PLM for the US Army

Dr. Raj IyerTeam Lead, PLM Technologies

US Army Tank Automotive RDE Center, Warren, MI

Presented at the 7th NASA-ESA Workshop on Product Data Exchange (PDE 2005)

April 22, 2005

April 22, 2005 PDE2005 2

• Combat Vehicles • Tactical Vehicles• Trailers • Construction Equipment• Materiel Handling Equipment • Tactical Bridges• Fuel & Water Dist Equipment • Sets, Kits & Outfits• Chemical Defense Equipment • Shop Equipment• Howitzers • Large Caliber Guns• Mortars • Rifles• Machine Guns • Ammunition• Aircraft Armaments • Demolitions & Explosives• Rail • Watercraft• Fuel & Lubricant Products • Non-Tactical Vehicles

Plus Technology Development for the Objective Force

Capital Value of TACOM Equipment

$81.7B141 Allied

Countries own TACOM Equipment

All ArmyParent UICs ContainTACOM Supported

Equip

2993 Fielded Systems Supported

> 26,000 Components

The Army’s Lead Systems IntegratorThe Army’s Lead Systems IntegratorThe Army’s Lead Systems IntegratorThe Army’s Lead Systems Integrator

Systems Supporting Army ReadinessSystems Supporting Army Readiness

SUPPORTSUPPORTSUPPORTSUPPORTPRODUCT LINESPRODUCT LINESPRODUCT LINESPRODUCT LINES

MAGNITUDEMAGNITUDEMAGNITUDEMAGNITUDE

April 22, 2005 PDE2005 3

Driving Factors• Product data is distributed among RDECs, PMs, LCMCs and

OEMs• Product data formats and systems to manage product data are

not standardized – CAD and PDM interoperability issues• Data exchange and collaboration among organizations is

inefficient and time consuming• Fundamental requirement towards a true Army Product Lifecycle

Management (PLM) strategy (SALE)• Need for integrated product data throughout the product’s

lifecycle spanning both engineering and logistics– Conceptual models, 2D drawings, 3D solid models, modeling &

simulation data, analysis models, test data, repair & maintenance history, IETMs, assembly instructions

• Need for a single set of logically unified product data

IOCBAConcept

RefinementSystem Development

& DemonstrationProduction &Deployment

Systems Acquisition

Operations &Support

C

Sustainment

FRP DecisionReview

FOC

LRIP/IOT&EDesign

ReadinessReview

TechnologyDevelopment

(ProgramInitiation)

ConceptDecision

Pre-Systems Acquisition

IOCBAConcept

RefinementSystem Development

& DemonstrationProduction &Deployment

Systems Acquisition

Operations &Support

C

Sustainment

FRP DecisionReview

FOC

LRIP/IOT&EDesign

ReadinessReview

TechnologyDevelopment

(ProgramInitiation)

ConceptDecision

Pre-Systems Acquisition

April 22, 2005 PDE2005 4

Challenges

• Heterogeneous systems and formats for product data

• Extended lifecycle• Legacy data• Systems of systems integration• Spiral development• Performance Based Logistics (PBL)• Contractor Logistics Support (CLS)• Parts obsolescence• Disposal issues

April 22, 2005 PDE2005 5

Standards vs. Point-to-point Solutions

SAP

Teamcenter

MatrixOne

CMStat

Enovia

Windchill

SAP

Teamcenter

MatrixOne

CMStat

Enovia

Windchill

April 22, 2005 PDE2005 6

The Need for Standards

• No guarantee that any of these commercial systems will last as long as the Army’s product lines

• Version independence and upward compatibility• Variety of commercial middleware solutions are

available– Point to point solutions– Expensive to maintain and upgrade

• DoD mandate for open architecture standards-based systems leveraging best commercial practices

April 22, 2005 PDE2005 7

The Solution

• Use of international standards ISO 10303 – also known as STEP PDM Schema

• STEP is a neutral format not just for 2D/3D product data but also for PDM interoperability

• Specific STEP Application Protocols are already widely used in private industry

• STEP is well supported by most of the major PDM/ CAD vendors – PTC, SAP, UGS, MatrixOne, Dassault

• STEP is starting to be standardized for 3D solid models at the DoD (Navy and Air Force have mandated it already)

• Enormous potential for long term retention and archival of product data

STEP has the potential to save $928 million (2001$) per year by reducing interoperability problems in the automotive, aerospace, and shipbuilding industries alone

April 22, 2005 PDE2005 8

Architecture for the TACOM Lifecycle Management Command

STEP – STandard for Exchange of Product dataACMS – Automated Configuration Management SystemACE – Advanced Collaborative EnvironmentPLM+ - Product Lifecycle Management PlusSALE – Single Army Logistics Enterprise

Soldier & Ground Systems Collaborative

Gateway(ACMS + ACE)

STEP Standards

Program Executive Offices

OEMs

TACOMGSIE

DLA (BSM)

TARDEC

FCS - ACE

Interface to SALE

April 22, 2005 PDE2005 9

Vision

• Federated system of systems approach to product data management

• Web-based access• Product data on demand• Product-centric data management• Single access and control point• Improved real-time data collaboration• Implement open data standards and best practices• Manage heterogeneous data formats• Automate CM/DM functions with workflows• Manage product structures/ BOMs• Maintain “as-designed”, “as-built”, “as-maintained” BOMs• Manage serialized parts• Access OEM controlled product data• Integration to ERP and logistics systems

April 22, 2005 PDE2005 10

STEPPart 21/28 File

STEP AP214 Translator

for Teamcenter

EPMWindchill

Connector

Automatically poll source for

changes to master data

Updated product data

available

Automatically update product data at target or

provide notification to approved users

AutomaticImport

AutomaticExport

User searches for part using

ACMS

Federation Windchill Adapter

Federation Teamcenter Adapter

Search for part inside

Teamcenter

Data Exchange Workflow

April 22, 2005 PDE2005 11

STEP for the DoD Acquisition Cycle

AP 233 – Systems Engineering Data Representation

AP

201 – Explicit drafting

AP

202 – Associative drafting

AP

203 – Configuration controlled design

AP

207 – Sheet m

etal die planning & design

AP

214 – Autom

otive mechanical design processes

Design Analysis

AP

209 – Com

posite & m

etal structural analysisA

P 237 – C

omputational F

luid Dynam

ics

ManufacturingA

P 223 – D

esign & m

anufacturing of cast partsA

P 224 – M

achining features for process planningA

P 238 – C

omputer num

erical controllersA

P 240 – P

rocess plans for machined parts

AP

219 – Dim

ensional inspection for parts

Data Management

AP

214 cc6 – PD

M S

chema

AP

232 – Technical data packaging

AP

239 – Product lifecycle support

April 22, 2005 PDE2005 12

STEP Data Management APs

• STEP AP 214 CC6 – PDM Schema

• STEP AP 232 – Technical Data Packaging

• STEP AP 239 – Product Lifecycle Support (PLCS)

April 22, 2005 PDE2005 13

PDM Schema

Life-cycle

Systems Engineering

(AP233)

Design(AP214)

AP203

Life-cycleSupport(AP239)

Analysis(AP209)

STEP-PDMSCHEMA

Supply chain(AP232)

April 22, 2005 PDE2005 14

product

product_definition_formation

applied_document_reference

product_definition_with_associated_

documents

role_association

object_role

product_definition_context

document_file

document_representation_type

product_related_product_category

document_type

property_definition

identification_role

external_source

applied_external_identification_

assignment

property_definition_representation

representation

descriptive_representation_itemname = ‘data format’description = ‘CADDS5’ (InfoFile_1)

name = ‘document format’

name = ‘document property’description = $

id = ‘ms21050-07028’ (InfoFile_2) name = ‘’description = $name = ‘’description = ‘’

name = ‘digital’

name = ‘common location ’description = $

assigned_id = ‘’

product_data_type = ‘’

source = ‘’

name = ‘mandatory’description = $

id = ‘ms21050-07028_19980820174415_A001’(InfoFile_2+8+9+6+3) description = $

id = ‘ms21050-07028’ (InfoFile_2) name = $description = $

id = ‘_A001’ (InfoFile_6 +3)description = $

name = ‘digital document definition’life_cycle_stage = ‘’

name = ‘document’description = $

source_id = ‘BES’ (InfoFile_5)

shape_definition_representation

product_definition_

shapeproduct_definition

product_definition_context

product_related_product_categoryname = ‘part’description = $

id = ‘ms21050-07028’(InfoFile_2) name = ‘/NULL’(InfoFile_7)description = $

id = ‘_A001’ (InfoFile_6+3)description = $

id = ‘ms21050-07028 _A001’(InfoFile_2+6+3) description = $

application_context

name = ‘part definition’life_cycle_stage = ‘design’

application = ‘digital mock-up’

name = ‘’description = $

name = ‘’

property_definition

axis2_placement_3dname = ‘’

property_definition_representation

shape_representation

name = ‘external definition’description = $

S1 : part and associated CAD representations- Instanciated figure for EPDC Export

approval

applied_approval_assignment

level = ‘design’(InfoFile_4)

approval_status

date_and_time

calendar_date local_time(InfoFile_8)year_component = 1998day_component = 20month_component = 08

(InfoFile_9)hour_component = 17minute_component = 44seconde_component = 15

applied_date_and_time_assignment

date_time_rolename = ‘update’

organizationid = ‘AIC F’ (InfoFile partner) name = ‘’description = ‘company’

applied_organization_assignment

organization_rolename = ‘id owner’

name = ‘not yet approved’(InfoFile_4)

documentid = ‘’name = ‘’description = $

description_attribute

attribute_value = ‘testing’

application_protocol_definition

status = ‘international standard’application_interpreted_model_schema_name = ‘automotive design’application_protocol_year = 2001

product_contextname = ‘’discipline_type = ‘’

product_category_relationship

name = ‘hierarchy’description = $

product_related_product_categoryname = ‘standard’description = $

application_context

application = ‘Core Data forAutomotive MechanicalDesign Process’

description_attribute

attribute_value = ‘A380’

product_related_product_category

name = ‘geometry’description = $

product_category_relationship

name = ‘hierarchy’description = $

document_typeproduct_data_type = ‘configurationcontrolled document definition’

document_product_equivalencename = ‘equivalence’description = $

applied_external_identification_

assignmentassigned_id =‘ms21050-07028’ (InfoFile_2)

identification_rolename = ‘external document id and location’description = $

coordinated_universal_time_offset

hour_offset = 1minute_offset = $sense = ‘ahead’

product

product_definition_formation

representation_context context_identifier = ‘’context_type = ‘document parameters’

name_attribute

attribute_value = ‘detailed representation’

cartesian_pointname = ‘’coordinates = (0.,0.,0.)

direction name = ‘’direction_ratios = (1.,0.,0.)

direction name = ‘’direction_ratios = (0.,0.,1.)

description_attribute attribute_value = $

id_attribute attribute_value = ‘ms21050-07028’ (InfoFile_2)

organizationid = ‘AIC F’name = ‘’description = ‘company’

applied_organization_assignment

organization_rolename = ‘id owner’

geometric_representation_context

context_identifier = ‘’context_type = ‘external’coordinate_space_dimension = 3

product

product_definition_formation

applied_document_reference

product_definition_with_associated_

documents

role_association

object_role

product_definition_context

document_file

document_representation_type

product_related_product_category

document_type

property_definition

identification_role

external_source

applied_external_identification_

assignment

property_definition_representation

representation

descriptive_representation_itemname = ‘data format’description = ‘CADDS5’ (InfoFile_1)

name = ‘document format’

name = ‘document property’description = $

id = ‘ms21050-07028’ (InfoFile_2) name = ‘’description = $name = ‘’description = ‘’

name = ‘digital’

name = ‘common location ’description = $

assigned_id = ‘’

product_data_type = ‘’

source = ‘’

name = ‘mandatory’description = $

id = ‘ms21050-07028_19980820174415_A001’(InfoFile_2+8+9+6+3) description = $

id = ‘ms21050-07028’ (InfoFile_2) name = $description = $

id = ‘_A001’ (InfoFile_6 +3)description = $

name = ‘digital document definition’life_cycle_stage = ‘’

name = ‘document’description = $

source_id = ‘BES’ (InfoFile_5)

shape_definition_representation

product_definition_

shapeproduct_definition

product_definition_context

product_related_product_categoryname = ‘part’description = $

id = ‘ms21050-07028’(InfoFile_2) name = ‘/NULL’(InfoFile_7)description = $

id = ‘_A001’ (InfoFile_6+3)description = $

id = ‘ms21050-07028 _A001’(InfoFile_2+6+3) description = $

application_context

name = ‘part definition’life_cycle_stage = ‘design’

application = ‘digital mock-up’

name = ‘’description = $

name = ‘’

property_definition

axis2_placement_3dname = ‘’

property_definition_representation

shape_representation

name = ‘external definition’description = $

S1 : part and associated CAD representations- Instanciated figure for EPDC Export

approval

applied_approval_assignment

level = ‘design’(InfoFile_4)

approval_status

date_and_time

calendar_date local_time(InfoFile_8)year_component = 1998day_component = 20month_component = 08

(InfoFile_9)hour_component = 17minute_component = 44seconde_component = 15

applied_date_and_time_assignment

date_time_rolename = ‘update’

organizationid = ‘AIC F’ (InfoFile partner) name = ‘’description = ‘company’

applied_organization_assignment

organization_rolename = ‘id owner’

name = ‘not yet approved’(InfoFile_4)

documentid = ‘’name = ‘’description = $

description_attribute

attribute_value = ‘testing’

application_protocol_definition

status = ‘international standard’application_interpreted_model_schema_name = ‘automotive design’application_protocol_year = 2001

product_contextname = ‘’discipline_type = ‘’

product_category_relationship

name = ‘hierarchy’description = $

product_related_product_categoryname = ‘standard’description = $

application_context

application = ‘Core Data forAutomotive MechanicalDesign Process’

description_attribute

attribute_value = ‘A380’

product_related_product_category

name = ‘geometry’description = $

product_category_relationship

name = ‘hierarchy’description = $

document_typeproduct_data_type = ‘configurationcontrolled document definition’

document_product_equivalencename = ‘equivalence’description = $

applied_external_identification_

assignmentassigned_id =‘ms21050-07028’ (InfoFile_2)

identification_rolename = ‘external document id and location’description = $

coordinated_universal_time_offset

hour_offset = 1minute_offset = $sense = ‘ahead’

productproduct

product_definition_formation

product_definition_formation

representation_context context_identifier = ‘’context_type = ‘document parameters’

name_attribute

attribute_value = ‘detailed representation’

cartesian_pointname = ‘’coordinates = (0.,0.,0.)

direction name = ‘’direction_ratios = (1.,0.,0.)

direction name = ‘’direction_ratios = (0.,0.,1.)

description_attribute attribute_value = $

id_attribute attribute_value = ‘ms21050-07028’ (InfoFile_2)

organizationid = ‘AIC F’name = ‘’description = ‘company’

applied_organization_assignment

organization_rolename = ‘id owner’

geometric_representation_context

context_identifier = ‘’context_type = ‘external’coordinate_space_dimension = 3

April 22, 2005 PDE2005 15

EXPRESS Data Manager Software

QUERY_SCHEMAproduct_doc_approvalFOR PDM_SCHEMA;

GLOBALDECLARE exps

INSTANCE OF PDM_SCHEMA;

END_GLOBAL;

VIEW_ENTITY product_view;

Product_Id : STRING;

Product_Name : STRING;

Document_Id : STRING;

Document_Name : STRING;

Product_Data_Type : STRING;

END_VIEW_ENTITY;

QUERY_FUNCTION product_documentation(prod_id , prod_name : STRING) : SET OF product_view;

LOCALresult : SET of

product_view;curr_product :

product_view;found :

Boolean;doc :

document;END_LOCAL;

FROM(p:exps::PRODUCT)

WHEN TRUE;BEGIN

curr_product:= ?;found := true;

Start the modelling

Existing Data models

Create your own

Data models

Publish yourwork

to the team

Web Output

Text andgraphic

document

Create the Repository

Populate thesystem

Step-fi le - P21SDAI

C,C++, J AVA XML

Connectany

application

Mapping, Query/ View, Methods & Rules

Put into operation

The ProcessExpress Object

Server

Web Application Server

XM

L b a

sed

WE

B A

pplic

a tio

ns w

ith

Bu s

ines

s O

b je c

ts u

s in g

Q

uery

,Vie

w a

n d R

u le s

Net - User

ST

EP-fi

le, P21

Prog

ram

min

g -C,

C++,

Jav

a

EDMvisualExpress , the complete data modelling tool.

Mapping Query/View

MethodsDefine your operations on the objects

Rules, adding any constraint on your modelMay be of any kind, such as Business, Engineering, Project, Knowledge, Corporate etc.

More about EPM Technology and EXPRESS Data Manager at

http:/ / www.epmtech.jotne.com

STEP instance data basebased on EPM tool

CAD/FM System

Conversion of system information to an EXPRESS based instance model A with system objects

EXPRESS models for the legacy source system

Conversion between the instance models A and B based on EXPRESS-X

EXPRESS model of the Target Schema

EXPRESS-X modelfor the mapping of the Target schema to the system

SDAI

Export process

1

2

3

Writing of the STEP/XML file

WEB ServerAccess

Clear Width

Direction ofdoor opening

WALLWALL

Lining

Door panel

1. Ther e should be a minimum clear width of 850mm2. Doors should open in the direct ion of exit tr avel

if ((door.genericType = SINGLESWI NG) or (door.genericType = DOUBLESWI NG)) thenif (exitDirection= 1) thenxpxPrintf ('\ n\ nI nstance: %lu Clause 2.3.9 PASSED', door);

SCHEMA_METHODS for DOOR

(*-------------RECTANGLE----------------)

ENTITY Rectangle;(* one method for moving a rectangle *)

PROCEDURE Move(deltax,deltay : REAL);LowerBorder.StartPoint.Move(deltax,deltay);LowerBorder.EndPoint.Move(deltax,deltay);UpperBorder.StartPoint.Move(deltax,deltay);UpperBorder.EndPoint.Move(deltax,deltay);

END_PROCEDURE;

EDMmodelChecker, Execute the modelEDMmodelConverter, supporting Express-X EDMDeveloperSeat

Easy to use interf ace I nteractive Debugger

Generic Mapping and translation engineQuery / View Define your own Query/ View

QUERY_SCHEMAproduct_doc_approvalFOR PDM_SCHEMA;

GLOBALDECLARE exps

INSTANCE OF PDM_SCHEMA;

END_GLOBAL;

VIEW_ENTITY product_view;

Product_Id : STRING;

Product_Name : STRING;

Document_Id : STRING;

Document_Name : STRING;

Product_Data_Type : STRING;

END_VIEW_ENTITY;

QUERY_FUNCTION product_documentation(prod_id , prod_name : STRING) : SET OF product_view;

LOCALresult : SET of

product_view;curr_product :

product_view;found :

Boolean;doc :

document;END_LOCAL;

FROM(p:exps::PRODUCT)

WHEN TRUE;BEGIN

curr_product:= ?;found := true;

Start the modelling

Existing Data models

Create your own

Data models

Publish yourwork

to the team

Web Output

Text andgraphic

document

Create the Repository

Populate thesystem

Step-fi le - P21SDAI

C,C++, J AVA XML

Connectany

application

Mapping, Query/ View, Methods & Rules

Put into operation

The ProcessExpress Object

Server

Web Application Server

XM

L b a

sed

WE

B A

pplic

a tio

ns w

ith

Bu s

ines

s O

b je c

ts u

s in g

Q

uery

,Vie

w a

n d R

u le s

Net - User

ST

EP-fi

le, P21

Prog

ram

min

g -C,

C++,

Jav

a

EDMvisualExpress , the complete data modelling tool.

Mapping Query/View

MethodsDefine your operations on the objects

Rules, adding any constraint on your modelMay be of any kind, such as Business, Engineering, Project, Knowledge, Corporate etc.

More about EPM Technology and EXPRESS Data Manager at

http:/ / www.epmtech.jotne.com

STEP instance data basebased on EPM tool

CAD/FM System

Conversion of system information to an EXPRESS based instance model A with system objects

EXPRESS models for the legacy source system

Conversion between the instance models A and B based on EXPRESS-X

EXPRESS model of the Target Schema

EXPRESS-X modelfor the mapping of the Target schema to the system

SDAI

Export process

1

2

3

Writing of the STEP/XML file

WEB ServerAccess

STEP instance data basebased on EPM tool

CAD/FM System

Conversion of system information to an EXPRESS based instance model A with system objects

EXPRESS models for the legacy source system

Conversion between the instance models A and B based on EXPRESS-X

EXPRESS model of the Target Schema

EXPRESS-X modelfor the mapping of the Target schema to the system

SDAI

Export process

1

2

3

Writing of the STEP/XML file

WEB ServerAccess

Clear Width

Direction ofdoor opening

WALLWALL

Lining

Door panel

Clear Width

Direction ofdoor opening

WALLWALL

Lining

Door panel

1. Ther e should be a minimum clear width of 850mm2. Doors should open in the direct ion of exit tr avel

if ((door.genericType = SINGLESWI NG) or (door.genericType = DOUBLESWI NG)) thenif (exitDirection= 1) thenxpxPrintf ('\ n\ nI nstance: %lu Clause 2.3.9 PASSED', door);

SCHEMA_METHODS for DOOR

(*-------------RECTANGLE----------------)

ENTITY Rectangle;(* one method for moving a rectangle *)

PROCEDURE Move(deltax,deltay : REAL);LowerBorder.StartPoint.Move(deltax,deltay);LowerBorder.EndPoint.Move(deltax,deltay);UpperBorder.StartPoint.Move(deltax,deltay);UpperBorder.EndPoint.Move(deltax,deltay);

END_PROCEDURE;

EDMmodelChecker, Execute the modelEDMmodelConverter, supporting Express-X EDMDeveloperSeat

Easy to use interf ace I nteractive Debugger

Generic Mapping and translation engineQuery / View Define your own Query/ View

April 22, 2005 PDE2005 16

Implementation Methodology

• Import PDM Object Model into EPM Model Migrator software

• Map objects and attributes between PDM and STEP

• Where one-one mapping is not possible, write code in EXPRESS-X

• Package software as a translator• Web enabled links inside PDM callable by

user screen or callable as batch process

April 22, 2005 PDE2005 17

EPM Model Migrator Mapping Software

April 22, 2005 PDE2005 18

Fxml

FederationServer 1

FederationServer 2

ADAPTER(TEAMCENTER)

GROUP(WHAT)

SCHEDULER(WHEN)

MAPPER(CONVERSION)

TRANSPORT(SECURE)

ADMIN(DASHBOARD)

DELTA ANALYZER(CHANGES)

ADAPTER(WINDCHILL)

GROUP(WHAT)

SCHEDULER(WHEN)

MAPPER(CONVERSION)

TRANSPORT(SECURE)

ADMIN(DASHBOARD)

DELTA ANALYZER(CHANGES)

Federation-based Product Data Synchronization

April 22, 2005 PDE2005 19

For more details

Dr. Raj G. Iyer

Team Lead, PLM Technologies

Engineering Business Group

TARDEC

E-mail: raj.iyer@us.army.mil

COM: (586) 574-7186

PLM Technologies

Team