life cycle baseline reconciliation a system overview and description of the basic configuration...
TRANSCRIPT
Life Cycle Baseline Reconciliation
A System Overview and Description of the
Basic Configuration Verification System (BCVS)
ACDM 15th Annual Technical Conference 21-22 March 2010
Ram White, Integrated Support Systems, Inc.
1
Life Cycle Baseline Reconciliation Basic Configuration Verification System (BCVS)
Presentation Agenda: • The Basics/Fundamentals
– Product Life Cycle, Bills of Material, Data/Documentation, Baselines and BL Comparisons, Audits and Reconciliation
• The BCVS Business Values• The System Environments
– Functional Systems Architectures– Communications (point-to-point or Standards)
• Data Object Modeling (The devil is in the detail)• Data Mapping Strategies
– XLS/CVS, XML, Standards & Direct Integration
• ISS/InSync Proposed Solution• Supporting the DD 250 Process• The Back Story: Boeing’s SI/BCA & P-8A
2
CSCI CI
-1-3
CSC CSC
Unit PartPartUnitUnitUnit
Item Item Number
Product Structure(Bill of Material)
Item
Number
Drawing(s)/Doc(s)/Std(s)/Spec(s)HW/SW/Tooling/PlanningCosts/Schedule(s)/Personnel/
OrganizationsFiles/Records/Data/CAD Model(s)Associations/Attributes
(FN, NSN, MS, UM, Qty, etc.)3
As-Authorized(_________)
As-Designed(_________)
As-Committed(_________)
As-Planned(_________)
As-Delivered(_________)
As-Maintained(_________)
As-Built(_________)
As-Purchased(_________)
As-Tested(_________)
Cost EstimatingCapacity Planning & AssessmentSpecifications
Master ScheduleWork Breakdown StructureBudgetsSales OrdersCost AccountsEffectivity
Baseline ReleaseDocument ControlProduct Definition EBOM Bill of RoutingsEffectivity (Eng.)
MBOMEffectivity (Manf.)Bill of Routings/ResourcesMaster Production ScheduleProposed Capacity PlanningMRP/CRP/ProcurementWork Order Release
Receiving/InspectionReceiving InstructionsDock-to-StockInventory (WIP)Lot Code / Serial NumberingShop Floor ControlLabor CollectionWork MeasurementsProcess InstructionsTest ProceduresTest ResultsCM Status Accounting
As-Built SnapshotCM ReconciliationCM Status AccountingLot Code / Serial NumberingDeviations / Waivers
Field Return / RetrofitField ServiceCM ReconciliationLot Code / Serial No.CM Status AccountingAs-Built History
Product’s Life Cycle Management(Basic Life Cycle Process)
As-Disposed(_________)
Storage, SalvageTo-Become (Recycle) CM ReconciliationLot Code / Serial No.CM Status AccountingAs-Was/Is History
ConceptDefinition
DetailedDevelopment
Pre-Production
ProductionDeployment/Operation
DesignUpgrades
Disposal As-Authorized
As-Committed
Product Life Cycle Management
As-Designed
As-Planned
As-Built
As-Disposed
As-Delivered
As-Maintained
4
As-Authorized
Authorize Data
As-Committed
Schedule Data
As-Designed
DesignData
As-Planned
Plan Data
As-Built
Build Data
As-Supported
SupportData
Authorized Baseline
Scheduled Baseline
DesignBaseline
Planned Baseline
Built Baseline
SupportedBaseline
BaselineCompares
BaselineCompares
BaselineCompares
BaselineCompares
BaselineCompares
BaselineCompares
ComparisonReports
ComparisonReports
ComparisonReports
ComparisonReports
ComparisonReports
Traditional Life Cycle Reconciliation
5Multiple Manual Methods – The Usual
ConfigurationAudits
ConfigurationAudits
ConfigurationAudits
ConfigurationAudits
ConfigurationAudits
ConceptDefinition
DetailedDevelopment
Pre-Production
ProductionDeployment/Operation
DesignUpgrades
Disposal Master DataRepository/Vault
(IDs, Baselines, Changes, CSA, Audits, Etc,)
As-Authorized
As-Committed
As-Designed
As-Built
As-Planned
As-Tested
As-Disposed
As-Supported
As-Delivered
As-Maintained
Product Life Cycle Management
6
Configuration(Audit)
Reconciliation
As-Authorized
Authorize Data
As-Committed
Schedule Data
As-Designed
DesignData
As-Planned
Plan Data
As-Built
Build Data
As-Supported
SupportData
Configuration Reconciliation
Accounting and Audit Process
Authorized Baseline
Scheduled Baseline
DesignBaseline
Planned Baseline
Built Baseline
SupportedBaseline
BaselineCompares
BaselineCompares
BaselineCompares
BaselineCompares
BaselineCompares
BaselineCompares
ComparisonReports
ComparisonReports
ComparisonReports
ComparisonReports
ComparisonReports
Generic Life Cycle ReconciliationBills of Material (BOMs)
Configuration Reconciliation Accounting and Audit Process (CRAAP)
7
As-Authorized(_________)
As-Designed(_________)
As-Planned_________)
As-Maintained(_________)
As-Built(_________)
EBOMStructure
MBOMStructure
OBOMStructure
RBOMStructure
RetrofitProcessesRoutingsResourcesToolingSerial NumberLot CodeQA/MRBAs-Built HistoryRepair/Refurbish Records
OperationalProcessesRoutingsResourcesToolingSerial NumberLot CodeQA/MRBService Records
ManufacturingMaterial CatalogProcessesRoutingsResourcesTooling
EngineeringMaterial CatalogProcesses
Marketing Contracts
WBSBudgets
Sales Orders
Computer-AidedEngineering
ConfigurationAudit(s)
ReconciliationEngineeringRelease
As-Disposed(_________)
DisposedProcessesResourcesSerial NumberLot CodeAs-Was/Is HistoryStorage, Salvage Disposal RecordsRecycling
DBOMStructure
Product’s Life Cycle Management(Basic Configuration Reconciliation Process)
As-Committed(_________)
8
Basic Configuration Verification System
Business Values:
• Ensure Released Drawing Defined Parts are in the As-Designed.
• Ensure the As-Designed Parts are in the Manufacturing Plans and Orders.
• Ensure the As-Designed Parts in the Manufacturing Orders and applicable serialization is identified.
• Ensure applicable Change information is related to the life cycle views of the product definition.
• Enable Part Restriction Documentation and Evolution to be managed and maintained.
• Provide a common infrastructure to report and review “Configuration Verification Action Items” in the various life cycle states.
9
Fielding
Life Cycle Generic System Architecture
CAD & PDMSystem
(__________)
CAEScheduleSystem
(________)ProgramMgmt.
System(________)
CLSSystem
(__________)
Part Test &Certification
System
CSAR
CSA Reports
Legend:CAPP - Computer-aided Process PlanningBOM - Bill of MaterialSFC - Shop Floor ControlNCM - Number Control MachineCA - Corrective ActionCAD-E - Computer-aided Design ElectricalCAD - Computer-aided DesignPDM – Product Data ManagementComputer-aided Engineering CLS - Contractor Logistic Support
Engineering
CAPPSystem
(__________)
BOMSystem
(__________) SFCSystem
(__________)
NCMSystem
(__________)
CASystem
(__________)
As-built(Orders)
As-planned(Planning)
Manufacturing
As-supported(Parts/Locations)
As-authorized (Contract
& Changes)
CAD-ESystem
(__________)
As-designed(Electrical)
As-designed(Parts & BOM)
As-committed(Schedules)
Fielding
Life Cycle Generic System Architecture
As-designed(Electrical)
As-committed(Schedules)
As-supported(Parts/Locations)
As-designed(Parts & BOM)
As-authorized (Contract
& Changes)
CAPPSystem
(__________)
BOMSystem
(__________)SFC
System(__________)
NCMSystem
(__________)
CASystem
(__________)
As-built(Orders)
As-planned(Planning)
CAD & PDMSystem
(__________)
CAD-ESystem
(__________)
CAEScheduleSystem
(________)
Manufacturing
ProgramMgmt.
System(________)
CLSSystem
(__________)
Part Test &Certification
System
CSAR
CSA Reports
Legend:CAPP - Computer-aided Process PlanningBOM - Bill of MaterialSFC - Shop Floor ControlNCM - Number Control MachineCA - Corrective ActionCAD-E - Computer-aided Design ElectricalCAD - Computer-aided DesignPDM – Product Data ManagementComputer-aided Engineering CLS - Contractor Logistic Support
Engineering
Point to P
oint
Data Exchange
Life Cycle Generic System Architecture
As-designed(Electrical)
As-committed(Schedules)
As-supported(Parts/Locations)
As-designed(Parts & BOM)
As-authorized (Contract
& Changes)
CAPPSystem
(__________)
BOMSystem
(__________)SFC
System(__________)
NCMSystem
(__________)
CASystem
(__________)
As-built(Orders)
As-planned(Planning)
CAD & PDMSystem
(__________)
CAD-ESystem
(__________)
CAEScheduleSystem
(________)
Manufacturing
ProgramMgmt.
System(________)
CLSSystem
(__________)
Part Test &Certification
System
CSAR
CSA Reports
Legend:CAPP - Computer-aided Process PlanningBOM - Bill of MaterialSFC - Shop Floor ControlNCM - Number Control MachineCA - Corrective ActionCAD-E - Computer-aided Design ElectricalCAD - Computer-aided DesignPDM – Product Data ManagementComputer-aided Engineering CLS - Contractor Logistic Support
Engineering
DataExchangeStandards
Data Management
Exchange Standard
s
Fielding
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Functional Environment
(Program Management / Engineering / Manufacturing / Fielding)
Functional System(s)Architectures
13
System A System B System C System D
Fielding
Life Cycle Generic System Architecture
CAD & PDMSystem
(__________)
CAEScheduleSystem
(________)ProgramMgmt.
System(________)
CLSSystem
(__________)
Part Test &Certification
System
CSAR
CSA Reports
Legend:CAPP - Computer-aided Process PlanningBOM - Bill of MaterialSFC - Shop Floor ControlNCM - Number Control MachineCA - Corrective ActionCAD-E - Computer-aided Design ElectricalCAD - Computer-aided DesignPDM – Product Data ManagementComputer-aided Engineering CLS - Contractor Logistic Support
Engineering
CAPPSystem
(__________)
BOMSystem
(__________) SFCSystem
(__________)
NCMSystem
(__________)
CASystem
(__________)
As-built(Orders)
As-planned(Planning)
Manufacturing
As-supported(Parts/Locations)
As-authorized (Contract
& Changes)
CAD-ESystem
(__________)
As-designed(Electrical)
As-designed(Parts & BOM)
As-committed(Schedules)
Data Object Modeling
Objects:DrawingsDocuments• Specs/plans/orders
PartsSoftwareChanges (Effectivity)• Request/Orders/
events
Etc.
Object -1Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
14
The Devil’s in the Detail
Location / RepresentationMedia (format)Storage (located)Application (used by)Protocols (exchanged)Operating SystemDatabase (related)Meta-data (about)Characteristics,Attributes, & Features
One to OneOne to ManyMany to OneMany to Many
Fielding
Life Cycle Generic System Architecture
CAD & PDMSystem
(__________)
CAEScheduleSystem
(________)ProgramMgmt.
System(________)
CLSSystem
(__________)
Part Test &Certification
System
CSAR
CSA Reports
Legend:CAPP - Computer-aided Process PlanningBOM - Bill of MaterialSFC - Shop Floor ControlNCM - Number Control MachineCA - Corrective ActionCAD-E - Computer-aided Design ElectricalCAD - Computer-aided DesignPDM – Product Data ManagementComputer-aided Engineering CLS - Contractor Logistic Support
Engineering
CAPPSystem
(__________)
BOMSystem
(__________) SFCSystem
(__________)
NCMSystem
(__________)
CASystem
(__________)
As-built(Orders)
As-planned(Planning)
Manufacturing
As-supported(Parts/Locations)
As-authorized (Contract
& Changes)
CAD-ESystem
(__________)
As-designed(Electrical)
As-designed(Parts & BOM)
As-committed(Schedules)
Data Object Modeling Object -2Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -1Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -4Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -3Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -6Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -5Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
15
Fielding
Life Cycle Generic System Architecture
CAD & PDMSystem
(__________)
CAEScheduleSystem
(________)ProgramMgmt.
System(________)
CLSSystem
(__________)
Part Test &Certification
System
CSAR
CSA Reports
Legend:CAPP - Computer-aided Process PlanningBOM - Bill of MaterialSFC - Shop Floor ControlNCM - Number Control MachineCA - Corrective ActionCAD-E - Computer-aided Design ElectricalCAD - Computer-aided DesignPDM – Product Data ManagementComputer-aided Engineering CLS - Contractor Logistic Support
Engineering
CAPPSystem
(__________)
BOMSystem
(__________) SFCSystem
(__________)
NCMSystem
(__________)
CASystem
(__________)
As-built(Orders)
As-planned(Planning)
Manufacturing
As-supported(Parts/Locations)
As-authorized (Contract
& Changes)
CAD-ESystem
(__________)
As-designed(Electrical)
As-designed(Parts & BOM)
As-committed(Schedules)
Data Object Modeling Object -2Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -1Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -4Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -3Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -6Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -5Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
16
Fielding
Life Cycle Generic System Architecture
CAD & PDMSystem
(__________)
CAEScheduleSystem
(________)ProgramMgmt.
System(________)
CLSSystem
(__________)
Part Test &Certification
System
CSAR
CSA Reports
Legend:CAPP - Computer-aided Process PlanningBOM - Bill of MaterialSFC - Shop Floor ControlNCM - Number Control MachineCA - Corrective ActionCAD-E - Computer-aided Design ElectricalCAD - Computer-aided DesignPDM – Product Data ManagementComputer-aided Engineering CLS - Contractor Logistic Support
Engineering
CAPPSystem
(__________)
BOMSystem
(__________) SFCSystem
(__________)
NCMSystem
(__________)
CASystem
(__________)
As-built(Orders)
As-planned(Planning)
Manufacturing
As-supported(Parts/Locations)
As-authorized (Contract
& Changes)
CAD-ESystem
(__________)
As-designed(Electrical)
As-designed(Parts & BOM)
As-committed(Schedules)
Data Object ModelingObject -2Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -1Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -4Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -3Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -6Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Object -5Identification:• ID#/Name,/
OwnerAttributes:• Size• QtyRelationships:• To-From• Up-Down• Other Objects
Export/Import
XMLFiles
.XLS/.CVSFiles
StandardsFiles
Direct Integrate
17
Fielding
Life Cycle Generic System Architecture
CAD & PDMSystem
(__________)
CAEScheduleSystem
(________)ProgramMgmt.
System(________)
CLSSystem
(__________)
Part Test &Certification
System
CSAR
CSA Reports
Legend:CAPP - Computer-aided Process PlanningBOM - Bill of MaterialSFC - Shop Floor ControlNCM - Number Control MachineCA - Corrective ActionCAD-E - Computer-aided Design ElectricalCAD - Computer-aided DesignPDM – Product Data ManagementComputer-aided Engineering CLS - Contractor Logistic Support
Engineering
CAPPSystem
(__________)
BOMSystem
(__________) SFCSystem
(__________)
NCMSystem
(__________)
CASystem
(__________)
As-built(Orders)
As-planned(Planning)
Manufacturing
As-supported(Parts/Locations)
As-authorized (Contract
& Changes)
CAD-ESystem
(__________)
As-designed(Electrical)
As-designed(Parts & BOM)
As-committed(Schedules)
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Export/Import
XMLFiles
.XLS/.CVSFiles
StandardsFiles
Direct Integrate
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Export/Import
XMLFiles
.XLS/.CVSFiles
StandardsFiles
Direct Integrate
Data Mapping Strategies
System A System B
MappingVerify/Certify
MappingVerify/Certify
MappingVerify/Certify
MappingVerify/Certify
18
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Export/Import
XMLFiles
.XLS/.CVSFiles
StandardsFiles
Direct Integrate
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Export/Import
XMLFiles
.XLS/.CVSFiles
StandardsFiles
Direct Integrate
XMLFiles
.XLS/.CVSFiles
StandardsFiles
Direct Integrate
Data Mapping Strategies
19
System A System BMapping
Verify/Certify
MappingVerify/Certify
MappingVerify/Certify
MappingVerify/Certify
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Export/Import
XMLFiles
.XLS/.CVSFiles
StandardsFiles
Direct Integrate
Object -2Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -1Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -4Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -3Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -6Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Object -5Identification:•ID#/Name,/OwnerAttributes:•Size•QtyRelationships:•To-From•Up-Down•Other Objects
Export/Import
XMLFiles
.XLS/.CVSFiles
StandardsFiles
Direct Integrate
XMLFiles
.XLS/.CVSFiles
StandardsFiles
Direct Integrate
Data Mapping Strategies
20
System A System BMapping
Verify/Certify
MappingVerify/Certify
MappingVerify/Certify
MappingVerify/Certify
Costs Costs CostsCosts
As-Authorized
Authorize Data
As-Committed
Schedule Data
As-Designed
DesignData
As-Planned
Plan Data
As-Built
Build Data
As-Supported
SupportData
InSync®: A CM/PDM Functional Architecture
Business Management
Identification
AccountingControl
Bills of MaterialBOM
Contracts CI
Baseline Audits
As-DesignedAs-Built
As-PlannedAs-Maintained
PartsDocuments
SoftwareDrawings
Integrated Workflow
Vault/Launch Ad Hoc Export/Import SecurityITK
Change Control
CR CP
CO
InSync
Authorized Baseline
Scheduled Baseline
DesignBaseline
Planned Baseline
Built Baseline
SupportedBaseline
BaselineCompares
BaselineCompares
BaselineCompares
BaselineCompares
BaselineCompares
BaselineCompares
ComparisonReports
ComparisonReports
ComparisonReports
ComparisonReports
ComparisonReports
Basic Configuration Verification System Concept
21
STEP AP 232GEIA 836 GEIA 836
ISS Use of Standards In Life Cycle Supportability
Engineering Data:
Drawing, Model, Metrics…
DESIGNENGINEERING
90021
DesignData/Structure
R & M Data Feedback
Product Structure Data, Specs and Parameters
Delive
red
Produ
ct
Data
Defini
tion
Initi
al P
rodu
ct/
Sup
port
Def
initi
on
MANUFACTURING/PRODUCTION
165837 ‘165443 ‘
DeliveredData/Structure
ERP Data
IN-SERVICE/ SUPPORT
Serialized Part Data: Maintenance
‘165837 ‘
165443 ‘
In-ServiceData/Structure
One-Two -Way Data Flow
Two-Way collaboration, reconciliation, coordination
Asset Management
Product/ Process/
Cost Im
provements
LSAR/LMI
Supportability Analysis
Supportability Data Feedback
IETMs, Condition-Based Maintenance, etc.
Tech Pub/ IETM
Data
TrainingData
IPB / IPC/ IPL
Data and Graphics
Spares Ordering, Inventory Mgmt, Obsolescence Planning, …
STEP AP 203 / 232 / pdm schema STEP AP 232*, pdm schema
1388-2B, 00-60
(STEP AP 239)
(STEP AP 239)ASD 2000M
(ST
EP
AP
239
)
(STEP AP
239)
STEP AP 232*: Not used in conjunction with Life Cycle Supportability, today,
IP Plan/Fab Plans1 Assembly, PN
The Mechanisms & Processes(Basic Configuration Reconciliation Process)
As-Designed As-Planned As-Built
Parts Planned(IP Plans)
Parts Defined
(Dwgs/PLs)
Parts Ordered
(Fab. Orders)
End Item1 Assembly, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 2 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN2 Assembly, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 2 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN
1 Sub Assy., PN1 Component, PN2 Component, PN3 Component, PN
2 Sub Assy., PN1 Component, PN2 Component, PN3 Component, PN
IP Plan/Fab Plans2 Assembly, PN
1 Sub Assy., PN1 Component, PN2 Component, PN3 Component, PN
2 Sub Assy., PN1 Component, PN2 Component, PN3 Component, PN
Fab . Orders1 Assembly, PN
1 Sub Assy., PN1 Component, PN2 Component, PN3 Component, PN
2 Sub Assy., PN1 Component, PN2 Component, PN3 Component, PN
Fab. Orders2 Assembly, PN
1 Sub Assy., PN1 Component, PN2 Component, PN3 Component, PN
2 Sub Assy., PN1 Component, PN2 Component, PN3 Component, PN
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As-Designed Baseline BOM for Parts & Assemblies
Manufacturing Planning for Parts & Assemblies
Fabrication Orders for Parts & Assemblies
Fielding
Life Cycle Generic System Architecture
CAD & PDMSystem
(__________)
CAEScheduleSystem
(________)ProgramMgmt.
System(________)
CLSSystem
(__________)
Part Test &Certification
System
CSA(InSync)
CSA Reports
Legend:CAPP - Computer-aided Process PlanningBOM - Bill of MaterialSFC - Shop Floor ControlNCM - Number Control MachineCA - Corrective ActionCAD-E - Computer-aided Design ElectricalCAD - Computer-aided DesignPDM – Product Data ManagementComputer-aided Engineering CLS - Contractor Logistic Support
Engineering
CAPPSystem
(__________)
BOMSystem
(__________)SFC
System(__________)
NCMSystem
(__________)
CASystem
(__________)
As-built(Orders)
As-planned(Planning)
Manufacturing
As-supported(Parts/Locations)
As-authorized (Contract
& Changes)
CAD-ESystem
(__________)
As-designed(Electrical)
As-designed(Parts & BOM)
As-committed(Schedules)
Validation & Verification Cycle(Configuration Verification Action Items)
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CVAI:ConfigurationVerificationAction Item
Analysis
Cycle
AnalysisCycle
Plans
Orders
Parts List FinalReconciledReports
CVAI:ConfigurationVerificationAction Item
25
As-Authorized(_________)
As-Designed(_________)
As-Planned(_________)
As-Built(_________)
Product’s Life Cycle Management(Basic Confirmation Process)
As-Committed(_________)
Installation Plan (IP)(Planning for final assembly) In Work Completed Approved Inspected Delivered
Make Parts – Fabrication/Assembly(Planning for Fabrication/Assembly) In Work Completed Approved Inspected Stocked to Inventory
Buy Parts - Purchase(Planning for Buy) Purchase Request Purchase Order Received Inspected Stocked to Inventory
Engineering Design(Perform engineering design) In Work Completed Approved Released
Commitment Scheduling(Commitment to schedule) In Work Completed Approved Released
Authoring Engineering(Authorizing parts design) In Work Completed Approved Released
DD 250 Reporting Audit Trail Was the installation right?Was the purchase right?Was the fabrication right?Was the design right?Was the commitment right?Was the authorization right?
All’sRight
Not RightWaiversDeviations
DD Form 250
CSA Reports
1 2 3
4 5
As-Authorized(_________)
As-Designed(_________)
As-Planned(_________)
As-Maintained(_________)
As-Built(_________)
EBOMStructure
MBOMStructure
OBOMStructure
RBOMStructure
RetrofitProcessesRoutingsResourcesToolingSerial NumberLot CodeQA/MRBAs-Built HistoryRepair/Refurbish Records
OperationalProcessesRoutingsResourcesToolingSerial NumberLot CodeQA/MRBService Records
ManufacturingMaterial CatalogProcessesRoutingsResourcesTooling
EngineeringMaterial CatalogProcesses
Marketing Contracts
WBSBudgets
Sales Orders
Computer-AidedEngineering
Configuration Reconciliation
(InSync)EngineeringRelease
As-Disposed(_________)
DisposedProcessesResourcesSerial NumberLot CodeAs-Was/Is HistoryStorage, Salvage Disposal RecordsRecycling
DBOMStructure
Product’s Life Cycle Management(Basic Reconciliation Process)
As-Committed(_________)
DD250
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27
STEP Data Exchange(The Back Story – SI/BCA)
Enterprise Supplier
Type Design Data/Process Flow
Type Design Data PDM Output
STEPFiles
OS Vaults- Reports (XML, PDF)- STP- PS- PKG
VistaReporting
PKGFiles
PSFiles
OtherFiles
TranslatedFiles
GeneratedXML* Files
ImportedFiles
FormattedPDF* Files
InSync
InSync/SI Processing
InSyncScreens
Browser View- “Generated XML”- “Formatted PDF”- Formatted HTML - Multi-Level - XML File Compare
Non-Vaulted “Work”
ERPor otherSystems
* Interface / Integration with other data systems may be implemented as a “push or pull” transaction process or as a “web service.”
*
28
Email Notification of TDP Received
wwwwww
SupplierPDM System
Documents
Geometry
Supplier
Vault
Supplier Integration Software
Email Notification of TDP Ready
Data Collection andOutsourcing System
Documents
Geometry
ContentCollection
•Generate STEP File•Zip and/or encrypt TDP
Product Information (PDM System)
Engineering / ProcurementEngineering / Procurement
PDM Database
Enterprise
View Product Information, and related files
TDP Archive
Unzip and/or decrypt TDP
FTP/HTTP
ISS’s Integrated Support SystemSupplier Integration (SI/BCA)
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As-Authorized(ECCM)
As-Designed(DCAC)
As-Committed(DM2000)
As-Planned(MES)
As-Delivered(InSync)
As-Maintained(OOMA)
As-Tested(ALRMS)
As-Built(MES)
Cost EstimatingCapacity Planning & AssessmentSpecifications
Master ScheduleWork Breakdown StructureBudgetsSales OrdersCost AccountsEffectivity
Baseline ReleaseDocument ControlProduct Definition EBOM Bill of RoutingsEffectivity (Eng.)
MBOMEffectivity (Manf.)Bill of Routings/ResourcesMaster Production ScheduleProposed Capacity PlanningMRP/CRP/ProcurementWork Order Release
Receiving/InspectionReceiving InstructionsDock-to-StockInventory (WIP)Lot Code / Serial NumberingShop Floor ControlLabor CollectionWork MeasurementsProcess InstructionsTest ProceduresTest ResultsPart and System RestrictionsCM Status AccountingAs-Built Snapshot
CM ReconciliationCM Status AccountingLot Code / Serial NumberingDeviations / Waivers
Field Return / RetrofitField ServiceCM ReconciliationLot Code / Serial No.CM Status AccountingAs-Built History
As-Disposed(????)
Storage, SalvageTo-Become (Recycle) CM ReconciliationLot Code / Serial No.CM Status AccountingAs-Was/Is History
30
Product’s Life Cycle Management(Boeing MMA P-8A)
As-Authorized(ECCM)
As-Designed(DCAC)
As-Planned(MES)
As-Maintained(OOMA)
As-Built(MES)
EBOMStructure
MBOMStructure
OBOMStructure
RBOMStructure
RetrofitProcessesRoutingsResourcesToolingSerial NumberLot CodeQA/MRBAs-Built HistoryRepair/Refurbish Records
OperationalProcessesRoutingsResourcesToolingSerial NumberLot CodeQA/MRBService Records
ManufacturingMaterial CatalogProcessesRoutingsResourcesTooling
EngineeringMaterial CatalogProcesses
Marketing Contracts
WBSBudgets
Sales Orders
Computer-AidedEngineering
Configuration Reconciliation
(InSync)EngineeringRelease
As-Disposed(????)
DisposedProcessesResourcesSerial NumberLot CodeAs-Was/Is HistoryStorage, Salvage Disposal RecordsRecycling
DBOMStructure
Product’s Life Cycle Management(Boeing MMA P-8A Reconciliation Process)
As-Committed(DM2000)
31
Life Cycle Baseline ReconciliationA System Overview and Description of the
Basic Configuration Verification System (BCVS)
ACDM 15th Annual Technical Conference 21-22 March 2010
Ram White, Integrated Support Systems, Inc.
32
Questions & Comments
Life Cycle Baseline Reconciliation
A System Overview and Description of the
Basic Configuration Verification System (BCVS)
ACDM 15th Annual Technical Conference 21-22 March 2010
Ram White, Integrated Support Systems, Inc.
33