Product Life Cycle Support PLCS The Information Backbone

The PLCS Initiative l l The Business Context Overview of PLCS v Vision v

Setting the Business Context Business Drivers l l l PLCS Inc. (c) 2002 Reduced Cost of Ownership v Users of products are seeking improved availability, reliability, maintainability and lower cost of ownership. Sustainable Business Growth v Companies are seeking to make money through the life cycle support of their products to improve profits, improve quality and be more competitive Protect investment in product data v Users of information systems want more open platforms to reduce IT costs and ensure longevity in use of information 3

Setting the Business Context Digital Product Data has become a valuable business asset l l l New Business Opportunities v Leading manufacturers are ‘going downstream’ to generate additional revenue from supply of lifecycle support services Product Lifecycle Management v Increased focus on managing information throughout the product lifecycle – Concept to Disposal v Businesses are focusing on total cost of ownership, as product life cycles increase and products become more expensive to maintain Extended Enterprise v Increasingly complex business networks v Knowledge workers need to share information in real time v Not practical to adopt common system mandate v Internet technology has changed the way of working PLCS Inc. (c) 2002 4

Setting the Business Context Requirements of the Extended Enterprise l Extended enterprises are formed to meet project specific requirements v v v v Partners may differ from project to project Different partners are likely use different systems Companies want a common way to exchange digital product data Configuration Management becomes a key enabler for information exchange Suppliers want a unified approach from Prime Contractors and OEMs International collaboration demands product data exchange and sharing across many organizations Worldwide operation demands a worldwide standard PLCS Inc. (c) 2002 Program Manager Marketing Product Team 2 Engineering Sales Product Team 1 Mfg. Support FIREWALL Project X Project Z Project Y Supplier A Partner Supplier B Supplier C 5

Setting the Business Context Configuration Management is a major challenge v v v Multiple product views Major problems keeping information to operate and maintain a product aligned to actual product configuration through life Major problems linking support information to product information Software applications use proprietary data standards and are often difficult to integrate Inconsistent data definitions PLCS Inc. (c) 2002 Customer Requirements Concept and Assessment Demonstration and Manufacture In Service and Disposal As Designed Configuration As Manufactured Configuration As Planned Configuration As Maintained Configuration Feedback 6

Setting the Business Context Limitations with current standards (as at November 1999) Current standards are specialized and focus on either: v a piece of a business transaction or process, e. g. Order, Part or v presentation of specific content, I. e. Aircraft maintenance manual Example: Transaction oriented v Defence: AECMA 2000 M v Commercial: ATA Spec 2000, EDIFACT, ANSI X. 12 Example: Content oriented v Manufacturing and process centric: l v ISO 9000, STEP Operations and maintenance centric: l l PLCS Inc. (c) 2002 Defence: MIL-STD-1388, Def-Stan 00 -60, AECMA S 1000 D Commercial: ATA Spec 2000, 2100 7

Setting the Business Context Available capabilities - ISO STEP is an established international standard for the exchange, integration and sharing of product data v v Geometry Product structure Manufacturing interfaces Drawings STEP Release 2 covers new functions: v v v Finite Element Analysis Printed Circuit Assemblies Wiring looms Mechanical Design Construction industry XML for the Web PLCS Inc. (c) 2002 8

Setting the Business Context STEP in service Product Data Management exchange for Eurofighter Supplier interface for Lockheed Martin Configuration Management and Digital Pre-Assembly exchange at Boeing - RR, GE and P&W Interface between A 380 and its engines IBM's global e-procurement design data exchange Solid model exchange for Electric Boat US and UK Navy RAMP programmes Japanese SCADEC programme for the construction industry Ford CAD/PDM data integration NASA Engineering information PLCS Inc. (c) 2002 9

Overview Imagine the opportunities if … v v v PLCS Inc. (c) 2002 Configuration management information was always accurate, up to date and immediately accessible Maintenance information was precisely tailored to the work to be done Spares and inventory costs were minimized through vendor involvement in an integrated supply chain In-service feedback was accurate, meaningful and readily available to product designers and support managers Change was easy to manage 10

Overview The Key Business Problem How to keep the information needed to operate and maintain a product aligned with the changing product over its life cycle? Product in Focus Product Definition Information Transportation Consumables Maintenance Schedules Feedback Tools Spares Test Equipment Support Facilities PLCS Inc. (c) 2002 Software Training Storage Requirements 11

Product Life Cycle Support (PLCS) Membership Finnish Defence Forces PLCS Inc. (c) 2002 12

Product Life Cycle Support (PLCS) The Initiative A joint industry and government initiative to accelerate development of new standards for product support information An international project to produce an approved ISO standard within 4 years; commenced November 1999 PLCS will ensure support information is aligned to the evolving product definition over the entire life cycle PLCS extends ISO 10303 STEP - the STandard for Exchange of Product model data PLCS Inc. (c) 2002 13

Product Life Cycle Support (PLCS) Goals l l PLCS Standard: v Improve product availability v Reduce operating, support and maintenance costs v Improve quality and accessibility of Product Life Cycle Support information PLCS, Inc: v Accelerate technical development of the ISO standards v Encourage early implementation commercial software vendors v Encourage early industry participation in the development and testing of the standard PLCS Inc. (c) 2002 14

Product Life Cycle Support (PLCS) The Vision Change Directives Scope of STEP Today Product Structure Product Representations Product Performance Life Shared Cycle Data Support Performance and d e Fe ract Ext Query Re sp on d Support Environment Failure Analysis Standard Commercial Transactions Maintain/Dispose Use Derived Disposable Data Maintenance Analysis Task Resource Data Support and Operational Feedback PLCS Inc. (c) 2002 15

Product Life Cycle Support (PLCS) Extended Enterprise enabled by Internet technology Customers Tier 1 Tier 2 Partners Suppliers Extended Enterprise of OEM’s, Customer, Partners and Suppliers Product Lifecycle Management (PLM) Enterprise Integration through dedicated networks Enterprise Dept Extended Enterprise Integration Internet-based architecture and federated data models make possible implementations involving thousands of users across many sites PLCS Domain specific information systems (e. g. CAD, MRPII, Planning) Define and implement the support solution, maintain the product configuration Concept PLCS Inc. (c) 2002 Assessment Demonstration Feedback Manufacture Operational Product Life Cycle In-Service Disposal 16

Product Life Cycle Support (PLCS) Extended Enterprise – Importance of PLCS Customers Tier 1 Tier 2 Partners Suppliers Enterprise 5 – 10 years Typically 25 – 50 years Operational Life PLCS Domain Design for Supportability In Service Support and Operational Feedback Dept Extended Enterprise Integration When set against a timeline – the picture looks more like this! C PLCS Inc. (c) 2002 A D M In-Service Product Life Cycle D 17

Product Life Cycle Support (PLCS) Typically complex systems environment – point to point integration Operational Objectives CM Data Functional Requirements 5. Requirements Management 12 Depot Maint Mgmt 9. Product Data 14 Defects & Failure Reporting 4. Maintenance Management Defects and Failures CM Data Maintenance Mgt Data 1. Support Data 7. FMECA LSA Data Support Data 3. Stock Mgmt Design Data FMECA Results Support Data LSA Data 6. LSAR 13. Distribution, Transportation 8. CAD 11 Parts Supplier Database Distribution Data 2. Maintainers Viewing Tool 10 IETM Part Data LSA Data Tech Pubs Data Support Data PLCS Inc. (c) 2002 18

Product Life Cycle Support (PLCS) PLCS will enable cost effective information exchanges 1. Support Data Support data 2. Maintainers Viewing Tool Maintenance Mgmt Data 3. Stock Mgmt Part data 4. Maintenance Management 5. Requirements Management 6. LSAR 7. FMECA Maintenance Mgmt Data Functional Req. LSA Data FMECA Results PLCS compliant information exchanges Design Data Design data Tech Pub Data Parts Data Maintenance Mgt Data 8. CAD 9. Product Data 10 IETM 11 Parts Supplier Database 12 Depot Maint Mgmt Distribution Data 13. Distribution, Transportation Defects & Failures 14 Defects & Failure Reporting In future, support system integration will be easier to implement PLCS Inc. (c) 2002 19

Product Life Cycle Support (PLCS) Example: PLCS for Mo. D and Defence Contractors Multiple Contracts with UK Defence Contractors Etc … Eurofighter Astute LPD(R) Etc … Trent 800 Astute RB 199 Etc … Bowman EH 101 Merlin WAH-64 Apache Project specific ‘Point to Point’ interfaces to be developed and maintained ISO 10303 STEP, AP 239 (PLCS) Support Contractor CRISP LITS MRC DR 4 OASIS Etc … Mo. D (PE) Databases for Product Support PLCS Inc. (c) 2002 20

Product Life Cycle Support (PLCS) Capabilities enabled by PLCS – ISO 10303 AP 239 Product Description Capability to define product requirements and configuration, including relationships between parts and assemblies in multiple product structures (as-designed, as-built, as-maintained) Work Management AP 239 Capabilities Capability to request, define, justify, approve, schedule and capture feedback on work (activities) and related resources. Property, State and Behaviour Capability that describes and captures feedback on product properties, operating states, behaviour and usage Support Solution and Environment Capability to define the necessary support for a given set of products in a specified environment and to define support opportunity, facilities, personnel and organizations PLCS Inc. (c) 2002 21

PLCS, Inc deliverables l l l l A new vision for life cycle support A terminology dictionary An illustrative process model (AAM) A large data model, standardised through ISO (AP 239) A set of data exchange standards (constrained subsets of AP 239) Improved capability to tailor or extend the data model or exchange sets using external reference data (e. g. existing standards) A standardised interface to one (or more) transaction standards/systems. . (eb. XML, Exostar, Covisint, 2000 M)? ? PLCS Inc. (c) 2002 22

PLCS: relationship to other standards “If we reach high, we do so only because

PLCS: Inputs to AP 239 IDEF 1 -X EXPRESS based POSC/ Caesar Mil Spec 2549 Relational Mil Spec 1388 Def Stan 00 -60 Logical RCM IT AP 208 TC 184/SC 4 WG 3/T 8 PWI FMV CTG 2 PLCS Initiative STEP NCDM AP 203 AECMA 1000 D 2000 M PLCS Inc. (c) 2002 SGML EDIFACT ATA Effectivity PDM Schema OMG AP 233 PLIB ISO 15288 24

PLCS development principles l l Create a durable data model standard that can be extended/adapted over time without re-modelling or re-ballot v Identify key generic concepts and relationships v Extend/adapt by classification and reference data libraries Build on existing standards: v PDM Schema and the STEP Modular Architecture Accommodate values that change over time v Support multiple values for the same property v Support back-tracking & audit Maintain unambiguous histories v Product Structure, State, Activity Aim: to enable optimisation of support through life PLCS Inc. (c) 2002 25

Product Life Cycle Support (PLCS) Main activity areas Business NATO CALS PP 1 and TLBM Limited scope Fixed boundaries ISO Prelim Work Item Hard to Change Poor cost awareness Process Fragmented “As is” Scenarios Duplicated Launch PLCS Industry Testing ISO Exchange Requirements Islands of IT PLCS Inc. (c) 2002 Test and Testand Integrate Process Coherent Simplified Open IT independent Common language Inconsistent Terminology Massive duplication Lean and focused Data Format dependent Agile Usage Guides Published Submit to standards Develop Activity Models Organization Specific Information Requirements Locked by IT Business New Automate Life cycle. Integrated business Current Processes Open and Flexible Better , Cheaper Information Develop Single Integrated Data Model based on Express Format “ as required” Reduced data set Portable data 26

Product Life Cycle Support – Activity Model l l An IDEF 0 model with 157 activities (boxes) and 220 information exchanges (arrows) Purpose: v 1999/00: to define the scope of PLCS activity v 2001/2: to expose data requirements v 2003: (current role) to represent the activities and information flows supported by Application Protocol 239 Future use v Communication the PLCS Vision v Charting information exchange boundaries between organizations v Identifying and illustrating DEXs Available as. bp 1, . idl, html, xml or pdf. PLCS Inc. (c) 2002 27

AP 239 Product Life Cycle Support – Activity Model Concepts l l The PIF – Product in focus: “what products do you want me to support? ” A PIF will be supported by one or more support solution definitions: how to support these products Each support solution definition is based on v A deployment environment v A support solution requirement The deployment environment defines: v v v l l A product group – a sub-set of the PIF needing tailored support A usage pattern A definition of the expected support organizations, locations, facilities and resources A support requirement is a structured requirement statement including performance metrics and targets for support performance Support metrics are required to enable: v Continuous optimization of support solution definition through life, based on feedback from use v Specification of an assessment strategy (what data to collect and how) A PIF scope may include many deployment environments and hence many support solution definitions These will be derived from a common set of task and resources descriptions PLCS Inc. (c) 2002 28

AP 239 Product Life Cycle Support – Activity Model Concepts l (Each) Support solution definition includes: v v v Tasks specifications and task logic (e. g. diagnostic procedures) Relationship of tasks to the product configuration (including “effectivity” /“applicability” to all product versions) Specification of task trigger conditions based on: l l l State of individual product (as identified by UID) Usage of individual product Prior task or other events Identification and quantification of resources needed for each task, including a resource consumption model Task specifications may: v point to an existing document v point to an SGML document (e. g. an AECMA 1000 Module) v be fully “machine readable” Task specifications may be linked to resources v Required resources v Resource items (products, people, facilities etc) v l l PLCS Inc. (c) 2002 29

APSI and Related Information l l l Assured Product Support Information comprises v PIF scope v Description of relevant deployment environments v Support Solution requirements v Product Definition Information (at least that needed for support) v Support Solution Definitions This full data set is subject to configuration change management (CM = IM? ) Related Information may comprise v Test results v Manufacturing records v History of collected feedback on: l l l PLCS Inc. (c) 2002 Individual product configuration over time Product state and properties over time Activities, including: u Product use u Work done u Resource use 30

AP 239 – The information model l Main concepts v v A large, generic data model Defined in EXPRESS 144 Modules, ~500 Entities, ~1200 attributes Can be extended using classification based on Reference Data, stored in an external Library (RDL) PLCS Inc. (c) 2002 31

PLCS is a Modular STEP AP l l Modules allow common definitions of product data to be reused Extensive re-use of PDM modules v To bring compatibility with design/PDM tools v Basic work order/work request process common to change in design Extended to provide v Life cycle CM v Full work management capability v Condition based task triggers All modules feature two levels of model, with mapping v User view of information v Link to common concepts across all of STEP v Full harmonization achieved where needed by common modules l l PLCS Inc. (c) 2002 With CAD/PDM via PDM Modules With Requirement Tools 32

PLCS enables requirement management through life l AP 239 will share common modules with AP 233 – Systems Engineering: v v v Text-based Requirements Multiple, related breakdowns, including “System” concept Interfaces l Aim is to support requirements trace from pre-design through to maintenance and disposal l UK MOD has funded demonstration project for this capability with BAE Systems PLCS Inc. (c) 2002 33

PLCS provides full history to support optimization and change over time l In the PLCS models it is assumed that any value supplied v E. g. a property such as mean time to perform a task may have multiple values over time where each value could have been: v v v l l supplied at different times by different people subject to approval subject to security classification Have an associated justification/probability/risk This requirement has been recognised from the start of modelling Improve CM of support information by use of “single source” Assured Product and Support Information (APSI) PLCS Inc. (c) 2002 34

Product Life Cycle Support (PLCS) Life Cycle Configuration Management is a major challenge v v v Need to distinguish and compare data from different life cycle phases “Class” & Individual Need multiple (and different) views at each stage Product structures provide “Life cycle core” Used to navigate and control applicability of support solution and of feedback data Core used to manage configuration change PLCS Inc. (c) 2002 Customer Requirements Concept and Assessment Demonstration and Manufacture System Requirement Configuration In Service and Disposal As Designed Configuration As Manufactured Configuration As Maintained Configuration As Planned Configuration Feedback 35

PLCS Core: Life Cycle PDM Capability (1) l PDM Schema already supports automated exchange of v v l Part id and properties Associated documents and files (incl. CAx) Product structure Product (and document) approval status This is already in production use by v v v US Aerospace and Defence prime contractors (via AP 203) German/Swedish/French Automotive sector (via AP 214 cc 6) Eurofighter Typhoon PDM partners . . A powerful and proven capability for Configuration Management of a complex product design PLCS Inc. (c) 2002 36

PLCS Core: Life Cycle PDM Capability (2) l AP 239 has added: v Classification, supported by Reference data libraries v Product_as_individual (planned and realized) v Product breakdowns (system, physical, functional, zonal and hybrid) v Text based requirements (from AP 233) v Extended property capability v Interfaces v Attachment_slot v Message, Envelope (similar to ENGDAT) v Information Rights … A powerful capability for Life Cycle Configuration Management of Assured Product and Support Information PLCS Inc. (c) 2002 37

Work Management modules Work Management Work_record Product Definition Information Product State & Usage Product_ as_realized Activity_ as_realized Support_ Provider Resource_ as_realized Resource_ Management PLCS Inc. (c) 2002 Work_request + Work_order + Work_ Definition Resourced_ Activity Resourced Task Spec Resource_ Item Required_ Resource Work Order Work Request Activity Method Task_ Specification Scheme 38

PLCS uses Reference data l What is it? v v v l Values for attributes that are agreed and defined in advance of use E. g types of task, grades of people, types of products, types of document E. g. Nato Stock Number – classifications Why use it? v v Because it improves reliability and effectiveness of exchange Because it can be extended: l l v l To add to the scope of the standard To provide project specific capabilities Because it supports re-use of values from existing standards Idea proven in Oil and Gas industry PLCS Inc. (c) 2002 39

AP 239 – Data Exchange Sets l DEXs are: v v l l Subsets of the AP 239 Information model Selected to meet a specific data exchange need Relevant modules Supported by Usage Guidance, population rules and Reference data DEXs may be standardized at any level (work group, company, project, organization, national, international) DEXs enable v v Consistent implementation of AP 239 Data consolidation through time l l PLCS Inc. (c) 2002 Same DEX Different DEX 40

Current DEX developments l l l l Product as individual Product breakdown for support Maintenance plan Task set Operational feedback Fault states Work Package Definition Work Package Reporting PLCS Inc. (c) 2002 41

Current situation (December 2004) l l l l Activity Model published (available to all) 1750 requirements allocated to ~130 modules Module development completed: v PDM Modules under publication as ISO Technical Specifications v PLCS modules under publication as ISO Technical Specifications v AP 239 information model accepted as ISO Technical Specification Draft International Standard ballot for Application Protocol successfully completed 13 September, with unanimous acceptance Publication by ISO January 2005 - hyperlinked CD-ROM product to follow Development of first eight Data Exchange Sets nearing completion Implementation activities are gaining momentum in Norway, Sweden, Finland, UK and US PLCS Inc. (c) 2002 42

Product Life Cycle Support (PLCS) Unique Value Proposition l l l International Standard for product support information - based on the ISO 10303 standard for product data (STEP) Complete product lifecycle – from concept to disposal Single source of assured product and support information Data independence - Processes, Systems, Format Interoperability across enterprises and systems through: v v v l Standardization of semantics for product support Integrated suite of data models for data exchange and information sharing Utilization of ISO STEP standards, methods and tools Extensibility and tailoring through the use of Reference data libraries Customers, Contractors and Software Vendors working together to develop and implement a neutral data exchange standard for product support PLCS Inc. (c) 2002 43

PLCS: relationship to other standards l Looking back v l Current position v v v l AP 239 acknowledges a debt to all listed inputs AP 239 can use the data generated by current ILS standards AP 239 implementations will need resource to cleanse and enhance data generated by current standards (it’s not very good!) AP 239 enables, but does not force, much higher levels of data integration The future v v AP 239, and other factors, will drive change in most current ILS standards (e. g. DEF STAN 00 -60) The pace and direction of this change depends on market factors PLCS Inc. (c) 2002 44

Exploiting the benefits PLCS Inc. (c) 2002

Implementing PLCS l PLCS (a standardized information model) can be implemented in 3 ways: v As an integration architecture for a new product life cycle support management system (c. f. PIPPIN, EPISTLE, ISO 15926, NPDM) l v As a mapping between systems (APIs) (LITS to RR CM system) v As a standardized data exchange capability (plus compliant software) STEP technology supports all three and is language independent (Cobol, Java, C++, XML) l STEP is in production use, with proven benefits, for CAD, CAM and PDM systems l STEP has mainly been used to standardize data exchange l PLCS can also be used to promote further standardization via Reference Data (e. g. fault codes, skill grades) PLCS Inc. (c) 2002 46

Implementing PLCS on a new program l Use PLCS/STEP formats to capture design information as it is generated in a way that support engineers can re-use l l Develop Support Information in PLCS format v Less duplication – single assured source v Easy to present/deliver in any required form (e. g. Spec 1000 D, XML, PDF) v Improved management of effectivity/applicability Deliver a PLCS enabled maintenance management capability v Automatic upload from single assured source v The right data is available for maintainers (can be tailored to serialized item) v Improved feedback collection (report in the language used to specify, auto-complete) v Better in-service metrics v Faster learning PLCS Inc. (c) 2002 47

Implementing PLCS for an existing program l Identify current information shortfalls or problems l Use the PLCS Activity Model to identify relevant data exchanges (arrows) that cross IT system boundaries, within and beyond your company l Implement appropriate DEXs, where there is a valid business case l Consider adopting PLCS for new data generated (changes, modifications, upgrades etc. ) v N. B. Most current formats can readily be delivered from a PLCS integrated source. The latter is cheaper to build and easier to maintain. l What NOT to do – immediately abandon current systems (and standards) that meet business needs PLCS Inc. (c) 2002 48

Norwegian pilot - New frigate programme PLCS Inc. (c) 2002 49

UK MOD demonstrator Scenario: l Ship damaged by fire l Compartment containing mixture of equipment due for maintenance, due for upgrade, or no longer available l Consolidation of planned and unplanned maintenance requirements into work programme l PLCS to link five legacy support applications PLCS Inc. (c) 2002 50

Swedish pilot l The purpose of this pilot is to verify the possibility to use the PLCS data exchange sets to transmit information regarding assembly breakdowns, spares recommendations and maintenance plans for the Gripen Fighter aircraft according to the OASIS PLCS defined Data Exchange Sets (DEX 001 and DEX 005). The result of the study will be reported back to the OASIS community. v The study is a joint effort by a number of FMV projects and industry, funded by FMV. It will be carried out between mid September 2004 and January 2005. PLCS Inc. (c) 2002 51

Standards development and maintenance l l l ISO TC 184/SC 4 is responsible for “Industrial data” Working Group 3 is responsible for “Product modelling” Team 8 is responsible for “Product life cycle” Team 8 will retain responsibility for AP 239 Resources committed through national standards bodies Also provides clear liaison to Systems Engineering development PLCS Inc. (c) 2002 53

DEX Development and publication l l l l Open-source infrastructure developed Seeking more open participation v lower cost entry Need enhanced links with other information standards development Selected OASIS consortium as parent Formed OASIS Technical Committee for “Product Life Cycle Support” Open to all OASIS members Operating under OASIS rules PLCS Inc. (c) 2002 54

The OASIS Technical Committee l The purpose of the OASIS Product Life Cycle Support TC is to: v v v establish structured data exchange and sharing capabilities for use by industry to support complex engineered assets throughout their total life cycle define, develop, test and publish OASIS Product Life Cycle Support DEX’s based upon ISO 10303 (STEP) Application Protocol 239 (Product Life Cycle Support). liaise with ISO TC 184/SC 4 coordinate with relevant OASIS Technical Committees promote the use of OASIS Product Life Cycle Support DEX’s across industries and governments world-wide PLCS Inc. (c) 2002 55

The Challenge l The PLCS consortium has delivered the basic standard, and an infrastructure for exploiting it, and has closed down l Join in an early implementation Join the OASIS Technical Committee to participate in DEX development l v l See www. oasis-open. org and select PLCS Contribute to further developments in ISO through your national standards body PLCS Inc. (c) 2002 56