Let’s face it—if you’re still using a legacy product lifecycle management (PLM) system this late in the game, you’re probably feeling the pain.
Not to mention, the immense pressure from both your consumers and competitors to speed your time to market while simultaneously increasing product quality.
Because today, getting it done "eventually" just doesn’t cut it.
Let’s break down the biggest limitations of outdated product lifecycle management systems, consider some real-life use case horror stories, and explore how modern cloud-native solutions are more of a game-changer than you may realize.
1. Data Silos and Fragmented Product Information
Legacy PLM systems are infamous for creating data silos, where product information is scattered across different departments like confetti at a parade. Engineering teams have one version of the truth, manufacturing has another, and by the time customer support gets involved, it’s a game of telephone gone terribly wrong.
Scenario: A consumer electronics company struggled to launch a new product because the design team updated the bill of materials (BOM), but the manufacturing team was still working with outdated data. This led to expensive rework, missed timelines, and one very unhappy CEO.
These systems were never designed to support cross-functional collaboration. They trap data in departmental silos, making it impossible to maintain a single source of truth. And without consistent product information, decision-making turns into a guessing game. This is where modern PLM software shines, by offering advanced data management capabilities to ensure accurate and reliable information across the board.
Consequences
- Inconsistent product information leading to design errors.
- Reduced data quality, impacting decision-making accuracy.
- Rework and delays, increasing time to market.
2. Inflexible Change Management
Ever tried changing workflows in a legacy PLM system? It’s like trying to teach a cat to fetch—it’s technically possible but incredibly painful. Most legacy systems are hardcoded and require expensive customizations for even minor process changes.
Scenario: A medical device manufacturer needed to adjust approval workflows to comply with new regulations. Their legacy system couldn’t be updated without costly custom coding. The result? Delays in change requests, extended timelines, and a compliance nightmare.
Legacy systems are built on rigid architectures that don’t allow for dynamic workflow changes. This inflexibility slows down the entire product development process and increases the risk of non-compliance. Modern PLM solutions offer configurable workflows that adapt to any management process, reducing bottlenecks and enabling end-to-end visibility for decision-makers.
Consequences
- Slow change management, affecting product development timelines.
- Increased compliance risks due to poor version control and approval tracking.
- Bottlenecks in engineering change orders, affecting product quality and time to market.
3. Ineffective (or Non-Existent) Collaboration
Traditional PLM systems were never designed to connect external stakeholders like suppliers and partners. This leads to fragmented communication, delayed decisions, and a serious lack of visibility into the supply chain.
Scenario: An automotive manufacturer faced multiple production delays because their legacy PLM couldn’t provide real-time updates on supplier inventory. By the time they realized a critical component was on back order, production had already ground to a halt.
These systems can’t support enterprise-wide collaboration or real-time data exchange. The result? Teams work in silos, leading to misalignment, delays, and costly mistakes. Today’s PLM software promotes enterprise-wide collaboration and synchronizes development teams, ensuring everyone—from engineers to suppliers—is on the same page.
Consequences
- Fragmented communication, leading to misalignment between design and manufacturing.
- Delays in supply chain management due to poor visibility into supplier data.
- Increased risk of product recalls due to miscommunication and quality issues.
4. Poor Integration with Enterprise Systems
You’ve got ERP, CRM, PDM, and about a dozen other systems that need to communicate with your PLM. With a legacy system, that’s a pipe dream. Poor integration leads to data duplication, manual entry errors, and inconsistent product information.
Scenario: A consumer goods company manually entered data from their PDM system into their ERP, leading to mismatched product information. This caused shipping delays, inventory mismanagement, and some very unhappy customers.
Legacy PLM systems are siloed and struggle to integrate with modern enterprise solutions. This lack of connectivity leads to inefficiencies, increased operational costs, and poor user experiences. Modern PLM solutions seamlessly integrate with ERP and CRM systems, enhancing product data management and ensuring consistent data quality across all touchpoints.
Consequences
- Data inconsistencies across systems, leading to poor decision-making.
- Increased operational costs due to manual data entry and rework.
- Delays in new product introductions, affecting competitive advantage.
5. Lack of Scalability and Extensibility
Your business is growing, but your legacy PLM system can’t keep up. These systems were built for a time when “scalability” meant adding another filing cabinet. They’re rigid, difficult to customize, and can’t support new product lines or market expansions.
Scenario: A startup expanded to international markets, only to discover that their legacy PLM couldn’t handle multiple currencies or regional compliance requirements. The costly workaround involved manual processes and spreadsheets, which still weren't safe from mistakes caused by human error.
Legacy systems are built on outdated architectures that aren’t designed for scalability or extensibility. They can’t easily adapt to new business requirements or digital transformation initiatives. In contrast, modern PLM software solutions are designed for scalability and extensibility, ensuring smooth growth and adaptability to future advancements.
Consequences
- Inability to support product line expansions or new market entries.
- High costs of customization and maintenance.
- Difficulty in adopting new digital initiatives, impacting competitiveness.
6. Security Vulnerabilities and Data Integrity Risks
You wouldn’t store your valuables in a cardboard box, so why are you storing your intellectual property in a legacy PLM system with outdated security features? These systems lack advanced encryption, role-based access control, and compliance with modern data protection regulations.
Scenario: An aerospace manufacturer suffered a data breach due to inadequate access controls in their legacy PLM system. Sensitive product data was stolen, resulting in financial losses and a damaged reputation.
Legacy systems simply weren’t built with modern security threats in mind. Without advanced security features, your product data is vulnerable to breaches and unauthorized access. Modern PLM solutions prioritize security and data management, ensuring your intellectual property stays safe and compliant with international regulations.
Consequences
- Data breaches leading to loss of intellectual property and competitive advantage.
- Non-compliance with modern data security regulations (e.g., GDPR).
- Damage to brand reputation and financial losses.
The Solution: Propel PLM – The Modern Cloud-Native Hero
You’ve seen the horrors of outdated PLM systems. But here’s the good news: Propel Software is the answer. Propel PLM is a modern, cloud-native software solution that addresses every limitation listed above. Here’s how Propel redefines product lifecycle management with unmatched functionality and adaptability to meet evolving customer needs.
- Continuous Product Thread: Propel maintains a continuous product thread that connects all product data from ideation to end-of-life, ensuring a single source of truth. This end-to-end visibility empowers real-time decision-making, eliminates data silos, and significantly improves data quality. With Propel’s unified platform, teams can easily track changes, versions, and approvals throughout the product life cycle.
- Configurable Workflows: Unlike rigid legacy systems, Propel offers configurable workflows that adapt to your unique business processes. This flexibility allows organizations to easily adjust change management processes, ensuring compliance, efficiency, and agility. Propel’s automated workflow functionality is designed to handle complex product design iterations, prototyping processes, and engineering change orders (ECOs). Teams can collaborate in real time, seamlessly managing multiple iterations while maintaining full version control and traceability.
- Enterprise-Wide Collaboration: Propel connects cross-functional team members—including product development, engineering, manufacturing, marketing, and customer support—on a single platform. This collaboration accelerates decision-making, ensuring all stakeholders are aligned with the product roadmap and strategic objectives.
- Seamless Integration: Built on Salesforce, Propel integrates effortlessly with ERP, CAD, CRM, PDM, and other enterprise systems, ensuring consistent product information and streamlined workflows. This seamless integration supports comprehensive collaboration and eliminates data silos across the value chain.
- Scalability and Extensibility: Propel’s cloud-native architecture offers unmatched scalability and extensibility. Whether you’re expanding globally, adding new product lines, or adopting new digital initiatives, Propel grows with you.
- Trusted Security & Data Protection: Propel provides enterprise-grade security, including advanced encryption and role-based access control. Your product data stays safe and compliant with international regulations.
Why Wait? Propel is the Future of PLM
Legacy PLM systems are holding you back. Propel is the modern, cloud-native hero you need to streamline workflows, improve collaboration, and accelerate time to market. Explore how Propel PLM can revolutionize your product development process and discover the power of a cloud-native platform that drives enterprise-wide collaboration, scalability, and business transformation.
