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ACDM 15 th Annual Technical Conference 21-22 March 2010

Life Cycle Baseline Reconciliation A System Overview and Description of the Basic Configuration Verification System (BCVS). ACDM 15 th Annual Technical Conference 21-22 March 2010 Ram White, Integrated Support Systems, Inc.

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ACDM 15 th Annual Technical Conference 21-22 March 2010

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  1. 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.

  2. 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

  3. Product’s Life Cycle Management (Basic Life Cycle Process) As-Authorized (_________) Cost Estimating Capacity Planning & Assessment Specifications Master Schedule Work Breakdown Structure Budgets Sales Orders Cost Accounts Effectivity As-Committed (_________) Baseline Release Document Control Product Definition EBOM Bill of Routings Effectivity (Eng.) As-Designed (_________) MBOM Effectivity (Manf.) Bill of Routings/Resources Master Production Schedule Proposed Capacity Planning MRP/CRP/Procurement Work Order Release As-Planned (_________) Receiving/Inspection Receiving Instructions Dock-to-Stock Inventory (WIP) Lot Code / Serial Numbering Shop Floor Control Labor Collection Work Measurements Process Instructions Test Procedures Test Results CM Status Accounting As-Purchased (_________) As-Tested (_________) As-Built (_________) As-Built Snapshot CM Reconciliation CM Status Accounting Lot Code / Serial Numbering Deviations / Waivers As-Delivered (_________) Field Return / Retrofit Field Service CM Reconciliation Lot Code / Serial No. CM Status Accounting As-Built History As-Maintained (_________) Storage, Salvage To-Become (Recycle) CM Reconciliation Lot Code / Serial No. CM Status Accounting As-Was/Is History As-Disposed (_________)

  4. Product Life Cycle Management Concept Definition Detailed Development Disposal As- Authorized As- Disposed As- Committed As- Maintained As- Designed Design Upgrades Pre- Production As- Planned As- Delivered As- Built Production Deployment/ Operation

  5. Traditional Life Cycle Reconciliation As- Authorized As- Committed As- Designed As- Planned As- Built As- Supported Authorize Data Schedule Data Design Data Plan Data Build Data Support Data Authorized Baseline Scheduled Baseline Design Baseline Planned Baseline Built Baseline Supported Baseline Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Comparison Reports Comparison Reports Comparison Reports Comparison Reports Comparison Reports Configuration Audits Configuration Audits Configuration Audits Configuration Audits Configuration Audits Multiple Manual Methods – The Usual

  6. Product Life Cycle Management Concept Definition Detailed Development Disposal Master Data Repository/Vault (IDs, Baselines, Changes, CSA, Audits, Etc,) As- Authorized As- Committed As- Disposed Configuration (Audit) Reconciliation As- Designed As- Maintained Design Upgrades Pre- Production As- Supported As- Planned As- Delivered As- Tested As- Built Production Deployment/ Operation

  7. Generic Life Cycle ReconciliationBills of Material (BOMs) Configuration Reconciliation Accounting and Audit Process (CRAAP) As- Authorized As- Committed As- Designed As- Planned As- Built As- Supported Authorize Data Schedule Data Design Data Plan Data Build Data Support Data Configuration Reconciliation Accounting and Audit Process Authorized Baseline Scheduled Baseline Design Baseline Planned Baseline Built Baseline Supported Baseline Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Comparison Reports Comparison Reports Comparison Reports Comparison Reports Comparison Reports

  8. Product’s Life Cycle Management (Basic Configuration Reconciliation Process) As-Authorized (_________) As-Committed (_________) As-Designed (_________) As-Planned _________) As-Built (_________) As-Maintained (_________) As-Disposed (_________) EBOM Structure MBOM Structure OBOM Structure RBOM Structure DBOM Structure Marketing Contracts Engineering Material Catalog Processes Manufacturing Material Catalog Processes Routings Resources Tooling Operational Processes Routings Resources Tooling Serial Number Lot Code QA/MRB Service Records Retrofit Processes Routings Resources Tooling Serial Number Lot Code QA/MRB As-Built History Repair/Refurbish Records Disposed Processes Resources Serial Number Lot Code As-Was/Is History Storage, Salvage Disposal Records Recycling WBS Budgets Sales Orders Computer-Aided Engineering Configuration Audit(s) Reconciliation Engineering Release

  9. 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.

  10. Life Cycle Generic System Architecture Manufacturing BOM System (__________) NCM System (__________) CA System (__________) As-built (Orders) As-planned (Planning) SFC System (__________) CAPP System (__________) Part Test & Certification System Engineering CSAR CAD & PDM System (__________) Fielding CLS System (__________) CAE Schedule System (________) As-designed (Parts & BOM) As-supported (Parts/Locations) Program Mgmt. System (________) CAD-E System (__________) CSA Reports As-committed (Schedules) Legend: CAPP - Computer-aided Process Planning BOM - Bill of Material SFC - Shop Floor Control NCM - Number Control Machine CA - Corrective Action CAD-E - Computer-aided Design Electrical CAD - Computer-aided Design PDM – Product Data Management Computer-aided Engineering CLS - Contractor Logistic Support As-authorized (Contract & Changes) As-designed (Electrical)

  11. Life Cycle Generic System Architecture Point to Point Data Exchange Manufacturing BOM System (__________) NCM System (__________) CA System (__________) As-built (Orders) As-planned (Planning) SFC System (__________) CAPP System (__________) Part Test & Certification System Engineering CSAR CAD & PDM System (__________) Fielding CLS System (__________) As-designed (Parts & BOM) CAE Schedule System (________) As-supported (Parts/Locations) Program Mgmt. System (________) CAD-E System (__________) CSA Reports Legend: CAPP - Computer-aided Process Planning BOM - Bill of Material SFC - Shop Floor Control NCM - Number Control Machine CA - Corrective Action CAD-E - Computer-aided Design Electrical CAD - Computer-aided Design PDM – Product Data Management Computer-aided Engineering CLS - Contractor Logistic Support As-committed (Schedules) As-authorized (Contract & Changes) As-designed (Electrical)

  12. Life Cycle Generic System Architecture Data Management Exchange Standards Manufacturing BOM System (__________) NCM System (__________) CA System (__________) As-built (Orders) As-planned (Planning) SFC System (__________) CAPP System (__________) Part Test & Certification System Engineering Data Exchange Standards CAD & PDM System (__________) Fielding CSAR CLS System (__________) As-designed (Parts & BOM) CAE Schedule System (________) As-supported (Parts/Locations) Program Mgmt. System (________) CAD-E System (__________) CSA Reports Legend: CAPP - Computer-aided Process Planning BOM - Bill of Material SFC - Shop Floor Control NCM - Number Control Machine CA - Corrective Action CAD-E - Computer-aided Design Electrical CAD - Computer-aided Design PDM – Product Data Management Computer-aided Engineering CLS - Contractor Logistic Support As-committed (Schedules) As-authorized (Contract & Changes) As-designed (Electrical)

  13. Functional System(s) Architectures System A System B System C System D Functional Environment (Program Management / Engineering / Manufacturing / Fielding)

  14. Data Object Modeling The Devil’s in the Detail Location / Representation Media (format) Storage (located)Application (used by) Protocols (exchanged) Operating System Database (related) Meta-data (about) Characteristics, Attributes, & Features • Object -1 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects One to One One to Many Many to One Many to Many • Objects: • Drawings • Documents • Specs/plans/orders • Parts • Software • Changes (Effectivity) • Request/Orders/events • Etc.

  15. Data Object Modeling • Object -2 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -1 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -3 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -4 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -6 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -5 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects

  16. Data Object Modeling • Object -2 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -1 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -3 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -4 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -6 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -5 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects

  17. Data Object Modeling Export/Import • Object -2 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects .XLS/.CVS Files • Object -1 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -3 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects XML Files Standards Files • Object -4 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -6 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects • Object -5 • Identification: • ID#/Name,/Owner • Attributes: • Size • Qty • Relationships: • To-From • Up-Down • Other Objects Direct Integrate

  18. Data Mapping Strategies System A System B Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify

  19. Data Mapping Strategies System A System B Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify .XLS/.CVS Files XML Files Standards Files Direct Integrate

  20. Data Mapping Strategies System A System B Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify .XLS/.CVS Files XML Files Standards Files Direct Integrate Costs Costs Costs Costs

  21. Basic Configuration Verification SystemConcept GEIA 836 GEIA 836 STEP AP 232 As- Authorized As- Committed As- Designed As- Planned As- Built As- Supported Authorize Data Schedule Data Design Data Plan Data Build Data Support Data InSync Authorized Baseline Scheduled Baseline Design Baseline Planned Baseline Built Baseline Supported Baseline Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Comparison Reports Comparison Reports Comparison Reports Comparison Reports Comparison Reports

  22. ISS Use of Standards In Life Cycle Supportability MANUFACTURING/ PRODUCTION Product Structure Data, Specs and Parameters ERP Data Delivered Data/Structure 165443 ‘ 165837 ‘ 90021 165443 ‘ 165837 ‘ ‘ DESIGN ENGINEERING One-Two -Way Data Flow Two-Way collaboration, reconciliation, coordination Engineering Data: Drawing, Model, Metrics… STEP AP 203 / 232 / pdm schema Design Data/Structure STEP AP 232*, pdm schema (STEP AP 239) Supportability Analysis Initial Product/ Support Definition (STEP AP 239) Delivered Product Data Definition (STEP AP 239) R & M Data Feedback IN-SERVICE/ SUPPORT Product/ Process/ Cost Improvements LSAR/ LMI Asset Management Serialized Part Data: Maintenance ASD 2000M 1388-2B, 00-60 (STEP AP 239) Spares Ordering, Inventory Mgmt, Obsolescence Planning, … Supportability Data Feedback IPB / IPC/ IPL Data and Graphics Tech Pub/ IETM Data In-Service Data/Structure IETMs, Condition-Based Maintenance, etc. Training Data STEP AP 232*: Not used in conjunction with Life Cycle Supportability, today,

  23. The Mechanisms & Processes(Basic Configuration Reconciliation Process) As-Designed As-Planned As-Built Parts Defined (Dwgs/PLs) Parts Planned (IP Plans) Parts Ordered (Fab. Orders) End Item 1 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 2 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 IP Plan/Fab Plans 1 Assembly, PN Fab . Orders 1 Assembly, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN IP Plan/Fab Plans 2 Assembly, PN Fab. Orders 2 Assembly, PN 2 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., PN 1 Component, PN 2 Component, PN 3 Component, 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 2 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN Manufacturing Planning for Parts & Assemblies As-Designed Baseline BOM for Parts & Assemblies Fabrication Orders for Parts & Assemblies 23

  24. Validation & Verification Cycle (Configuration Verification Action Items) CVAI: Configuration Verification Action Item Plans Orders Analysis Cycle Analysis Cycle Parts List Final Reconciled Reports CVAI: Configuration Verification Action Item

  25. 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? Product’s Life Cycle Management (Basic Confirmation Process) As-Authorized (_________) As-Committed (_________) As-Designed (_________) As-Planned (_________) As-Built (_________) All’s Right Engineering Design (Perform engineering design) In Work Completed Approved Released Installation Plan (IP) (Planning for final assembly) In Work Completed Approved Inspected Delivered Commitment Scheduling (Commitment to schedule) In Work Completed Approved Released 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 Not Right Waivers Deviations Authoring Engineering (Authorizing parts design) In Work Completed Approved Released CSA Reports 1 2 3 4 5 DD Form 250

  26. Product’s Life Cycle Management (Basic Reconciliation Process) As-Authorized (_________) As-Committed (_________) As-Designed (_________) As-Planned (_________) As-Built (_________) As-Maintained (_________) As-Disposed (_________) EBOM Structure MBOM Structure OBOM Structure RBOM Structure DBOM Structure Marketing Contracts Engineering Material Catalog Processes Manufacturing Material Catalog Processes Routings Resources Tooling Operational Processes Routings Resources Tooling Serial Number Lot Code QA/MRB Service Records Retrofit Processes Routings Resources Tooling Serial Number Lot Code QA/MRB As-Built History Repair/Refurbish Records Disposed Processes Resources Serial Number Lot Code As-Was/Is History Storage, Salvage Disposal Records Recycling WBS Budgets Sales Orders Computer-Aided Engineering Configuration Reconciliation (InSync) Engineering Release DD250 26

  27. STEP Data Exchange (The Back Story – SI/BCA) Enterprise Supplier

  28. Type Design Data/Process Flow ERP or other Systems Type Design Data PDM Output * Interface / Integration with other data systems may be implemented as a “push or pull” transaction process or as a “web service.” STEP Files PS Files PKG Files Other Files * InSync/SI Processing Vista Reporting InSync Translated Files Imported Files Browser View - “Generated XML” - “Formatted PDF” - Formatted HTML - Multi-Level - XML File Compare Non-Vaulted “Work” Generated XML* Files InSync Screens Formatted PDF* Files OS Vaults - Reports (XML, PDF) - STP - PS - PKG

  29. ISS’s Integrated Support SystemSupplier Integration (SI/BCA)

  30. Product’s Life Cycle Management (Boeing MMA P-8A) As-Authorized (ECCM) Cost Estimating Capacity Planning & Assessment Specifications Master Schedule Work Breakdown Structure Budgets Sales Orders Cost Accounts Effectivity As-Committed (DM2000) Baseline Release Document Control Product Definition EBOM Bill of Routings Effectivity (Eng.) As-Designed (DCAC) MBOM Effectivity (Manf.) Bill of Routings/Resources Master Production Schedule Proposed Capacity Planning MRP/CRP/Procurement Work Order Release As-Planned (MES) Receiving/Inspection Receiving Instructions Dock-to-Stock Inventory (WIP) Lot Code / Serial Numbering Shop Floor Control Labor Collection Work Measurements Process Instructions Test Procedures Test Results Part and System Restrictions CM Status Accounting As-Built (MES) As-Tested (ALRMS) As-Built Snapshot CM Reconciliation CM Status Accounting Lot Code / Serial Numbering Deviations / Waivers As-Delivered (InSync) Field Return / Retrofit Field Service CM Reconciliation Lot Code / Serial No. CM Status Accounting As-Built History As-Maintained (OOMA) Storage, Salvage To-Become (Recycle) CM Reconciliation Lot Code / Serial No. CM Status Accounting As-Was/Is History As-Disposed (????)

  31. Product’s Life Cycle Management (Boeing MMA P-8A Reconciliation Process) As-Authorized (ECCM) As-Committed (DM2000) As-Designed (DCAC) As-Planned (MES) As-Built (MES) As-Maintained (OOMA) As-Disposed (????) EBOM Structure MBOM Structure OBOM Structure RBOM Structure DBOM Structure Marketing Contracts Engineering Material Catalog Processes Manufacturing Material Catalog Processes Routings Resources Tooling Operational Processes Routings Resources Tooling Serial Number Lot Code QA/MRB Service Records Retrofit Processes Routings Resources Tooling Serial Number Lot Code QA/MRB As-Built History Repair/Refurbish Records Disposed Processes Resources Serial Number Lot Code As-Was/Is History Storage, Salvage Disposal Records Recycling WBS Budgets Sales Orders Computer-Aided Engineering Configuration Reconciliation (InSync) Engineering Release

  32. Life Cycle Baseline ReconciliationA System Overview and Description of the Basic Configuration Verification System (BCVS) Questions & Comments ACDM 15th Annual Technical Conference 21-22 March 2010 Ram White, Integrated Support Systems, Inc.

  33. 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.

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