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Life After I-DEAS - Part IFastTrack TDM to Teamcenter Migration

Brian Garcia MetaforeSr. PLM Applications Engineerbrian.garcia@meta-fore.com

Matthew PeytonMoog Components GroupSr. Designer/CAD Administratormpeyton@moog.com

Agenda

Introductions

TDM Audit Findings

TDM Clean-up

Installation & Configuration of Teamcenter Engineering

Migration and Pilot Team Testing

TCE Training and TCE Cutover

NX Training & Configuration

What we learned

Q & A

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Metafore - Who We Are

Metafore is an independent, vendor and technology neutral full service product lifecycle

management (PLM) solution provider.

We help organizations to drive innovation, increase productivity, and improve operational

effectiveness through the integration and resourceful utilization of PLM technologies,

processes and practices.

We make PLM easy and affordable by offering:

PLM Consulting

PLM Systems Integration

PLM Operation and Support

PLM Software

PLM Hosting

PLM On-Demand

Moog Components GroupBlacksburg, Virginia

Moog Components Group is an innovative motion company with related design and manufacturing capabilities for optical components, fiber optics and electronic systems.

Motion Technology- High performance motors- Slip rings and fiber optic rotary joints- Actuators

Electronic Systems- Fiber optic switches- Fiber optic modems (FOM)- Avionics instruments and displays

Moog - Map Location

Moog History

Moog Corporation purchased Moog Components Group (formerly Poly-Scientific) in 2003. Moog Corporation has standardized on Teamcenter Engineering with NX and has been a long time UGS/Siemens customer.

Moog Components Group, a division of Moog Inc., has been a long time I-DEAS CAD site with roughly 56 users.

They use Windows workstations and used I-DEAS Team Data Manager (TDM) for their CAD data management system.

Moog CAD Objectives

Moog Inc. is moving towards a standardized data management system at the same time I-DEAS customers are being encouraged to launch the migration process to convert to NX as the replacement CAD system.

Moog is a highly multi-CAD environment with a desire to reduce the overall number of systems being supported enterprise wide while allowing the autonomy of each division’s engineering practices.

Moog Components GroupBlacksburg, VA - FastTrack Goals

Teamcenter I-DEAS Integration (TCII) by Fall 2007

Independent of timing of moving to NX

Teamcenter NX Integration by the time new Moog engineering project start for 2008.

TDM Audit Findings

During the week of June 10th , 2007 Metafore performed an audit of Moog’s I-DEAS Team Data Manager (TDM)

At the time, Moog was on I-DEAS 12M2

10 year old TDM

2,064 Projects

Evaluated the TDM for cleanliness and ran miadmin (metadata integrity administration tool)

miadmin results

3 MISSING_ITEM_NAME errors found

32 MULTIPLE_ITEM_NAMES errors found

15654 MISSING_PART_NUMBER errors found

24 MULTIPLE_PART_NUMBERS errors found

18 MULTIPLE_MIGRATED_DRAWINGS errors found

77 INCOMPLETE_MIGRATED_DRAWING errors found

894 INVALID_MIGRATED_DRAWING errors found

1 MULTIPLE_LEGACY_DRAWINGS errors found

33 INVALID_LEGACY_DRAWING errors found

6104 DUPLICATE_PART_NUMBER errors found

7808 DUPLICATE_ITEM_NAME errors found

81 INVALID_CHARACTERS_IN_ITEM_NAME errors found

28 INVALID_CHARACTERS_IN_PART_NUMBER errors found

920 ITEM_NAME_TOO_LONG errors found

308 PART_NUMBER_TOO_LONG errors found

miadmin Analysis

The MISSING_PART_NUMBER, MULTIPLE_PART_NUMBERS, and DUPLICATE_PART_NUMBER conditions need to be addressed

The MULTIPLE_ITEM_NAMES, MISSING_ITEM_NAME and DUPLICATE_ITEM_NAME errors do not need to be fixed, since Teamcenter keys on unique part number rather than item name.

The ITEM_NAME_TOO_LONG can be ignored.

The PART_NUMBER_TOO_LONG conditions should be addressed. 32 characters for the Teamcenter Item Number

The INVALID_COPY_OF_MIGRATED_DRAWING and INVALID_MIGRATED_DRAWING_ATTRIBUTE errors can usually be automatically fixed by an miadmin update.

MULTIPLE_MIGRATED_DRAWINGS were fixed by breaking the association of incorrect Migrated Drawings by manually entering BREAK_RELATIONSHIP keyword in the Action field.

Feature Migration Status (Nov. 2006)

Average 95.7% feature migration success rate

Example: 100 parts each with 100 features = total 10000 features and 9570 features migrate to NX exactly as if created natively in NX (including sketches, constraints and geometry fidelity)

1.8% of remaining failed features migrate in yellow status (final geometry and features okay, but maybe a missing constraint in a sketch)

Average repair time 2 minutes

Remaining failed feature data is stored in Data Access Features (DAF) and take on average 10 minutes to repair

Example: 100 parts with 100 features = 10000 features. 9570 pass, 180 yellow features at 2 minutes repair time per feature and 250 features at 10 minutes repair time per feature for a total repair time estimate on average of (2860 minutes) 48 hours per 10000 features

Individual customer pass rate is given by audit and is accurate +-1% or less

Feature Audit Tool Results

With the release of NX5, many of the Moog migrated feature failures for Parts, Assemblies, and Drawings are resolved leaving approximately less than 5% not migrated.

Yielded a high rate of confidence to proceed with project

For Teamcenter I-DEAS Integration (TCII), the first phase of the project, this is a non-issue. The I-DEAS data features are not migrated to NX. I-DEAS metadata is only imported (migrated) into Teamcenter.

TDM Clean-up

Overall, the miadmin analysis was very clean and the I-DEAS Admin had done an excellent job maintaining the TDM after 10 years.

The Moog strategy to correct the miadmin errors was an aggressive one.

Major Cleanup work started on July 9 thru 24

Cleaning took approximately 20 days spread across 4 months before the GO LIVE date for TCII.

TDM Clean-up strategy

Missing parts numbers were assigned generic part numbers, such as, NOPN-00000, NOPN-00001, etc

Duplicate part number errors were resolved by checking what TDM libraries the items were in. There were lots of hardware copies by users in personal Project/Libraries. Appended copies with “_DUP1”, “_DUP2”, etc.

This was not ALWAYS the case, so at times there was some user discretion in determining the correct master, but usually there was a focus on quickness rather than accuracy due to the chaotic nature of the TDM.

TDM Clean-up strategy – Excel work

Another important factor for the quick clean-up was the Excel spreadsheet technique used by Moog.

There was a team of about 4 people that did the clean-up.

Everyday a new report was created from miadmin and the excel file was put on a network location.

Excel has a "share" option which allows multiple users to manipulate the document at once and it updates all changes each time you save. 

To keep people from overwriting each other or doing duplicate work, there were a range of numbers in Excel assigned to each person, so every day “user X” would do cells 101 thru 400, and “user Y” would do 401 thru 800, etc...  Then at the end of the day, the changes would be updated into TDM and the process would be repeated the next day. Scan, Analyze, and Update.

Installation:Versions of Software Used

Upgraded to NX I-DEAS 5

The compatibility of each release gets better and we want to utilize the most up to date functionality and robustness of all software products when possible.

Better Content Migration with NX I-DEAS 5 to NX 5

Teamcenter Engineering 2005 SR1 MP1

Teamcenter I-DEAS Integration 5.0.2.2

NX I-DEAS 5m1

NX 5.0.2.2

Installation & Configuration of Teamcenter Engineering

A Four-Tier Architecture Installation was done on virtual machines on the Host Server. This is becoming more of a “Best Practice” because of the ease of recovery.

Host Server – Dell PowerEdge 6950 32GB – 42 GB RAM 4 Dual Core 2.8Ghz AMD Opteron Processor All drives reside on an EMC CX340 SAN

VM Server 1 – Database Server Microsoft Server 2003 R2 SP2 2GB RAM 1 Dual Core 2.8Ghz AMD Opteron Processor

VM Server 2 – Web and Visualization Server Microsoft Server 2003 R2 SP2 3GB RAM 1 Dual Core 2.8Ghz AMD Opteron Processor

More on Server Installation

Microsoft SQL Server 2005 Standard Edition was chosen for the database component.

3 databases were created. Development (DV), Quality Assurance (QA), and Production (PD).

This would allow for test migrations, trials with different configurations, and training in the QA and DV databases without compromising the Production (PD) database.

Installation of Engineering Translation Services (ETS) was also performed.

Migration and Pilot Team Testing

Sample migrations of TDM data into Teamcenter were preformed on the QA database and tested

The QA database was populated with 100’s of parts, assemblies and drawings for the Pilot Team to manipulate and test the functionality of the Teamcenter I-DEAS Integration (TCII)

8 pilot team users from different departments and disciplines tested the TCII for several weeks performing daily tasks as they did before with I-DEAS TDM

After validation of QA, the production database (PD) was populated with all the TDM datasets.

Migration to Production (PD)

While Metafore was importing items into the Teamcenter QA database, two Moog personnel were trained on how to run the migration batch files into Teamcenter.

Migration of all TDM data into the Production database was done by the Moog I-DEAS Administrator which was now becoming the Teamcenter Database Administrator.

The migration work was spread over several days during a two week time period.

Team Data Manager(TDM)

I-I-deasdeasDataData

I-I-deasdeasDataData

Teamcenter Engineering

I-I-deasdeasDataData

I-I-deasdeasDataData

Team DataTeam DataManagerManager

Team DataTeam DataManagerManager

I-deasI-deasI-deasI-deas

Metadata MigrationMetadata MigrationMetadata MigrationMetadata Migration

I-deasI-deasI-deasI-deas

IntegrationIntegrationfor I-deasfor I-deas

IntegrationIntegrationfor I-deasfor I-deas

TCE Training and TCE Cutover

While the Pilot Team tested TCII in QA, the remaining I-DEAS, Pro/E, and Solidworks users were trained to use Teamcenter with I-DEAS.

The Moog Information Technology (IT) department put together a final image for client machines and was pushed out over the remaining weeks leading up to the cutover.

A delta migration was run the weekend before GO LIVE TCII to find the new I-DEAS data in the existing TDM that had been created during the transition months.

Using dmadmin, you can export a file by date which gave us a short list of items to migrate before cutting over to Teamcenter.

TCE in Production Use with I-DEAS

October 29, 2007 TCII - GO LIVE date

Metafore was on-site to support the transition and shake out the system, if needed.

The Teamcenter interface takes some getting use to for any user.

Finding Items in Teamcenter is different than TDM but more powerful

Once users understood how to use the new TDM attribute queries, Life after I-DEAS TDM was a little easier

Renaming items in Teamcenter is very difficult

The inability to run Ham_Medic with Teamcenter created additional work for users. Fixed in newer versions of TCII.

The “One Path” to NX: Definition & Understanding for users

“One Path” is a set of options that must be used in the migration from I-deas to NX through Teamcenter Engineering

One Version Per Revision During Metadata Migration

During Save to Teamcenter Engineering

Part, Assembly, Drawing & FEM Datasets Each Dataset Type in It’s Own Item Revision

No Two Dataset Types in the Same Item Revision

During the transition to TCII, ALL I-DEAS users need to go up this learning curve and understand this how this works to avoid confusion.

NX Training

While the current I-DEAS users were getting up to speed on TCII, training laptops were prepared for NX training to complete the final phase of the project.

From November 5 – December 21, 2007, NX Basic Training was offered on-site by Metafore to all CAD users.

The training was two weeks long for each group. There were two - 4 hour sessions per day with a maximum of 8 students in each group to allow for a good student to teacher ratio. This also allowed flexibility so people had the rest of the day to get their other required job tasks done.

NX/Teamcenter Configuration

During the NX Training period, Metafore and Moog personnel configured NX and Teamcenter Production (PD) environment according to “Best Practices”.

Environment variables were set. (ugii_env.dat, etc.)

Custom Moog templates for NX were created and imported into Teamcenter.

NX preferences and drafting standards were set.

Other setup (as we came across them) required for a smooth transition from I-DEAS, Solidworks, Pro/E to NX for the Moog CAD user were addressed.

More details on the configuration will be covered in Part 2 of the Life After I-DEAS Presentation on Wednesday, June 4th 4:15pm.

Slice of Life - Virginia Tourism

Blue Ridge Parkway

November 2007

Fall Colors

Country Living

Floyd, Virginia Sleepy town, lots of character

The Floyd Country StoreFriday Night Jamboree

Pickin’…

…and a Grinin’

Music Lovers

The Crooked Road – Western Virginia

Back on TopicNX CAD Begins at Moog

GO LIVE date – January 2nd, 2008

Only a half dozen users used NX initially. Tool designers, R&D dept., and some Drafting Designers

Other users were wrapping up project still in I-DEAS

Status today June 2008

50/50 user split right now, but with all the heavy CAD users using NX

All new jobs are started in NX, and I-DEAS jobs are still being finished in I-DEAS

What We Learned

In the end, the project was completed ahead of schedule and under budget. The I-DEAS to NX/Teamcenter was complete in 6 months.

The Migration Tools are more powerful than ever. In the CAD World, nothing like this has been done before and the support from UGS/Siemens is strong. There’s always room for improvement, but there is some great support from our user community.

Keep sending people to PLM World and shaking some trees to find out the “Best Practices”. They are ever-changing.

Get people involved that have been using I-DEAS for a long time

With the help of the customer’s management to clear road blocks and keep committed to getting the job done, the project moved along at a steady pace. Attitude is everything.

Issues come up and it’s a given. Staying calm and even keeps the project moving along schedule.

Questions?

The Continuation of this story, Life After I-DEAS – Part II NX/Teamcenter Integration Wednesday, June 4th 4:15pm.

See you there.

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Thank You!

Brian GarciaMetaforeSr. PLM Applications Engineerbrian.garcia@meta-fore.comPhone: 503-236-0975

Matthew Peyton Moog Components GroupSr. Designer/CAD Administratormpeyton@moog.com