Mylars to Models: Managing Legacy Data Migration

Charles LeeIntegrated Product LeadBoeing IDS Rotorcraft

Mylar Drawings

2D CV4

3D CV4

Engineering Service Center

ENOVIA Load3D CV5

3D CV5 in

ENOVIA

High Level Process Flow for Converting Legacy Data to CV5

Work Package: 1300 Unique Detail Parts

Total Conversion Summary by ComplexityV4-V5 Pilot Conversion

Total Converted Parts Count (1175) Distribution Summary by Complexity

36

50

4

121

291

19

283

341

30

0 100 200 300 400 500 600 700 800

MBD

Mylar

Red. Dim

Complex Medium Simple

Total Conversion Summary by ComplexityV4-V5 Pilot Conversion Total Converted Parts (1175)

Percentage Distribution Summary by Complexity

3.1%

4.3%

0.3%

10.3%

24.8%

1.6%

24.1%

29.0%

2.6%

0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0%

MBD

Mylar

Red. Dim

Complex Medium Simple

Total Conversion Summary by Complexity

V4-V5 Pilot Conversion Total Converted Parts (1175)

Average Hours Summary by Complexity

24.0

39.2

17.6

10.3

19.2

11.1

4.1

12.0

7.6

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0

MBD

Mylar

Red. Dim

Complex Medium Simple

•Greater IPT involvement in SOW development•Highly detailed SOW

Off-site Execution

Supplier Setup

Lessons Learned

Daily Activity

On-site Execution

Verification

Close Out

•Provide loft models, key interface points, etc. to allow Supplier to model detail parts in context.

•Provide onsite representative at supplier to resolve engineering, drafting and modeling problems real time.

•Use a large digitizer to accurately transfer key geometry into the CAD program or have the drawings scanned on a high resolution scanner.

•Provide easily accessible metadata•Need tailored training similar to supplier symposium for Engineering Service Centers

Lessons Learned

Off-site Execution

Supplier Setup

Daily Activity

On-site Execution

Verification

Close Out

•Define performance metrics earlier

Lessons Learned

Off-site Execution

Supplier Setup

Daily Activity

On-site Execution

Verification

Close Out

•Verify all required hardware, software, and account access are functional (1) week prior to supplier’s arrival

Lessons Learned

Off-site Execution

Supplier Setup

Daily Activity

On-site Execution

Verification

Close Out

•Include line items in the quality checklist for geometry errors. These items should then be weighted for determining severity and therefore supplier performance.

•Use graphic art software which allows layering and overlaying raster and vector data to virtually check Mylar defined parts. Screen shots of this comparison can be used for feedback to the supplier for corrections.

•Too many modelers and only one checker. More checkers are needed.

Lessons Learned

Off-site Execution

Supplier Setup

Daily Activity

On-site Execution

Verification

Close Out

•Document process developed•Track lessons learned on weekly basis

Lessons Learned

Off-site Execution

Supplier Setup

Daily Activity

On-site Execution

Verification

Close Out

Quality Summary

• Re‐mastered PCM (Mylar) part  Overlay

• Re‐mastered Dimensioned part  CADIQ and manual inspection of dimensions

• Model Based Definition (Automated Conversion)  CADIQ plus manual comparison of FD&T

• All datasets checked for proper database format per SOW Checklist

Typical Errors

The original V4 part thickness is .032”. The V5 converted part thickness is .061”.

• PCM (Mylar) part

• Dimensioned part

Typical Errors

Was Is Should Be

Typical Errors• Model Based Definition (Automated Conversion)

Conclusion

• Re‐engineer not Re‐master

• Program Support = Program Buy‐in

QUESTIONS