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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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slide1

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.

life cycle baseline reconciliation basic configuration verification system bcvs
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
slide3

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

(_________)

product life cycle management
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

slide5

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

product life cycle management1
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

slide7

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

slide8

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

slide9

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.
slide10

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)

slide11

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)

slide12

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)

slide13

Functional System(s)

Architectures

System A

System B

System C

System D

Functional Environment

(Program Management / Engineering / Manufacturing / Fielding)

data object modeling
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.
data object modeling1
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
data object modeling2
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
data object modeling3
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

slide18

Data Mapping Strategies

System A

System B

Mapping

Verify/Certify

Mapping

Verify/Certify

Mapping

Verify/Certify

Mapping

Verify/Certify

slide19

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

slide20

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

slide21

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

slide22

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,

the mechanisms processes basic configuration reconciliation process
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

slide24

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

slide25

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

slide26

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

slide27

STEP Data Exchange

(The Back Story – SI/BCA)

Enterprise

Supplier

type design data process flow
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

slide30

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

(????)

slide31

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

slide32

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.

slide33

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.