Life Cycle Baseline Reconciliation
A 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.
1
Life Cycle Baseline Reconciliation
Basic Configuration Verification System (BCVS)
Presentation Agenda:
•
The Basics/Fundamentals
–
•
•
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
–
•
•
•
Product Life Cycle, Bills of Material, Data/Documentation,
Baselines and BL Comparisons, Audits and Reconciliation
XLS/CVS, XML, Standards & Direct Integration
ISS/InSync Proposed Solution
Supporting the DD 250 Process
The Back Story: Boeing’s SI/BCA & P-8A
2
As-Authorized
(_________)
Product’s Life Cycle Management
Cost Estimating
Capacity Planning
& Assessment
Specifications
As-Committed
(_________)
(Basic Life Cycle Process)
Master Schedule
Work Breakdown Structure
Budgets
Sales Orders
Cost Accounts
Effectivity
Baseline Release
Document Control
Product Definition
EBOM
Bill of Routings
Effectivity (Eng.)
MBOM
Effectivity (Manf.)
Bill of Routings/Resources
Master Production Schedule
Proposed Capacity Planning
MRP/CRP/Procurement
Work Order Release
As-Designed
(_________)
As-Planned
(_________)
As-Purchased
(_________)
Product Structure
(Bill of Material)
CSCI
CSC
As-Delivered
(_________)
CI
Item
CSC
Item
Number
-1
-3
Unit
Unit
Unit
Unit
Part
Part
Item
Number
As-Tested
(_________)
Drawing(s)/Doc(s)/Std(s)/Spec(s)
HW/SW/Tooling/Planning
Costs/Schedule(s)/Personnel/
Organizations
Files/Records/Data/CAD Model(s)
Associations/Attributes
(FN, NSN, MS, UM, Qty, etc.)
As-Built
(_________)
As-Built Snapshot
CM Reconciliation
CM Status Accounting
Lot Code / Serial Numbering
Deviations / Waivers
As-Maintained
(_________)
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
Field Return / Retrofit
Field Service
CM Reconciliation
Lot Code / Serial No.
CM Status Accounting
As-Built History
As-Disposed
(_________)
Storage, Salvage
To-Become (Recycle)
CM Reconciliation
Lot Code / Serial No.
CM Status Accounting
As-Was/Is History
3
Product Life Cycle Management
Concept
Definition
Disposal
AsDisposed
AsCommitted
AsMaintained
Design
Upgrades
Detailed
Development
AsAuthorized
AsDesigned
AsPlanned
AsDelivered
PreProduction
AsBuilt
Deployment/
Operation
Production
4
Traditional Life Cycle Reconciliation
AsAuthorized
AsCommitted
AsDesigned
AsPlanned
AsBuilt
AsSupported
Authorize
Data
Schedule
Data
Design
Data
Plan
Data
Build
Data
Support
Data
Authorized
Baseline
Baseline
Compares
Scheduled
Baseline
Baseline
Compares
Design
Baseline
Planned
Baseline
Built
Baseline
Supported
Baseline
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
5
Product Life Cycle Management
Concept
Definition
Master Data
Repository/Vault
Disposal
(IDs, Baselines, Changes, CSA, Audits, Etc,)
AsAuthorized
AsCommitted
Configuration
(Audit)
Reconciliation
AsDesigned
AsDisposed
AsMaintained
Design
Upgrades
AsSupported
AsDelivered
Deployment/
Operation
AsBuilt
Detailed
Development
AsPlanned
AsTested
PreProduction
Production
6
Generic Life Cycle Reconciliation
Bills of Material (BOMs)
Configuration Reconciliation Accounting and Audit Process (CRAAP)
AsAuthorized
AsCommitted
AsDesigned
AsPlanned
AsBuilt
AsSupported
Authorize
Data
Schedule
Data
Design
Data
Plan
Data
Build
Data
Support
Data
Configuration
Reconciliation
Accounting and Audit
Process
Authorized
Baseline
Baseline
Compares
Comparison
Reports
Scheduled
Baseline
Baseline
Compares
Design
Baseline
Planned
Baseline
Built
Baseline
Supported
Baseline
Baseline
Compares
Baseline
Compares
Baseline
Compares
Baseline
Compares
Comparison
Reports
Comparison
Reports
Comparison
Reports
Comparison
Reports
7
Product’s Life Cycle Management
(Basic Configuration Reconciliation Process)
As-Authorized As-Committed
(_________)
(_________)
As-Designed
(_________)
As-Planned
_________)
As-Built
(_________)
As-Maintained
(_________)
As-Disposed
(_________)
Marketing Contracts
EBOM
Structure
MBOM
Structure
OBOM
Structure
RBOM
Structure
DBOM
Structure
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
Engineering
Release
Configuration
Audit(s)
Reconciliation
8
Basic Configuration Verification System
Business Values:
• Ensure Released Drawing Defined Parts are in the AsDesigned.
• 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.
9
Life Cycle Generic System Architecture
Manufacturing
As-planned
(Planning)
CAPP
System
As-built
(Orders)
BOM
System
(__________)
(__________)
SFC
System
NCM
System
CA
System
(__________)
(__________)
(__________)
Part Test &
Certification
System
Engineering
Fielding
CAD & PDM
System
CSAR
CLS
System
(__________)
As-designed
(Parts & BOM)
CAE
Schedule
System
CAD-E
System
(________)
(__________)
As-designed
(Electrical)
As-committed
(Schedules)
(__________)
As-supported
(Parts/Locations)
Program
Mgmt.
System
(________)
As-authorized
(Contract
& Changes)
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
Life Cycle Generic System Architecture
Manufacturing
BOM
System
As-built
(Orders)
NCM
System
CA
System
CAPP
System
SFC
System
(__________)
(__________)
(__________)
(__________)
As-planned
(Planning)
(__________)
Part Test &
Certification
System
Engineering
Fielding
CAD & PDM
System
CSAR
CLS
System
(__________)
(__________)
As-designed
(Parts & BOM)
CAD-E
System
(__________)
As-designed
(Electrical)
CAE
Schedule
System
(________)
As-committed
(Schedules)
As-supported
(Parts/Locations)
Program
Mgmt.
System
(________)
As-authorized
(Contract
& Changes)
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
Life Cycle Generic System Architecture
Manufacturing
BOM
System
As-built
(Orders)
NCM
System
CA
System
CAPP
System
SFC
System
(__________)
(__________)
(__________)
(__________)
As-planned
(Planning)
(__________)
Part Test &
Certification
System
Engineering
Data
Exchange
Standards
CAD & PDM
System
CSAR
(__________)
As-designed
(Parts & BOM)
CAD-E
System
(__________)
As-designed
(Electrical)
Fielding
CLS
System
(__________)
CAE
Schedule
System
(________)
As-committed
(Schedules)
As-supported
(Parts/Locations)
Program
Mgmt.
System
(________)
As-authorized
(Contract
& Changes)
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
Life Cycle Generic System Architecture
Functional System(s)
Architectures
Manufacturing
As-planned
(Planning)
CAPP
System
As-built
(Orders)
BOM
System
(__________)
SFC
System
NCM
System
CA
System
(__________)
(__________)
(__________)
(__________)
Part Test &
Certification
System
Engineering
Fielding
CAD & PDM
System
CSAR
CLS
System
(__________)
As-designed
(Parts & BOM)
CAE
Schedule
System
CAD-E
System
(________)
(__________)
(__________)
As-supported
(Parts/Locations)
Program
Mgmt.
System
As-committed
(Schedules)
(________)
As-authorized
(Contract
& Changes)
As-designed
(Electrical)
CSA
Reports
System A
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
System B
System C
Object -2
Object -2
Object -2
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
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
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
Object -5
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -3
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -6
Object -4
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
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
Object -3
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -6
Object -4
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
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
System D
Object -2
Object -3
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -6
Object -4
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
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 -6
Object -5
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Functional Environment
(Program Management / Engineering / Manufacturing / Fielding)
13
Data Object Modeling
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Life Cycle Generic System Architecture
Manufacturing
As-planned
(Planning)
CAPP
System
As-built
(Orders)
BOM
System
(__________)
(__________)
SFC
System
NCM
System
CA
System
(__________)
(__________)
(__________)
Part Test &
Certification
System
Engineering
Fielding
CAD & PDM
System
CSAR
CLS
System
(__________)
As-designed
(Parts & BOM)
CAE
Schedule
System
CAD-E
System
(________)
(__________)
As-designed
(Electrical)
As-committed
(Schedules)
(__________)
As-supported
(Parts/Locations)
Program
Mgmt.
System
(________)
As-authorized
(Contract
& Changes)
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
Objects:
Location / Representation
Media (format)
Storage (located)
Application (used by)
Protocols (exchanged)
Operating System
Database (related)
Meta-data (about)
Characteristics,
Attributes, & Features
One to One
One to Many
Many to One
Many to Many
Drawings
Documents
•Specs/plans/orders
Parts
Software
Changes (Effectivity)
•Request/Orders/events
Etc.
14
Life Cycle Generic System Architecture
Manufacturing
As-planned
(Planning)
CAPP
System
As-built
(Orders)
BOM
System
(__________)
(__________)
SFC
System
NCM
System
CA
System
(__________)
(__________)
(__________)
Part Test &
Certification
System
Engineering
Fielding
CAD & PDM
System
CSAR
CLS
System
(__________)
As-designed
(Parts & BOM)
CAD-E
System
(__________)
As-designed
(Electrical)
CAE
Schedule
System
(________)
As-committed
(Schedules)
Data Object Modeling
(__________)
As-supported
(Parts/Locations)
Program
Mgmt.
System
(________)
As-authorized
(Contract
& Changes)
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
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -2
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
Object -6
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
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
15
Life Cycle Generic System Architecture
Manufacturing
As-planned
(Planning)
CAPP
System
As-built
(Orders)
BOM
System
(__________)
(__________)
SFC
System
NCM
System
CA
System
(__________)
(__________)
Data Object Modeling
(__________)
Part Test &
Certification
System
Engineering
Fielding
CAD & PDM
System
CSAR
CLS
System
(__________)
As-designed
(Parts & BOM)
CAD-E
System
(__________)
As-designed
(Electrical)
CAE
Schedule
System
(________)
As-committed
(Schedules)
(__________)
As-supported
(Parts/Locations)
Program
Mgmt.
System
(________)
As-authorized
(Contract
& Changes)
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
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -2
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
Object -6
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
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
16
Life Cycle Generic System Architecture
Manufacturing
As-planned
(Planning)
CAPP
System
As-built
(Orders)
BOM
System
(__________)
(__________)
SFC
System
NCM
System
CA
System
(__________)
(__________)
(__________)
Part Test &
Certification
System
Engineering
Fielding
CAD & PDM
System
CSAR
CLS
System
(__________)
As-designed
(Parts & BOM)
CAE
Schedule
System
CAD-E
System
(________)
(__________)
As-designed
(Electrical)
Data Object Modeling
As-committed
(Schedules)
Export/Import
(__________)
As-supported
(Parts/Locations)
Program
Mgmt.
System
(________)
As-authorized
(Contract
& Changes)
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
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -2
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
.XLS/.CVS
Object -3
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -4
Object -6
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
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
Files
XML
Files
Standards
Files
Direct
Integrate
17
Data Mapping Strategies
System A
System B
Export/Import
Export/Import
Object -2
Object -2
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
.XLS/.CVS
Files
Verify/Certify
Files
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
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
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
.XLS/.CVS
Object -3
Object -4
Object -5
Mapping
XML
Files
Standards
Files
Direct
Integrate
Mapping
XML
Files
Verify/Certify
Mapping
Verify/Certify
Mapping
Verify/Certify
Standards
Files
Direct
Integrate
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 -3
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -6
Object -5
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
18
Data Mapping Strategies
System A
Export/Import
Mapping
Object -2
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
.XLS/.CVS
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Files
Files
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -6
.XLS/.CVS
Object -2
.XLS/.CVS
Object -3
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Verify/Certify
Files
Object -4
Object -5
System B
Export/Import
Mapping
XML
Files
Verify/Certify
Standards
Files
Verify/Certify
Direct
Integrate
XML
Files
Mapping
Mapping
Verify/Certify
XML
Files
Standards
Files
Direct
Integrate
Standards
Files
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 -3
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -6
Object -5
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Direct
Integrate
19
Data Mapping Strategies
System A
Export/Import
Mapping
Object -2
Object -1
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
.XLS/.CVS
Files
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Files
Costs
Files
Object -1
Object -6
.XLS/.CVS
Object -2
.XLS/.CVS
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Verify/Certify
Object -3
Object -4
Object -5
System B
Export/Import
Mapping
XML
Files
Verify/Certify
Standards
Files
Verify/Certify
XML
Files
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
Mapping
Direct
Integrate
Mapping
Verify/Certify
Standards
Files
Direct
Integrate
XML
Files
Standards
Files
Costs
Costs
Object -4
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Object -6
Object -5
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Identification:
•ID#/Name,/Owner
Attributes:
•Size
•Qty
Relationships:
•To-From
•Up-Down
•Other Objects
Direct
Integrate
Costs
20
Basic Configuration Verification System Concept
GEIA
836
STEP
GEIA
AP 232
836
AsAuthorized
AsCommitted
AsDesigned
AsPlanned
AsBuilt
AsSupported
Authorize
Data
Schedule
Data
Design
Data
Plan
Data
Build
Data
Support
Data
InSync
InSync®: A CM/PDM
Functional Architecture
Business Management
CI
Audits
Contracts
Baseline
Bills of Material
BOM
Identification
Parts
Documents
Change Control
As-Designed
As-Built
As-Planned
As-Maintained
CR
Software
Drawings
CP
CO
Control
Accounting
Integrated Workflow
Vault/Launch
Authorized
Baseline
Baseline
Compares
Comparison
Reports
Scheduled
Baseline
Baseline
Compares
Ad Hoc
Export/Import
ITK
Security
Design
Baseline
Planned
Baseline
Built
Baseline
Supported
Baseline
Baseline
Compares
Baseline
Compares
Baseline
Compares
Baseline
Compares
Comparison
Reports
Comparison
Reports
Comparison
Reports
Comparison
Reports
21
ISS Use of Standards In Life Cycle Supportability
Engineering
Data:
Drawing, Model,
Metrics…
STEP AP 203
/ 232 / pdm
schema
Design
Data/Structure
90021
ERP
Data
Product Structure Data,
Specs and Parameters
165443 ‘
165837 ‘
STEP AP 232*, pdm schema
Supportability
Analysis
IN-SERVICE/
SUPPORT
LSAR/
LMI
ASD
2000M
1388-2B,
00-60
Tech
Pub/ IETM
Data
IPB / IPC/
IPL
Data and
Graphics
Delivered
Data/Structure
Serialized
Part Data:
Maintenance
In-Service
Data/Structure
Initial Product/
Support Definition
Two-Way
collaboration,
reconciliation,
coordination
MANUFACTURING/
PRODUCTION
DESIGN
ENGINEERING
(STEP AP 239)
One-Two -Way Data
Flow
Asset Management
Spares Ordering,
Inventory Mgmt,
Obsolescence
Planning, …
165443 ‘
165837 ‘
‘
Training
Data
STEP AP 232*: Not used in conjunction with Life Cycle Supportability, today,
The Mechanisms & Processes
(Basic Configuration Reconciliation Process)
As-Designed
As-Planned
As-Built
Parts
Defined
Parts
Planned
Parts
Ordered
(Dwgs/PLs)
(IP Plans)
(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
As-Designed Baseline
BOM for Parts & Assemblies
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
2 Sub Assy., PN
1 Component, PN
2 Component, PN
3 Component, PN
IP Plan/Fab Plans
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
Manufacturing Planning
for Parts & Assemblies
2 Sub Assy., PN
1 Component, PN
2 Component, PN
3 Component, PN
Fab. Orders
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
Fabrication Orders
for Parts & Assemblies
23
Validation & Verification Cycle
(Configuration Verification Action Items)
CVAI:
Life Cycle Generic System Architecture
Configuration
Verification
Action Item
Manufacturing
As-planned
(Planning)
As-built
(Orders)
BOM
System
(__________)
CAPP
System
SFC
System
(__________)
(__________)
NCM
System
CA
System
(__________)
(__________)
Part Test &
Certification
System
Engineering
Fielding
CSA
CAD & PDM
System
(InSync)
CLS
System
(__________)
As-designed
(Parts & BOM)
CAE
Schedule
System
CAD-E
System
(________)
(__________)
As-designed
(Electrical)
As-committed
(Schedules)
Plans
Orders
(__________)
As-supported
(Parts/Locations)
Program
Mgmt.
System
(________)
As-authorized
(Contract
& Changes)
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
Parts List
Final
Reconciled
Reports
CVAI:
Configuration
Verification
Action Item
24
Product’s Life Cycle Management
(Basic Confirmation Process)
As-Authorized
(_________)
As-Committed
(_________)
As-Designed
(_________)
As-Planned
(_________)
Engineering Design
(Perform engineering design)
In Work
Completed
Approved
Released
Commitment Scheduling
(Commitment to schedule)
In Work
Completed
Approved
Released
Authoring Engineering
(Authorizing parts design)
In Work
Completed
Approved
Released
CSA Reports
1
2
4
5
3
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?
As-Built
(_________)
Installation Plan (IP)
(Planning for final assembly)
In Work
Completed
Approved
Inspected
Delivered
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
All’s
Right
Not Right
Waivers
Deviations
25
DD Form 250
Product’s Life Cycle Management
(Basic Reconciliation Process)
As-Authorized As-Committed
(_________)
(_________)
As-Designed
(_________)
As-Planned
(_________)
As-Built
(_________)
As-Maintained
(_________)
As-Disposed
(_________)
Marketing Contracts
EBOM
Structure
MBOM
Structure
OBOM
Structure
RBOM
Structure
DBOM
Structure
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
Engineering
Release
Configuration
Reconciliation
(InSync)
DD250
26
STEP Data Exchange
(The Back Story – SI/BCA)
Enterprise
Supplier
27
Type Design Data/Process Flow
Type Design Data
PDM Output
STEP
Files
PS
Files
PKG
Files
ERP
or other
Systems
Other
Files
*
InSync/SI Processing
Translated
Files
* Interface / Integration with
other data systems may be
implemented as a “push or
pull” transaction process or
as a “web service.”
Vista
Reporting
Imported
Files
InSync
Generated
XML* Files
Formatted
PDF* Files
InSync
Screens
OS Vaults
- Reports (XML, PDF)
- STP
- PS
- PKG
Browser View
- “Generated XML”
- “Formatted PDF”
- Formatted HTML
- Multi-Level
- XML File Compare
Non-Vaulted “Work”
28
ISS’s Integrated Support System
Supplier Integration (SI/BCA)
Enterprise
Engineering / Procurement
Data Collection and
Outsourcing System
Product
Information
(PDM System)
Supplier
www
Supplier Integration
Software
View Product
Unzip and/or Information,
Email Notification decrypt TDP and related files
of TDP Ready
Content
Collection
Supplier
PDM System
PDM
Database
Vault
FTP/HTTP
Geometry
Geometry
Documents
•Generate
STEP File
•Zip and/or
encrypt TDP
Email Notification
of TDP Received
TDP Archive
Documents
29
As-Authorized
(ECCM)
Product’s Life Cycle Management
Cost Estimating
Capacity Planning
& Assessment
Specifications
As-Committed
(DM2000)
(Boeing MMA P-8A)
Master Schedule
Work Breakdown Structure
Budgets
Sales Orders
Cost Accounts
Effectivity
As-Designed
(DCAC)
Baseline Release
Document Control
Product Definition
EBOM
Bill of Routings
Effectivity (Eng.)
MBOM
Effectivity (Manf.)
Bill of Routings/Resources
Master Production Schedule
Proposed Capacity Planning
MRP/CRP/Procurement
Work Order Release
As-Planned
(MES)
As-Built
(MES)
As-Tested
(ALRMS)
As-Delivered
(InSync)
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 Snapshot
CM Reconciliation
CM Status Accounting
Lot Code / Serial Numbering
Deviations / Waivers
As-Maintained
(OOMA)
Field Return / Retrofit
Field Service
CM Reconciliation
Lot Code / Serial No.
CM Status Accounting
As-Built History
As-Disposed
(????)
Storage, Salvage
To-Become (Recycle)
CM Reconciliation
Lot Code / Serial No.
CM Status Accounting
As-Was/Is History
30
Product’s Life Cycle Management
(Boeing MMA P-8A Reconciliation Process)
As-Authorized As-Committed
(ECCM)
(DM2000)
As-Designed
(DCAC)
As-Planned
(MES)
As-Built
(MES)
As-Maintained
(OOMA)
As-Disposed
(????)
Marketing Contracts
EBOM
Structure
MBOM
Structure
OBOM
Structure
RBOM
Structure
DBOM
Structure
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
Engineering
Release
Configuration
Reconciliation
(InSync)
31
Life Cycle Baseline Reconciliation
A 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.
32
Life Cycle Baseline Reconciliation
A 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.
33