03 FALCON Iyer 2007-09 - · PDF filePDMLink Share-A-space loading bay ... • Accessing the documents associated to ... • powerLog is the reference Mil Std 1388 implementation produced

FALCON PilotFALCON PilotApplying Open Standards for PLM

Systems Interoperability

Dr. Raj IyerProgram Manager, PLMUS Army Tank Automotive R&D Center, Warren, Michigan, USA

Objectives

• Present the FALCON approach:– the application of the PLCS standard and Share-

A-space technology as a “master data integrator” within the Falcon Program Architecturewithin the Falcon Program Architecture

• Demonstrate:– Improved data communication from AM General to p

TARDEC– Visibility of richer design data sets to TARDEC

Abili• Ability to compare

– Access to details of individual delivered vehicles

MRAP – The CM Challenge

OEM 3OEM 2

CAT I

MRAPOEM 1OEM 4

CAT I

CAT II

OEM 7OEM 5

OEM 6

CAT II

CAT III

MRAP IIOEM 4

OEM 3OEM 2

CAT I

MRAP IIOEM 1

OEM 7OEM 5

OEM 6

CAT II

CAT IIIRetrofitUpgrades OEM 6UpgradesReset

Cross Domain Product Data Integration

IO CBAC o n c e p t

R e f in e m e n tS y s t e m D e v e lo p m e n t

& D e m o n s t r a t i o nP r o d u c t io n &D e p lo y m e n t

O p e r a t io n s &S u p p o r t

C

F R P

F O C

L R IP / IO T & ED e s ig n

T e c h n o l o g yD e v e lo p m e n t

( P r o g r a mIn i t i a t io n )

C o n c e p t

IO CBAC o n c e p t

R e f in e m e n tS y s t e m D e v e lo p m e n t

& D e m o n s t r a t i o nP r o d u c t io n &D e p lo y m e n t

O p e r a t io n s &S u p p o r t

C

F R P

F O C

L R IP / IO T & ED e s ig n

T e c h n o l o g yD e v e lo p m e n t

( P r o g r a mIn i t i a t io n )

C o n c e p t

S y s t e m s A c q u i s i t io n S u s t a in m e n t

D e c i s i o nR e v i e w

L R IP / IO T & ER e a d in e s sR e v ie w

C o n c e p tD e c is io n

P r e - S y s t e m s A c q u is i t io n S y s t e m s A c q u i s i t io n S u s t a in m e n t

D e c i s i o nR e v i e w

L R IP / IO T & ER e a d in e s sR e v ie w

C o n c e p tD e c is io n

P r e - S y s t e m s A c q u is i t io n

LSARCAD Config.Mgmt / PDM IETM

Defects & FailureUID

Reqmts.Mgmt.

CBMWarehouse

Analysis/M&S

SoftwareConfig. Mgmt./ PDM

ReportingMgmt. WarehouseM&SConfig.

Authoritative Sources of Master Data (Govt. or OEM)

Web Services

PLCS-based lifecycle product data integration & consolidation engine

Windchill PDM

Modeling &Simulation CAVE

Online DesignReviews

Spare PartBuys

DLA Buys Depot Reset/Recap

Readiness Provisioning

Product ImprovementsCollaboration

cycl

eca

tions

Windchill PDM

Simulation ReviewsDataValidation

What-ifAnalysis

ReadinessPredictionConfiguration

Management

g

CatalogingField Repair &Maintenance

Life

cA

pplic

Background: the existing process

• The Army receives design data as drawings (pdf files)• Drawings are held by the Army in WindchillDrawings are held by the Army in Windchill

– Corresponding meta data is entered manually• Product structure is supplied as indented parts lists

– Corresponding data is entered manually into Windchillp g y• LSAR data is also provided as 1388-2B

– Including Initial Provisioning Lists (as a report)• Change documentation held in the Windchill systemg y

– Other intermediate changes made by AMG held in SAP• What happens in AM General is not seen by the Army

– Changes to HMMWV design for manufacturing not delivered to Army by contract

– Approved changes do not necessarily get into manufacture

Manufacturing

Old way of doing businessManufacturing

As‐builtconfig

A d i d

OEM

ECP

New design Design changemade in 3D CAD

PDM

Design configurationcontrolled withinPDM

2D CAD drawingsdeveloped

As‐designedconfig

Drawing BOMstructurecreated manually

PDF filesgenerated

Drawings &BOM copied to CD’s created manuallyto CD s

E-mail/FTP/Snail mailto TACOM

Create product structure

Fill in metadataNon-value addFunctions +

Drawings only – no 3DLoss of config with

Technicianmanually loadsdata into Windchill

TACOM Windchill

Load drawingsValidate load

Functions + Loss of config. control

Loss of config with OEM

Govt. initiatedECP

“To-be” Product Data Process

ECP

New design Design changed i 3D CAD

Design configurationll d i hi

OEM

New designmade in 3D CAD

OEM PDMcontrolled withinPDM

FederatedData AccessFALCON

TACOM Wi d hillSingle point of entryUser access TACOM WindchillUser access

Humvee Pilot with AM General

Demonstration Process Overview

1. Load AM General design data 2. Load TARDEC Windchill data

WindchillPDMLi k

SAP R/3

WindchillPDMLinkPDMLinkPDMLink

4. Consolidated product data

5. Load Vehicle instance dataand view in Share-A-space

3 Load AM General

Windchill Plug-in

product data review with plug-in

3. Load AM General powerLog (1388-2b) data

Quick introduction to Share-A-space

• Share-A-Space implements the Master Data Integration functionality in FALCONIntegration functionality in FALCON

• Share-A-space is an information integration hub designed to manage data across collaborative

t ienterprises• Share-A-space is heavily based on use of the STEP

standardstandard– Import and consolidation of data uses STEP (PLCS) – Content can be exported as PLCS

I FALCON i t d t l l i f• In FALCON import data mappers plus a plug-in for Windchill have been developed– Share-A-space is being used “out-of-the-box”p g

HMMWV Pilot – Demo ScenarioHMMWV Pilot Demo Scenario

1. Initial Data Load – AM General SAP DataSAP Data

• Extract “As Used To Manufacture” data from AM General’s SAP

• Map/transform SAP data to PLCS (ISO 10303-239)

• Load data into Share-A-space

As-manufactured Data stored in AM General SAP

I iti l D t L d AMG SAP

HMMWV Pilot – Demo Scenario

As-builtP d

Initial Data Load – AMG SAP

FTP upload

TACOM NIPRNETTACOM DMZAM General DMZAM General Corporate Network

Windchill

Productstructures

SAP CSV

Server

SAP R/3

WindchillWindchillPDMLink

Share-A-space loading bay

PDMLink

Share-A-space™ App Server(Static IP Address)

SAP “As-Built” Structures exported as Flat File by AM General

SAP export


As-builtP d

Digital File Repository

FTP upload


Windchill

Productstructures

SAP CSV PLCSDEX1.p21

Server

SAP R/3



PDMLink


SAP to PLCS Mapper executed and resulting PLCS File and Associated Model Files placed on Upload Server

SAP data as PLCS


As-builtP d

FTPS (port 990)Sh A A ll fil

Digital File Repository

FTP upload


Windchill

Productstructures


Share-A-space App server pulls filesfrom suppliers FTP server via FTPS “get” command

Rules

Server

SAP R/3


As_Built View


PDMLink


PLCS DEX1 File “pulled” to the upload area and Imported into Share-A-Space

Video Introduction

The following video shows: A data file from AM General being placed into• A data file from AM General being placed into the Upload area that is monitored by Share-A-spaceA space

• The file is then processed by Share-A-space– Progress can be monitoredProgress can be monitored– The report from loading the file is itself held as a

document within Share-A-space• Together with the data file

– The report is browsed showing what was imported and identifying data already found versus newand identifying data already found versus new data

Data import – only shown once

• The preceding video actually showed the import of the smallest data set which is theimport of the smallest data set which is the LSAR data– Described laterDescribed later

• The process for importing the other data sets from AM General is the same

• Data describing the whole of the 1097-A2 was imported successfully from AM General’s SAP system with associated CAD models

SAP data in Share-A-space

Video Introduction

Th f ll i id hThe following video shows: • Searching for a part by id• Accessing the documents associated to

the partp• Accessing the digital file for the

documentdocument• Downloading the file to the local client

machinemachine

Video Introduction

Th f ll i id hThe following video shows: • Searching for a part by id• Accessing the documents associated to

the partp• Accessing the digital file for the

documentdocument• Opening the file in a CAD viewer

• Note: Spinfire is not part of the software used for FALCON at TARDEC


2. Initial Data Load – TARDEC Windchill DataWindchill Data

• Current content of TARDEC Windchill • Extracted data from Windchill as STEP• Loaded meta data into Share-A-spaceLoaded meta data into Share A space

– Not supporting drawings/models– Used to enable comparisonUsed to enable comparison

Initial Data Load – TARDEC Windchill

FTP upload


As-designedProduct structure

TDP

Server

SAP R/3

Windchill


PDMLink


TDP “As-Designed” Structures entered directly into Windchill by AM General

Video Introduction

Th f ll i id hThe following video shows:• the example subsystem used later in

this presentation in TARDEC’s Windchill

Initial Data Load – TARDEC Windchill

FTP upload


As-designedProduct structure

TDP3

Server

SAP R/3

WindchillRules


PDMLink

Windchill Export

As-designedProductstructureSTEP

AP214 .p21

Shared Network drivePull from Share-A-spaceApp server

Design View


“As_Designed” Data Structures exported from Windchill as an AP214/PDM Schema FileAP214/PDM Schema File “pulled” to upload area and imported into Share-A-space

Windchill Data in PDM Schema format

Windchill data in Share-A-space

What’s happened so far:Configuration Integration: SAP, WC => Share-A-space

“As Used To Manufacture” Version Release

As DesignedView

“As Used to Manufacture” View + As Designed View

Data load results

C l t A M f t d d t t• Complete As-Manufactured data set loaded from AM General SAP to Share-AA-space– 3030 parts plus example CAD models and

d idrawings• Partial data set loaded from TARDEC’s

Wi d hill f dWindchill system for demo– Exhaust sub system comprising 63 Parts


3. Initial Data Load –AM General powerLog DataAM General powerLog Data

LSA data background

• Mil Std 1388 covers a broad scope of logistic support analysis (LSA) including failure modes, task analysis and spare-parts

– This analysis is usually undertaken as part of designing the support system This analysis is usually undertaken as part of designing the support system for a product

• AM General use a report generated from Mil Std 1388 data to supply provisioning list data to the Army

– The data and report are created using the powerLog system– The data and report are created using the powerLog system• powerLog is the reference Mil Std 1388 implementation produced by LOGSA

• The data provided by AM General covers a limited subset of Mil Std 1388:

A b kd f th d it i L i ti C t l N b (LCN ) t– A breakdown of the end-item using Logistic Control Numbers (LCNs) to identify relevant positions

• The data here is a physical breakdown (cf. functional) that corresponds to an assembly structure

Links from that breakdown to the corresponding parts– Links from that breakdown to the corresponding parts • As much more of Mil Std 1388 is relevant to PLCS it was decided to

work with the data as held by powerLog rather than the output report– The reduced scope allowed use of existing PLCS DEX capabilities

• Coverage of the full scope of Mil Std 1388 by PLCS DEXs is not yet in place

AM General powerLog -> PLCS MDI

LSAR

Design ViewLCN Breakdown

LCN Breakdown

Initial Data Load – AM General powerLog-J

FTP upload


Server

SAP R/3

Windchill


PDMLink


Screenshot from powerLog-J


FTP upload


Server

SAP R/3

Windchill


PDMLink


powerLog LSAR Data exported to MilStd 1388-2B format using powerLog Export capability

1388-2B

LCNStructures

Export 1388 2B

LSA data exported as 1388-2B format


FTPS (port 990)Share-A-space App server pulls filesFTP upload


Share A space App server pulls filesfrom suppliers FTP server via FTPS “get” command

PLCS DEX1

Rules

Server

SAP R/3

Windchill

1388-2B

Support View


PDMLink


powerLog LSAR Data exported to MilStd 1388-2B format using powerLog Export 1388-2B

LCNStructures

Export

MilStd 1388-2B File put on Upload server

MilStd1388-2B File “pulled” to the upload area, and mapped to a PLCS DEX1 File

capability1388 2B

PLCS DEX1 File imported into Share-A-space and connected to the “As_Designed” structure

1388-2B export mapped to PLCS

powerLog data in Share-A-space

Logistics data from AM General

P h t i t LSAR d t• Proven approach to import LSAR data alongside design data– Demo limited to scope of available LSA

data (provisioning)M d il bl d t t PLCS– Mapped available data to PLCS

– Identified problems in LSA data– Resolution on-going


4. Consolidated Product Data ReviewReview

with Windchill Plug-in

Windchill Plug-in Browser

FTP upload


Server

SAP R/3

Windchill


PDMLink

WS Client

WS - HTTPS (port 443)


Windchill User starts Web Services Client toShare A spaceWindchill User selects a Part in the “As_Designed” structure and queries Share A spaceShare-A-space returns linkage to Support Data and comparison with the “as built”Share-A-spacestructure and queries Share-A-spacecomparison with the as_built

Plug-in Structure Browser

LCN Breakdown As Designed View

As-designed View

XWindchill Plug-in

“As Used to Manufacture” View

ASPASP NETNETSA GUISA GUII tI t/ t l i/ t l i PLCS W b SPLCS W b S

PLCS Master Data Integrator ShareShare--AA--spacespaceApplication ServerApplication Server

Business Object LayerBusiness Object Layer

COMCOM MTS

ASPASP .NET.NETSAs GUISAs GUIImportImport/ export logic/ export logic

Persistent objects handling and Database binding

PLCS Web SrvsPLCS Web Srvs

OracleOracle

TCP/IPTCP/IP

As-designed versus As-manufactured

• As-Designed data for the exhaust system comes from TARDEC’s Windchillfrom TARDEC s Windchill

• As-Manufactured data for the entire M1097-A2 comes from AM General’s SAP system

• (Plus the LSA data from powerLog)• Both sets of data are now available to navigate and

viewview – Via the Share-A-space interface– Via a plug-in to Windchill

• Can now look at consistency between As-Manufactured and As-Designed structures– The following slide shows how differences in the structures– The following slide shows how differences in the structures

are presented by use of icons

Visual representation of data consolidation

As-Built Data ImportConsolidating Data…….As-Designed Data ImportData Consolidation LCN Structure ImportReconciling LCN with “As_Designed Structure

NOT The Same

Exists in other LCN as-builtas-designed

NOT The Same

Does not exist

The Same

Exists in both

The Same

Exists in both “MecDes” “MecDev”“MaiSup”

Application View, but Children are Different

1in other Viewviews and identical childrenviews and no children

“MecDes” “MecDev”“MaiSup” context labels

Each data set is given a label that

2 3 is used in the Plug-in

4

5

Video Introduction

The following video shows: Th f th Wi d hill i t f• The use of the Windchill user interface:– to navigate to the exhaust system

• This is the structure exported from Windchill– To start up the viewer that enables browsing and

comparison of structures from Windchill to those from AM General

• The Use of the Plug-in to:– View the as-designed (TDP) data

Compare the As designed data against the As Manufactured– Compare the As-designed data against the As-Manufactured data from SAP

– View the As-Manufactured data and compare with the TDPSh h d i i d i diff t i b t– Show where a design is used in different versions between the TDP and As-Manufactured data

Video Introduction

The following video shows: • The Use of the Plug-in to:

– View the LSA data structureView the LSA data structure– Show where the same part is used in

different versions between the As-d e e t e s o s bet ee t e sDesigned and As-Manufactured structures

– Note that the LSA data does not carry any information concerning versions of the design used for the analysis

What does this bring TARDEC?

• Visibility of As-manufactured structures for the first time alongside As-Designed– for the first time alongside As-Designed

• Visibility of LSA structures – for the first time alongside As-Designedg g

• The possibility to understand where there are differences between the approved design and th A M f t d d tthe As-Manufactured product– Most parts in the chosen example sub-structure

are at different versions!• The ability to assess consistency of LSA data

(spare parts lists) against both As-Designed d A M f t d t tand As-Manufactured structures


5. Load Vehicle instance dataand view in Share-A-spaceand view in Share A space

• Data on serial numbered structures exported from SAP

• Mapped into PLCS• Loaded into Share-A-space• Four serial numbered items per vehicle

– plus the vehicle itself

Load Serial Numbered Product Data – AM General SAP

FTP upload


Serial NumberedProduct

FTPS (port 990)Share-A-space App server pulls filesServer

SAP R/3

Windchill

Productstructures



Rules


PDMLink

Individual ViewIndividual View


TACOM User

SAP “Serial Numbered Product” Information exported as Flat File by AM GeneralSAP to PLCS Mapper Run and resulting PLCS File placed on Upload ServerPLCS DEX1 File “pulled” to the upload area and Imported into Share-A-SpaceSerial numbered data can be viewed in Share-A-spaceView via Plug-in to be developed

The serial number of a 1097A2 as held

in SAP

Component serial numbers for the same 1097A2 as

held in SAPheld in SAP

SAP export – Serial numbered data as Ascii file

S i l

Serial Numbered data mapped to PLCS

Serial Numbereddata mapped ppto PLCS

Video Introduction

• The following video shows the use of the Sh A i t f t i tShare-A-space user interface to navigate:– To the design of a vehicle

To the instances of the vehicle– To the instances of the vehicle• Sample of 400 vehicles has been loaded

– To the serial structure of one vehicle– To the design of the engine fitted in that vehicle– To the instances of the engine

• Note that instances have a bar-code as icon

Viewing of Serial data from Windchill Plug-in

FTP upload


Serial NumberedProduct

FTPS (port 990)Share-A-space App server pulls filesServer

SAP R/3

Windchill

Productstructures



Rules


PDMLink

Individual ViewOutgoing SMTP (port 25)

WS - HTTPS (port 443)


TACOM User

WS Client

WS HTTPS (port 443)

TACOM User informed of New Serial Data arrivalTACOM User views Serial Data via Plug-in g

Conclusions

• The architecture proposed for FALCON has been successfully demonstrated with AM General

Th PLCS t d d d Sh A t h l id– The PLCS standard and Share-A-space technology provide a “master data integrator” function

– TARDEC and AM General continue to use existing systems• Through FALCON TARDEC can have access to a richer dataThrough FALCON, TARDEC can have access to a richer data

set from OEMs– As-used-to-manufacture data and LSAR data available at TARDEC

as well as approved design – Access to the data can be made available through TARDEC’s

existing tool (Windchill)• FALCON enables a route for improved data synchronization

between AM General and TARDECbetween AM General and TARDEC– Automated processes can be established– Manual intervention in the exchange of data can be eliminated– Out of Sync data can be identifiedOut of Sync data can be identified

Conclusions (continued)

• FALCON delivers improved Data Quality– Inconsistencies identified between As-released and As-used-to-Inconsistencies identified between As released and As used to

manufacture• Version differences• Part numbering and naming differences

– Different names between LSAR and As-released for same part• FALCON enables use of simple add-on services via web-

services– Bill-of-Material comparator (part of the Plug-in)

• FALCON offers the possibility of a through life approach– Individual (serialized) data from SAP now available to TARDEC( )– Starting point for tracking configuration of individual vehicles – Individual and support data in line with PLCS

Summary

• FALCON’s use of PLCS as the mediation format and Share-A-space as a host technology provide:p gy p– Reconciliation of product data cross-application– Configuration control of lifecycle views– Transparent interoperability servicesp p y– Independence between OEM and Army IT systems– Platform for additional application capability– Absence of data lock-inAbsence of data lock in

• FALCON approach applicable to other vehicle programs

Demonstration achieved using open approaches without– Demonstration achieved using open approaches without company specific developments

What next?

• Upload from Share-A-space to Windchill– Requires tailored STEP file to suit Windchill STEP import

• Establishment of FALCON as production approach for data synchronization between AM General and TARDECTARDEC– Use of FALCON Bill-of-Material comparator to aid clean up

and synchronization of data– Establishment of improved processesp p

• Application of FALCON to other programs– As the means for OEM delivery of design data to the Army

Use of FALCON as starting point for through life• Use of FALCON as starting point for through-life management of design and configuration of individual vehicles

F d th h f t d t i t A L i ti t– Feed through of accurate data into Army Logistics systems

To know more

Dr Raj I er• Dr. Raj IyerTeam Leader, Product Lifecycle ManagementTank Automotive R&D Center (TARDEC)Tank Automotive R&D Center (TARDEC)US Army Research Development and Engineering Commandg g6501 E. 11 Mile RoadWarren, MI 48397T l 1 586 574 7186Tel: +1 586 574-7186

Documents

03 FALCON Iyer 2007-09 - · PDF filePDMLink Share-A-space loading bay ... • Accessing the documents associated to ... • powerLog is the reference Mil Std 1388 implementation produced