Implementing PLM in the Discrete Manufacturing Sector and ...content.pi.tv/events/PI Berlin 2017/presentations/1288_Chandru... · crane aerospace & electronics proprietary: the information

CRANE AEROSPACE & ELECTRONICS PROPRIETARY: THE INFORMATION CONTAINED HEREIN IS PROPRIETARY TO CRANE AEROSPACE & ELECTRONICS AND SHALL NOT BE REPRODUCED OR DISCLOSED IN WHOLE OR IN PART OR USED FOR ANY DESIGN OR MANUFACTURE BY NON-CRANE AEROSPACE & ELECTRONICS EMPLOYEES EXCEPT WHEN SUCH USER POSSESSES DIRECT WRITTEN AUTHORIZATION FROM CRANE AEROSPACE & ELECTRONICS.

Implementing PLM in the Discrete Manufacturing Sector and Overcoming its

Unique Challenges

Chandru Narayan Group Director – Engineering Tools & Processes

PI Berlin 2017

© 2015 Crane Aerospace & Electronics

A diversified manufacturer of engineered products with four strong business segments !  11,500 employees !  Over 150 locations in 26 countries !  $2.9 billion sales (2014) !  Headquartered in Stamford, Connecticut, USA

Crane Overview

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Payment & Merchandising

Technologies $712M

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$253M

Aerospace & Electronics $696M

Built on foundation of strength and integrity since 1855

“I am resolved to conduct my business in the strictest honesty and fairness; to avoid all deception and trickery;

to deal fairly with both customers and competitors; to be liberal and just toward employees;

and to put my whole mind upon the business.”

Richard Teller Crane July 4, 1855

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Sales (2014)


Combines the experience of six core solutions within the Aerospace & Electronics segment !  2,800 employees worldwide !  10 manufacturing sites in Americas, Asia and Europe !  Global product support

Crane Aerospace & Electronics

Stable partner with balanced portfolio

Sales (2014) $696M

$696M

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OEM Commercial

43%

OEM Defense

23%

Commercial Aftermarket

19%

Defense Aftermarket

7%

Other 8% Defense

30%

Commercial 70%

OEM 71%

Aftermarket 29%


Supporting OEMs and Operators worldwide

Markets and Customers

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Aftermarket

Defense & Space

Commercial


Six integrated solutions provide proven technologies for niche markets and applications

!  Sensing Components & Systems !  Brake Control Systems !  Power Components & Subsystems !  Fluid Management !  Cabin Systems !  Microwave Components &

Integrated Assemblies

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Challenges

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!  The Process Challenge !  The Technology Challenge !  The Management Challenge


The Process Challenge

!  Why is PLM important for your Industry? –  Tie PLM Goals to Business Goals –  Model Enterprise Requirements Flow

!  Breakdown Business Goals to Operational Objectives – WHY TO WHAT? –  Business Goals - WHY

•  Profitability, Quality, Innovation, Time to Market

–  Operational Objectives – WHAT and by WHEN •  Percent completion by Time •  Reduce Errors and Escapes by % •  Reduce cost in Design Engineering

!  Breakdown Operational Objectives to Functional Requirements – HOW to WHERE? –  CAD Design, Partnering with Service Providers, Module Selection –  Configuration Control, Release/Change Mgmt, Publish-Subscribe –  Team Skills, Leadership Charter, Communication Plan

!  Breakdown Functional Requirements to Technical Specifications – By DOING? –  S/W and H/W Architectures –  Workflow and UI Design –  Interfaces CAD/CAM/MPP

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© 2015 Crane Aerospace & Electronics 8

The Process Challenge

Improve efficiency and productivity by providing a tightly integrated Common Tools architecture using Standard Templates supported by Central Teams through Systems Development (Products) and Program Support (Services)

Teams

Tools

Systems

Development &

Program Support

Templates

T3


Key Functional Requirements •  Integrated Information Availability

•  Configuration and Change Management •  Traceability & Accountability

•  Integrated and Common Processes •  Integrated Tools

Enterprise Requirements Flow

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Key Business Drivers •  Customer Satisfaction

•  Reduce Cost Cycle Time •  Reduce Time to Market

•  Simple and Robust Processes •  Compliance

•  Robust Product Representation •  Concurrent Engineering •  Configuration Management •  As-Designed Definition •  Visibility of smallest reusable definition •  Decoupled design identity •  Traceability and Accountability of Designs •  Flexible Release protocols •  Manage Change

Marketing

•  Standard & Custom Products •  Incremental Requirement Definition •  Forecast to Intermediate Definition •  Expected Cycle Time •  Manage Change

Engineering Manufacturing/Production

•  Release/Order of Parts with unique identity •  Schedule to Process Plan Operations •  Flexible and Timely Reactive Processes •  Decoupled Manufacturing Identity •  As-Planned Definition •  As-Built Definition •  Manage Change

Support/Maintain

•  Create Intermediate Design Definitions •  Document Maintenance Procedures •  As-Maintained Definition •  Manage Change


Tie PLM Goals to Business Objectives

10 © 2013 Crane Aerospace & Electronics

Objectives

!  Reduce complexity and eliminate 80% or more of customized code in lieu of off-the-shelf software

!  Significantly enhance capability, footprint and usability of TeamOne across all Solutions

!  Satisfy customer and FAA/EASA requirements for Changes to Type Design

!  Provide support for new and critical customer needs not satisfied by current TeamOne Enterprise system

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Communication Plan

!  Project Description Document

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Detailed Schedules

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Resource Plan

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The Technology Challenge

!  Information Modeling –  How deep? How broad ?

!  Data Modeling –  Off-the-shelf?

•  Data Migration •  CAD and other Interfaces

–  Customize? •  Upgrades and Patching

!  Proofs of Concept –  Systems Architecture –  Data Migration

!  Rapid Prototyping –  UI –  Workflow

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!  Design Patterns –  Master-Rev –  Revison/Date/Serialized Effectivity –  Publish Subscribe –  Multi BOM –  Flexible Release –  Targeted Concurrency

!  Server Architectures –  How many?

•  Prod, Dev, Test, Training, Poc –  Functions?

•  Corp, Volume, Disp, Web, Output


Many Process Structures

!  Market –  Conceptual BOM

!  Design –  CAD/eCAD BOM –  As-Designed BOM (Part, Req/Des Docs)

!  Plan –  As-Planned BOM (mBOM) –  Bill Of Process (BOP)

!  Build –  As-Built BOM

!  Service –  As-Supported BOM –  As Maintained BOM

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Multiple Product Structures

!  Best Practice organization of Product Structure into As-Designed, As-Planned, As-Built, and As-Supported views –  An overloaded Engineering view with downstream data such as process plans, test documents, quality, reliability, customer

submittals, STC data etc. The asynchronous nature of the downstream information causes problems with configuration controls, scheduling, complex approval processes etc.

!  The view network, advanced change schedule management , workflow architecture are essential for the integration of Manufacturing Process Planning, Technical Publications, R&O data, etc. TeamOne Unified will support the management of the Service Lifecycle

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Type Design Process Definition

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Proof of Concept Roadmap for Manufacturing Module

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Support Flexible Release Models

!  Accommodate Release of appropriate levels of design definition –  Current process release only when the definition is completely established. This results in

unnecessary inertia !  Provide Mechanism to ensure definition integrity while maintaining a Robust Release

process –  Allow Release (to manufacturing) of complete parts in the context of incomplete assemblies

•  Recognize that a part has been released as a dependent demand item, especially for long lead subassemblies

–  Provide unique identity to intermediate (but incomplete) part definitions, while allowing them to continue to evolve to a new final identity •  Allows for control and release of intermediate stages of a product

–  Recognize that an intermediate part release (engineering) must allow it to evolve in the context of a downstream domain (manufacturing)

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Systems Architectures

!  PoC is key!

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The Management Challenge

!  Program Management –  Extended Schedules –  Resource-Leveled or Schedule-Based?

!  People Management –  Process Designers, Architects, Code Developers, Workflow, UI –  Training Development, Training Delivery, Production Support –  Targeted Partnering can reduce technical challenges significantly –  Educating Leadership

!  Change Management –  Full CMII Change Model? –  PR, ECR, ECO, ECN

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!  Production Support –  Development Team and Production Support Team Priorities

!  Implementation Design –  Big-Bang –  Multiple Releases

!  Compliance Management –  Export Control –  DFARS –  DO178c –  DO254


Teamcenter Unified Project Timeline at Crane A&E

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•  Analyze updated eBOM ▪  New & removed parts / assemblies ▪  Changed parts

"  Identify change impact ▪  Related parts / process ▪  Related snapshots

"  Modify mBOM ▪  Properties alignment ▪  Configuration management

"  Modify WI ▪  Replaced parts automatically appear

in the product views ▪  Regenerate dynamic document

eBOM Analysis

Change Impact

Update mBOM

Update Document

Enterprise Change Impact


Enterprise multi-domain Change Management

•  Problem Report (PR) - used to describe a problem or an

idea in such a way that another party will be able to

reproduce the problem

•  Enterprise Change Request (ECR) - used to define and

justify solutions to problems identified by the PR

•  Enterprise Change Notice (ECN) - used to implement one

or more approved ECRs. Serves as an authority to release

the associated documents

•  Manufacturing Change Notice (MCN) - used to implement

one or more approved ECNs in the manufacturing

environment.


Clear communication of product structure definitions

!  CAD BOM –  Models and Drawing representations supporting various aspects of the design authored

Mechanical, Electrical and Electronic CAD tools. –  Comes from various sources and might contain reference parts from other models

!  eBOM –  The engineering bill of materials defines the product as it was designed to meet customer

requirements. It is a structured list of components that appear in the final product. –  It contains component and assembly parts including software and all the specification,

design, test, compliance documentation that leads to a certification of the product by the customer

–  Cadinality: Usually one eBOM is composed of many CAD BOMs, although not always •  eBOM contains parts, CAD BOM contains the design implementation of those parts •  The eBOM has to be resolved to fully represent the unique and distinct product being engineered

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Clear communication of product structure definitions

!  mBOM –  The manufacturing bill of materials contains all the parts and subassemblies required to build

and ship a complete product. It is a structured list of components that is consumed in the building of the product.

–  The structure reflects the organization of the build process such as pre-assembly requirements for kits, pre and post processing of CCA and so on

–  The content includes component boms that include materials and standard parts –  Includes consumable items such as cleaning solvents, adhesives etc. –  Cardinality: Usually One eBOM to One Global or Multiple Plant/Program Specific mBOMs

!  BOP –  The bill of process represents the build process and contains items from the mBOM

consumed at each operation of the process –  Also contains the Routings, Sequence, Timing and Work instructions needed to complete

each step of the process –  Cardinality: Usually One mBOM to One BOP

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CMII Closed-Loop Change Management Model

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Compliance

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Conclusions

!  Process Challenges are the most important to solve !  Clear communication of Goals – Live PDD !  Early Definition of Implementation Approach !  Tie to Financials are key to successful Implementation !  Targeted PLM Partnering can reduce Technology Challenges Significantly !  Priority of Production Support vs Project Development is very difficult to manage !  Others ???

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© 2015 Crane Aerospace & Electronics Data cleared by US Department of Defense (DoD) Office of Security Review (OSR)

for public release. OSR case number xx-xx-xxxx, dated Month, Day, Year.

The Crane Advantage!

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Documents

Implementing PLM in the Discrete Manufacturing Sector and ...content.pi.tv/events/PI Berlin 2017/presentations/1288_Chandru... · crane aerospace & electronics proprietary: the information