Life Cycle Baseline Reconciliation A System Overview and Description of the Basic Configuration...

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

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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)

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As-Planned_________)


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


DisposedProcessesResourcesSerial NumberLot CodeAs-Was/Is HistoryStorage, Salvage Disposal RecordsRecycling

DBOMStructure

Product’s Life Cycle Management(Basic Configuration Reconciliation Process)


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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.

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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







& Changes)

CAPPSystem

(__________)

BOMSystem

(__________)SFC

System(__________)

NCMSystem

(__________)

CASystem

(__________)

As-built(Orders)


CAD & PDMSystem

(__________)

CAD-ESystem

(__________)

CAEScheduleSystem

(________)

Manufacturing

ProgramMgmt.

System(________)

CLSSystem

(__________)


System

CSAR

CSA Reports


Engineering

Point to P

oint

Data Exchange







& Changes)

CAPPSystem

(__________)

BOMSystem

(__________)SFC

System(__________)

NCMSystem

(__________)

CASystem

(__________)

As-built(Orders)


CAD & PDMSystem

(__________)

CAD-ESystem

(__________)

CAEScheduleSystem

(________)

Manufacturing

ProgramMgmt.

System(________)

CLSSystem

(__________)


System

CSAR

CSA Reports


Engineering

DataExchangeStandards

Data Management

Exchange Standard

s

Fielding

Object -2Identification:•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


CAD & PDMSystem

(__________)

CAEScheduleSystem


System(________)

CLSSystem

(__________)


System

CSAR

CSA Reports


Engineering

CAPPSystem

(__________)

BOMSystem


(__________)

NCMSystem

(__________)

CASystem

(__________)

As-built(Orders)


Manufacturing



& Changes)

CAD-ESystem

(__________)




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


CAD & PDMSystem

(__________)

CAEScheduleSystem


System(________)

CLSSystem

(__________)


System

CSAR

CSA Reports


Engineering

CAPPSystem

(__________)

BOMSystem


(__________)

NCMSystem

(__________)

CASystem

(__________)

As-built(Orders)


Manufacturing



& Changes)

CAD-ESystem

(__________)




Data Object Modeling Object -2Identification:• ID#/Name,/












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Fielding


CAD & PDMSystem

(__________)

CAEScheduleSystem


System(________)

CLSSystem

(__________)


System

CSAR

CSA Reports


Engineering

CAPPSystem

(__________)

BOMSystem


(__________)

NCMSystem

(__________)

CASystem

(__________)

As-built(Orders)


Manufacturing



& Changes)

CAD-ESystem

(__________)




Data Object Modeling Object -2Identification:• ID#/Name,/












16

Fielding


CAD & PDMSystem

(__________)

CAEScheduleSystem


System(________)

CLSSystem

(__________)


System

CSAR

CSA Reports


Engineering

CAPPSystem

(__________)

BOMSystem


(__________)

NCMSystem

(__________)

CASystem

(__________)

As-built(Orders)


Manufacturing



& Changes)

CAD-ESystem

(__________)




Data Object ModelingObject -2Identification:• ID#/Name,/












Export/Import

XMLFiles

.XLS/.CVSFiles

StandardsFiles

Direct Integrate

17

Fielding


CAD & PDMSystem

(__________)

CAEScheduleSystem


System(________)

CLSSystem

(__________)


System

CSAR

CSA Reports


Engineering

CAPPSystem

(__________)

BOMSystem


(__________)

NCMSystem

(__________)

CASystem

(__________)

As-built(Orders)


Manufacturing



& Changes)

CAD-ESystem

(__________)










Export/Import

XMLFiles

.XLS/.CVSFiles

StandardsFiles

Direct Integrate







Export/Import

XMLFiles

.XLS/.CVSFiles

StandardsFiles

Direct Integrate

Data Mapping Strategies

System A System B

MappingVerify/Certify




18







Export/Import

XMLFiles

.XLS/.CVSFiles

StandardsFiles

Direct Integrate







Export/Import

XMLFiles

.XLS/.CVSFiles

StandardsFiles

Direct Integrate

XMLFiles

.XLS/.CVSFiles

StandardsFiles

Direct Integrate


19

System A System BMapping

Verify/Certify










Export/Import

XMLFiles

.XLS/.CVSFiles

StandardsFiles

Direct Integrate







Export/Import

XMLFiles

.XLS/.CVSFiles

StandardsFiles

Direct Integrate

XMLFiles

.XLS/.CVSFiles

StandardsFiles

Direct Integrate


20

System A System BMapping

Verify/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

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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


IP Plan/Fab Plans2 Assembly, PN



Fab . Orders1 Assembly, PN



Fab. Orders2 Assembly, PN



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As-Designed Baseline BOM for Parts & Assemblies

Manufacturing Planning for Parts & Assemblies

Fabrication Orders for Parts & Assemblies

Fielding


CAD & PDMSystem

(__________)

CAEScheduleSystem


System(________)

CLSSystem

(__________)


System

CSA(InSync)

CSA Reports


Engineering

CAPPSystem

(__________)

BOMSystem

(__________)SFC

System(__________)

NCMSystem

(__________)

CASystem

(__________)

As-built(Orders)


Manufacturing



& Changes)

CAD-ESystem

(__________)




Validation & Verification Cycle(Configuration Verification Action Items)

24

CVAI:ConfigurationVerificationAction Item

Analysis

Cycle

AnalysisCycle

Plans

Orders

Parts List FinalReconciledReports

CVAI:ConfigurationVerificationAction Item

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As-Built(_________)

Product’s Life Cycle Management(Basic Confirmation Process)


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-Built(_________)

EBOMStructure

MBOMStructure

OBOMStructure

RBOMStructure





Marketing Contracts

WBSBudgets

Sales Orders



(InSync)EngineeringRelease



DBOMStructure

Product’s Life Cycle Management(Basic Reconciliation Process)


DD250

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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.”

*

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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

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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





Marketing Contracts

WBSBudgets

Sales Orders



(InSync)EngineeringRelease

As-Disposed(????)


DBOMStructure

Product’s Life Cycle Management(Boeing MMA P-8A Reconciliation Process)

As-Committed(DM2000)

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Life Cycle Baseline ReconciliationA System Overview and Description of the




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Questions & Comments

Life Cycle Baseline Reconciliation

A System Overview and Description of the




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Life Cycle Baseline Reconciliation A System Overview and Description of the Basic Configuration...

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