability or time.
The challenge: aligning Windchill with ERP reality
Stark Future’s engineering environment was based on Windchill PLM from PTC, where product structures were defined and managed as Engineering Bills of Materials (EBOM). However, translating those EBOMs into Manufacturing Bills of Materials (MBOM) ready for production — and reliably connecting that information to Microsoft Dynamics ERP — was not automated.
The transition relied heavily on manual data handling. Engineering and manufacturing teams were not fully synchronized at system level, and changes required effort to track and validate. In practice, this meant product structures were exposed to inconsistencies, delays and operational risk. At the pace Stark Future was growing, this gap between PLM and ERP could quickly become a structural bottleneck.
The problem was not the quality of engineering. It was the absence of a controlled, automated integration layer between Windchill and the ERP.
The solution: structured integration with ISFsoft Connect
To address this challenge, ISFsoft Connect was introduced as the integration layer between Windchill and Microsoft Dynamics. The objective was clear: establish a structured, automated and governed data flow between engineering and manufacturing, eliminating manual intervention wherever possible.
The project began with a thorough pre-analysis phase to define scope, risks and integration requirements. Particular attention was given to defining precise EBOM-to-MBOM transformation rules, ensuring that what engineering designed in Windchill could be consistently and accurately translated into a manufacturing structure aligned with ERP processes.
Rather than treating PLM and ERP as separate initiatives, the approach aligned both environments from the outset. The integration ensured that product releases, revisions and changes could move between systems in a controlled and traceable way, creating a reliable digital thread across the organization.
The focus was not limited to technical connectivity. It was about long-term reliability and scalability. In high-growth contexts, short-term fixes create long-term instability. The objective was to build a foundation capable of supporting Stark Future’s expansion without constant rework or manual corrections.
The impact: a single source of truth at a decisive moment
The results were structural. Stark Future established a reliable method to derive MBOM from EBOM, fully connected to the ERP and free from manual duplication. Errors associated with manual data entry during product structure development were eliminated. Product releases became instantly controlled, and change management gained full traceability across systems.
Most importantly, the company achieved what every fast-growing manufacturer needs: a single source of truth between Windchill and ERP. Engineering and manufacturing now operate on synchronized data, reducing risk and increasing operational confidence at a critical stage of growth.
In industries evolving as rapidly as electric mobility, scalability depends on integration discipline. Stark Future’s case demonstrates that aligning Windchill with ERP through a structured integration layer is not simply a technical improvement — it is a strategic enabler of controlled growth.
If your company uses Windchill and is struggling to reliably integrate it with your ERP, we can help you design a controlled, scalable integration strategy. Contact ISFinnovation to explore how to eliminate manual bottlenecks and establish a true digital backbone between PLM and ERP.
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Why is access to information the biggest bottleneck in engineering?
The hidden costs of isolated engineering information
When engineering data is not accessible to the entire organization, the negative effects become immediately evident. Engineering teams turn into bottlenecks, constantly interrupted by information requests from other departments. This not only diverts their attention from essential innovation and development tasks but also creates a fragmented and inefficient workflow. The time lost responding to emails, attending calls, or generating specific content for other teams directly impacts the company’s productivity and agility.
The weaknesses of inaccessible engineering information
- Data duplication: Lack of access to updated information leads to the unnecessary creation of documents and files, resulting in redundancies and wasted resources.
- Proliferation of parts: Without a centralized view, different departments may generate similar or duplicate parts, hindering standardization and increasing operational complexity.
- Rework costs: Lack of access to reliable information leads to avoidable errors, requiring tasks to be redone, draining time and budget.
- Slowed innovation: Limited information flow between teams reduces the speed at which products can be developed and improved.
- Poor collaboration: Without a shared database, teams work with outdated or partial information, leading to poor decisions and missed opportunities.
- Longer development time: Fragmented information causes delays in design and manufacturing cycles, affecting the company’s competitiveness.
- Delayed time-to-market: Difficulty in accessing and sharing data affects responsiveness to market changes and opportunities, potentially leading to a loss of competitive advantage.
Inefficiency, overhead costs, and delays: The Price of Isolated Information
The lack of accessibility to engineering data has tangible consequences that directly impact operational efficiency and profitability:
- Lower productivity: Time spent searching for or requesting information translates to fewer hours dedicated to innovation and product development.
- Additional costs: Duplicated efforts and rework increase operating expenses.
- Innovation delays: Inefficient information flows extend development cycles.
- Higher error margin: The absence of a single, reliable source of information increases the risk of inconsistencies and product failures.
Data democratization: The key to optimizing processes and enhancing collaboration
To overcome these challenges, companies must invest in controlled and secure access to engineering information. This transformation of internal processes helps correct the previously mentioned weaknesses:
- Optimized resources and efficiency: Eliminating data duplication and facilitating access to accurate information allows teams to work more efficiently, reducing administrative time and maximizing productivity.
- Faster innovation and development: A smooth and transparent data flow enables better collaboration between departments, driving creativity and continuous improvement in design and production processes.
- Improved decision-making: Access to key information ensures that different departments work in alignment with up-to-date and reliable data, reducing errors and response times.
The solution: ISFsoft Viewer – Simplified Access and visualization of engineering data
To address the inefficiencies caused by limited access to engineering data, we have developed ISFsoft Viewer, an innovative solution that provides seamless access and visualization of critical Windchill information on a single, intuitive platform.
With ISFsoft Viewer, teams can:
- Quickly search for and access the information they need, without barriers or dependencies on other departments.
- Reduce time spent on administrative tasks, allowing engineers to focus on innovation and development.
- Enhance collaboration and decision-making by providing real-time, precise, and easily accessible data.
Eliminating barriers to engineering information access not only optimizes internal processes but also drives efficiency and innovation. With ISFsoft Viewer, companies can transform their data management approach, enabling each team to focus on what truly matters: developing high-quality products and achieving operational excellence.