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PLM for the US Army

PLM for the US Army. Dr. Raj Iyer Team Lead, PLM Technologies US Army Tank Automotive RDE Center, Warren, MI Presented at the 7th NASA-ESA Workshop on Product Data Exchange (PDE 2005) April 22, 2005. Systems Supporting Army Readiness. PRODUCT LINES. SUPPORT. MAGNITUDE.

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PLM for the US Army

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  1. PLM for the US Army Dr. Raj Iyer Team Lead, PLM Technologies US Army Tank Automotive RDE Center, Warren, MI Presented at the 7th NASA-ESA Workshop on Product Data Exchange (PDE 2005) April 22, 2005

  2. Systems Supporting Army Readiness PRODUCT LINES SUPPORT MAGNITUDE • Combat Vehicles • Tactical Vehicles • Trailers • Construction Equipment • Materiel Handling Equipment • Tactical Bridges • Fuel & Water Dist Equipment • Sets, Kits & Outfits • Chemical Defense Equipment • Shop Equipment • Howitzers • Large Caliber Guns • Mortars • Rifles • Machine Guns • Ammunition • Aircraft Armaments • Demolitions & Explosives • Rail • Watercraft • Fuel & Lubricant Products • Non-Tactical Vehicles Capital Value of TACOM Equipment $81.7B 141 Allied Countries own TACOM Equipment 2993 Fielded Systems Supported All Army Parent UICs Contain TACOM Supported Equip > 26,000 Components Plus Technology Development for the Objective Force The Army’s Lead Systems Integrator PDE2005

  3. Driving Factors • Product data is distributed among RDECs, PMs, LCMCs and OEMs • Product data formats and systems to manage product data are not standardized – CAD and PDM interoperability issues • Data exchange and collaboration among organizations is inefficient and time consuming • Fundamental requirement towards a true Army Product Lifecycle Management (PLM) strategy (SALE) • Need for integrated product data throughout the product’s lifecycle spanning both engineering and logistics • Conceptual models, 2D drawings, 3D solid models, modeling & simulation data, analysis models, test data, repair & maintenance history, IETMs, assembly instructions • Need for a single set of logically unified product data PDE2005

  4. Challenges • Heterogeneous systems and formats for product data • Extended lifecycle • Legacy data • Systems of systems integration • Spiral development • Performance Based Logistics (PBL) • Contractor Logistics Support (CLS) • Parts obsolescence • Disposal issues PDE2005

  5. SAP SAP Windchill Teamcenter Windchill Teamcenter STEP Standards Enovia Enovia MatrixOne MatrixOne CMStat CMStat Standards vs. Point-to-point Solutions   PDE2005

  6. The Need for Standards • No guarantee that any of these commercial systems will last as long as the Army’s product lines • Version independence and upward compatibility • Variety of commercial middleware solutions are available • Point to point solutions • Expensive to maintain and upgrade • DoD mandate for open architecture standards-based systems leveraging best commercial practices PDE2005

  7. The Solution • Use of international standards ISO 10303 – also known as STEP PDM Schema • STEP is a neutral format not just for 2D/3D product data but also for PDM interoperability • Specific STEP Application Protocols are already widely used in private industry • STEP is well supported by most of the major PDM/ CAD vendors – PTC, SAP, UGS, MatrixOne, Dassault • STEP is starting to be standardized for 3D solid models at the DoD (Navy and Air Force have mandated it already) • Enormous potential for long term retention and archival of product data STEP has the potential to save $928 million (2001$) per year by reducing interoperability problems in the automotive, aerospace, and shipbuilding industries alone PDE2005

  8. OEMs FCS - ACE TARDEC DLA (BSM) TACOM GSIE Soldier & Ground Systems Collaborative Gateway (ACMS + ACE) Interface to SALE PLM+ STEP Standards Program Executive Offices Architecture for the TACOM Lifecycle Management Command STEP – STandard for Exchange of Product data ACMS – Automated Configuration Management System ACE – Advanced Collaborative Environment PLM+ - Product Lifecycle Management Plus SALE – Single Army Logistics Enterprise PDE2005

  9. Vision • Federated system of systems approach to product data management • Web-based access • Product data on demand • Product-centric data management • Single access and control point • Improved real-time data collaboration • Implement open data standards and best practices • Manage heterogeneous data formats • Automate CM/DM functions with workflows • Manage product structures/ BOMs • Maintain “as-designed”, “as-built”, “as-maintained” BOMs • Manage serialized parts • Access OEM controlled product data • Integration to ERP and logistics systems PDE2005

  10. User searches for part using ACMS STEP Part 21/28 File Automatic Import STEP AP214 Translator for Teamcenter EPM Windchill Connector Automatic Export Search for part inside Teamcenter Federation Teamcenter Adapter Automatically poll source for changes to master data Federation Windchill Adapter Automatically update product data at target or provide notification to approved users Updated product data available Data Exchange Workflow PDE2005

  11. AP 233 – Systems Engineering Data Representation Design Analysis Manufacturing Data Management AP 214 cc6 – PDM Schema AP 232 – Technical data packaging AP 239 – Product lifecycle support AP 201 – Explicit drafting AP 202 – Associative drafting AP 203 – Configuration controlled design AP 207 – Sheet metal die planning & design AP 214 – Automotive mechanical design processes AP 223 – Design & manufacturing of cast parts AP 224 – Machining features for process planning AP 238 – Computer numerical controllers AP 240 – Process plans for machined parts AP 219 – Dimensional inspection for parts AP 209 – Composite & metal structural analysis AP 237 – Computational Fluid Dynamics STEP for the DoD Acquisition Cycle PDE2005

  12. STEP Data Management APs • STEP AP 214 CC6 – PDM Schema • STEP AP 232 – Technical Data Packaging • STEP AP 239 – Product Lifecycle Support (PLCS) PDE2005

  13. Design (AP214) Analysis (AP209) Life-cycle Support (AP239) Supply chain (AP232) AP203 STEP-PDM SCHEMA Systems Engineering (AP233) PDM Schema Life-cycle PDE2005

  14. PDE2005

  15. EXPRESS Data Manager Software PDE2005

  16. Implementation Methodology • Import PDM Object Model into EPM Model Migrator software • Map objects and attributes between PDM and STEP • Where one-one mapping is not possible, write code in EXPRESS-X • Package software as a translator • Web enabled links inside PDM callable by user screen or callable as batch process PDE2005

  17. EPM Model Migrator Mapping Software PDE2005

  18. Federation-based Product Data Synchronization Federation Server 1 Federation Server 2 GROUP (WHAT) ADMIN (DASHBOARD) SCHEDULER (WHEN) DELTA ANALYZER (CHANGES) MAPPER (CONVERSION) TRANSPORT (SECURE) ADAPTER (WINDCHILL) ADMIN (DASHBOARD) GROUP (WHAT) SCHEDULER (WHEN) DELTA ANALYZER (CHANGES) TRANSPORT (SECURE) MAPPER (CONVERSION) ADAPTER (TEAMCENTER) Fxml PDE2005

  19. For more details Dr. Raj G. Iyer Team Lead, PLM Technologies Engineering Business Group TARDEC E-mail: raj.iyer@us.army.mil COM: (586) 574-7186 PDE2005

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