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The Ultimate Upgrade Nicholas Garcia Bell Helicopter Textron

The Ultimate Upgrade Nicholas Garcia Bell Helicopter Textron. 1. Agenda. Who am I? What are we doing? Why are we doing it? How are we doing it? Are we going to do this again? Questions. Who am I?. Nicholas Garcia Bell Helicopter Textron IT CAD/CAM Fort Worth, TX

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The Ultimate Upgrade Nicholas Garcia Bell Helicopter Textron

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  1. The Ultimate UpgradeNicholas GarciaBell Helicopter Textron 1

  2. Agenda • Who am I? • What are we doing? • Why are we doing it? • How are we doing it? • Are we going to do this again? • Questions

  3. Who am I? • Nicholas Garcia • Bell Helicopter Textron • IT CAD/CAM • Fort Worth, TX • ngarcia@bellhelicopter.textron.com • (817) 280-6484 3

  4. Who am I? 4

  5. What are we doing? • Upgrade from NX 1 to NX 5 • Upgrade from Teamcenter Engineering 9.1.3 to Teamcenter Engineering 2007 • Migrate workstations from AIX Unix to Windows XP • Migrate from 32-bit to 64-bit • Migrate servers from AIX to Windows • Decommission Multi-site

  6. Why are we doing it? Current Environment • ~200 AIX 5.3 Workstations • NX 1 on AIX • Teamcenter Engineering 9 on AIX and Oracle 9i • 2.5 Terabytes of NX Data • Multi-site for WAN

  7. Why are we doing it?

  8. Why are we doing it? Issues • Loading times unacceptable • Multi-site sync issues • NX 1 “no patch” issues • No disk space for growth • “View” only capabilities • Users want to be current • No-support/EOL on current software versions

  9. Why are we doing it? Future Environment • ~200 Windows XP 64-bit Workstations • NX 5 64-bit on Windows • Teamcenter 2007 on Windows • 4 Terabytes total disk space • 2-tier for “local” sites (DFW Area) • 4-tier w/Site Cache for remote sites • No Multi-site!!!

  10. Why are we doing it?

  11. How did we do it? Background • Oct 2006 Project initiation • Upgrade from TCe 8 to TCe 9 • Move from HP-UX to AIX • NX 3 or NX 4? • What are the real issues?

  12. How did we do it? Review Current Environment • Users • ~200 Users • 4 Sites • Data • 2.4 Terabytes • Multisite between sites • Very large assemblies that do not open

  13. How did we do it? Review Current Environment • Processes • Over 70 customizations in NX • 10 Customizations in TCe • Hardware • AIX Servers • AIX Storage • Oracle Database

  14. How did we do it? Review Solutions • NX 3 vs NX 4 vs NX 5 (remember this was around July 2007) • Begin testing of Windows 32/64-bit vs AIX 32/64-bit • Compare NX 4 and NX 5 (NX 3 decided to be outdated) • Test everything with TCe 9

  15. How did we do it? Decisions • October 2007 • Loading capabilities with Windows showed to be greatly improved • NX 4 • Teamcenter 9 • How do we rollout?

  16. How did we do it? Rollout options • Upgrade to NX 4 on AIX then migrate to Windows as needed • Migrate to Windows with NX 1 then upgrade to NX 4 • Mix environments with some users on Windows and some on Unix • Final Decision: Full Migration to NX 4, TCe 2005 and Windows in one weekend

  17. How did we do it? Getting Started • Current skillset and past experiences (NX 1 upgrade) showed that we needed assistance • INCAT contracted to provide technical expertise, coding upgrades and training • CSC supports Bell infrastructure • Goal was for Mid-year 2008 rollout, which changes the targets

  18. How did we do it? Moore’s Law • 12+ months since project first started • NX 5.0.1 was available • Teamcenter 2007 was available • New Hardware (Quad Core) for Windows PC’s All this means change in scope!

  19. How did we do it? Hardware Definition and Acquisition • Compare 64-bit CAD compatible PC’s • Define and order • Servers • Disk Storage • Workstations

  20. How did we do it? PC Workstations • New at Bell • Windows XP 64-bit • Dual Quad Core Intel • 8 GB Memory • 2 x 250 GB Raid 1 Hard Drive (great for caching)

  21. How did we do it? Now for the fun stuff • Customizations • Server installation • Client installation • Training • Testing • Results? • Go Live

  22. How did we do it? Customizations • Needed before any testing can occur • Gather all source code (very little in source control) • Give to Incat to upgrade and migrate • Answer lots of questions about purpose, functionality and processes • Some don’t work because no longer on AIX • How do we handle these?

  23. How did we do it? Server Installation • 3 Environments • Sandbox (Development) • Test (Full copy of production, during project only) • Production • Multi-site Decommission • Stop creation of new parts at external site • Migrate all data back to single site (not an easy task)

  24. How did we do it? Server Installation Sandbox • Proof of Concept • Functionality only testing • Limited dataset • Use of existing desktop for immediate rollout

  25. How did we do it? Server Installation Test • Production server hardware • Full copy of production • Data migration • 200GB Limit for backup/restore • 4TB at 200GB = 20 different mounts • 2 weeks to migrate data from Unix • Database migration

  26. How did we do it? Server Installation Test • Install Teamcenter 9 to verify database connections • Install Teamcenter 2007 on Server • Perform upgrade to Teamcenter 2007 • NX 5 data upgrade? On the fly upon opening

  27. How did we do it? Client Installation • Create similar share on Windows • Installation process automated as much as possible with batch files, which reduced install time from 2 hours to 25 minutes • Small quirks are annoying • NX installation warning • Adding user id to XML install file • No silent install for patches

  28. How did we do it? Client Installation • 150 PC Workstations ordered, imaged, and delivered • 60 were “refreshes” • 2 months to rollout • All were ready prior to go live

  29. How did we do it? Training • Outsourced, onsite training • 6 weeks, 3 locations, 150+ users, 32 hours each • Pilot training class with Super Users in Engineering and Manufacturing • Courses available online after classes • Documentation, CAST, I.GET.IT for additional functionality

  30. How did we do it? Testing • Basic Functionality performed by core team • Sandbox used for code verification • Test system used for performance, load and timing tests • Pilot training class users asked to do “real” work in test system • Refresh of test system with production data

  31. How did we do it? Testing • Printing and Plotting changes • New functionality • Non-Project related issues • Moving to Windows • Downstream processes • 64-bit • Integrations with other systems • How to support Windows

  32. How did we do it? Results

  33. How did we do it? Go Live • 2 Dry Runs to ensure timing • Perform “sync” between production and test system volumes • Copy production database to test • Perform upgrade and ensure timing is correct • Everything is ready prior to go live

  34. How did we do it? Go Live • June 16th • Friday 3:30 pm – Monday 6 am • Coordination across 5 Plants, 2 cities • Coordination between 3 companies: Bell, CSC, Incat • 1 Team to make it happen

  35. How did we do it? Lessons Learned • Get help if needed • Hardware migration is hard • Dry Runs are useful for timing • 64-bit migration may have issues • Hardware/software changes quickly

  36. What did we do again? • Upgraded NX 4 versions • Upgraded Teamcenter 3 versions • Migrated from Windows to Unix on Clients • Migrated from Windows to Unix on Servers • Migrated from 32-bit to 64-bit All in one weekend!

  37. Are we going to do this again? NO

  38. Are we going to do this again? • Install Patches • Review new releases of TCe and NX • Review new hardware • Continual process improvements

  39. Questions?Nicholas Garciangarcia@bellhelicopter.textron.com(817) 280-6484 39

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