Product Life Cycle Support (PLCS) The Information Backbone to transform the Logistics Enterprise

Product Life Cycle Support (PLCS)The Information Backbone to transform the Logistics Enterprise

Howard Mason

BAE Systems

2PLCS Inc. (c) 2002

The PLCS Initiative

The Business Context Overview of PLCS

Vision Capabilities Deliverables Status

Exploiting the benefits Future plans

3PLCS Inc. (c) 2002

Setting the Business ContextBusiness Drivers

Reduced Cost of Ownership Users of products are seeking improved

availability, reliability, maintainability and lower cost of ownership.

Sustainable Business Growth 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 Users of information systems want more

open platforms to reduce IT costs and ensure longevity in use of information

4PLCS Inc. (c) 2002

Setting the Business Context Digital Product Data has become a valuable business asset

New Business Opportunities Leading manufacturers are ‘going downstream’ to generate

additional revenue from supply of lifecycle support services Product Lifecycle Management

Increased focus on managing information throughout the product lifecycle – Concept to Disposal

Businesses are focusing on total cost of ownership, as product life cycles increase and products become more expensive to maintain

Extended Enterprise Increasingly complex business networks Knowledge workers need to share information in real time Not practical to adopt common system mandate Internet technology has changed the way of working

5PLCS Inc. (c) 2002

Setting the Business Context Requirements of the Extended Enterprise

Extended enterprises are formed to meet project specific requirements

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

Program ManagerProgram Manager SalesSalesMarketingMarketing

EngineeringEngineering SupportSupportMfg.Mfg.

Project ZProject Z

Product Team 2

Product Team 2

Product Team 1

Product Team 1

Project YProject Y

Project XProject X

Supplier ASupplier A

Supplier BSupplier B Supplier CSupplier C

PartnerPartner

FIREWALLFIREWALL

6PLCS Inc. (c) 2002

Setting the Business Context Configuration Management is a major challenge

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

CustomerRequirements


Conceptand

Assessment

Conceptand

AssessmentDemonstration

andManufacture

Demonstrationand

ManufactureIn Service

and Disposal

In Serviceand

Disposal

Feedback

As ManufacturedConfiguration

As PlannedConfiguration

As DesignedConfiguration

Feedback

As MaintainedConfiguration

7PLCS Inc. (c) 2002

Setting the Business Context Limitations with current standards (as at November 1999)

Current standards are specialized and focus on either: a piece of a business transaction or process, e.g. Order,Part or presentation of specific content, I.e. Aircraft maintenance manual

Example: Transaction oriented Defence: AECMA 2000M Commercial: ATA Spec 2000, EDIFACT, ANSI X.12

Example: Content oriented Manufacturing and process centric:

ISO 9000, STEP

Operations and maintenance centric: Defence: MIL-STD-1388, Def-Stan 00-60, AECMA S1000D Commercial: ATA Spec 2000, 2100

8PLCS Inc. (c) 2002

Setting the Business Context Available capabilities - ISO STEP

STEP is an established international standard for the exchange, integration and sharing of product data

Geometry Product structure Manufacturing interfaces Drawings

STEP Release 2 covers new functions: Finite Element Analysis Printed Circuit Assemblies Wiring looms Mechanical Design Construction industry

XML for the Web

9PLCS Inc. (c) 2002

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 A380 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

10PLCS Inc. (c) 2002

Overview Imagine the opportunities if …

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


OverviewThe Key Business Problem

How to keep the information needed to operate and maintain a product aligned with the changing product over its life cycle?

Tools

TestEquipment

SupportFacilities

Consumables

Software

Transportation

Spares

StorageRequirements

Training

Product Definition Information

MaintenanceSchedules

Productin FocusProductin Focus

FeedbackFeedback


FinnishDefence Forces

Product Life Cycle Support (PLCS)Membership


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


Product Life Cycle Support (PLCS)Goals

PLCS Standard: Improve product availability Reduce operating, support and

maintenance costs Improve quality and accessibility of

Product Life Cycle Support information

PLCS, Inc: Accelerate technical development of

the ISO standards Encourage early implementation

commercial software vendors Encourage early industry

participation in the development and testing of the standard


Scope of STEP Today

Product Life Cycle Support (PLCS)The Vision

Shared Data

Product Representations

Product Performance

Product Structure

Support Performance

Change Directives

Support Environment

Failure Analysis

Maintenance Analysis

Task Resource Data

Life Life Cycle Cycle DataData

Maintain/DisposeMaintain/DisposeQuerQueryy

Derived Disposable Derived Disposable DataData

UseUseRespond

Respond

Support and Operational Feedback

Standard Standard Commercial Commercial TransactionsTransactionsFeed and

Feed and

ExtractExtract


Extended Enterprise ofOEM’s, Customer, Partners

and Suppliers

Enterprise Integrationthrough dedicated networks

Domain specific information systems

(e.g. CAD, MRPII, Planning)

Product Life Cycle Support (PLCS)Extended Enterprise enabled by Internet technology

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Product Life Cycle

Internet-based architecture and federated data models make possible implementations involving thousands of users across many sites

Concept Assessment Demonstration Manufacture In-Service DisposalOperational Feedback

PLCSDomain

Define and implement the support solution, maintain the product configuration

Product Lifecycle Management (PLM)


Product Life Cycle Support (PLCS)Extended Enterprise – Importance of PLCS

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Product Life Cycle

When set against a timeline – the picture looks more like this!

C A D M In-Service D

PLCS DomainPLCS Domain

Design forSupportability

Design forSupportability

In Service Support andOperational Feedback

In Service Support andOperational Feedback

Typically 25 – 50 years Operational Life5 – 10 years


Product Life Cycle Support (PLCS)Typically complex systems environment – point to point integration

7.FMECA

6.LSAR

2.Maintainers

ViewingTool

3.Stock Mgmt

8.CAD

4.MaintenanceManagement

10IETM

11Parts

Supplier Database

12 Depot Maint

Mgmt

13.Distribution,

Transportation

14 Defects & FailureReporting

9.Product

Data

Functional Requirements

LSA Data

LSA Data

5.RequirementsManagement

LSA Data

Support Data

CM Data

Support Data

Part Data

CM Data

CM DataCM Data

Defects and

FailuresMaintenance

Mgt Data

DesignData

Support Data

DistributionData

Tech Pubs Data

1.Support Data

CM DataOperational Objectives

FMECAResults


1.Support

Data

7.FMECA

6.LSAR

5.RequirementsManagement

2.Maintainers

ViewingTool

3.Stock Mgmt

8.CAD

4.MaintenanceManagement

9.Product

Data

10IETM

11Parts

Supplier Database

12 Depot Maint

Mgmt

13.Distribution,

Transportation

14 Defects & FailureReporting

Functional Req. FMECAResults

Part data MaintenanceMgmt Data

DistributionData

Defects& Failures

TechPub Data

Design data Parts Data

PLCS compliant information exchangesPLCS compliant information exchanges

Design Data

LSA DataMaintenanceMgmt Data

Support data

Maintenance

Mgt Data

In future, support system integration will be easier to implement

Product Life Cycle Support (PLCS)PLCS will enable cost effective information exchanges


Product Life Cycle Support (PLCS)Example: PLCS for MoD and Defence Contractors

CRISP

MRC

DR4LITS

OASIS Etc …

MoD (PE) Databases for Product Support

SupportContractor

Project specific ‘Point to Point’ interfaces to be developed and maintained

ISO 10303 STEP, AP 239 (PLCS)ISO 10303 STEP, AP 239 (PLCS)

LPD(R)

EurofighterEtc …

Astute AstuteTrent 800

RB 199

Etc … Etc …

WAH-64 ApacheEH 101 Merlin

Bowman

Multiple Contracts with UK Defence Contractors


Product Life Cycle Support (PLCS)Capabilities enabled by PLCS – ISO 10303 AP 239

Product DescriptionCapability to define product requirements and configuration, including relationships between parts and assemblies in multiple product structures (as-designed, as-built, as-maintained)

Work ManagementCapability to request, define, justify, approve, schedule and capture feedback on work (activities) and related resources.

Property, State and BehaviourCapability that describes and captures feedback on product properties, operating states, behaviour and usage

Support Solution and EnvironmentCapability to define the necessary support for a given set of products in a specified environment and to define support opportunity, facilities, personnel and organizations

AP 239Capabilities

AP 239Capabilities


PLCS, Inc deliverables

A new vision for life cycle support A terminology dictionary An illustrative process model (AAM) A large data model, standardised through ISO (AP239) A set of data exchange standards (constrained subsets of

AP239) 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 .. (ebXML, Exostar, Covisint, 2000M)??


PLCS: relationship to other standards

“If we reach high,

we do so only because

we stand on the shoulders

of those who went before”

(Albert Einstein)


PLCS: Inputs to AP239

ISO15288OMG

STEP

Mil Spec2549

ATAEffectivity

AP208

POSC/Caesar

FMVCTG2

NCDM

AECMA1000D2000M

Mil Spec1388

AP203

TC184/SC4WG3/T8

PWI

PDMSchema

PLCSInitiative

AP 233PLIB

Def Stan00-60

RCMITDef Stan

00-60Logical

SGMLEDIFACT

IDEF1-X

Relational

EXPRESSbased


PLCS development principles

Create a durable data model standard that can be extended/adapted over time without re-modelling or re-ballot

Identify key generic concepts and relationships Extend/adapt by classification and reference data libraries

Build on existing standards: PDM Schema and the STEP Modular Architecture

Accommodate values that change over time Support multiple values for the same property Support back-tracking & audit

Maintain unambiguous histories Product Structure, State, Activity

Aim: to enable optimisation of support through life


Business

Fixed boundaries

Limited scope

Hard to Change

Poor cost awareness

Life cycle business

Open and Flexible

Agile

Lean and focused

Business

Process

Duplicated

Fragmented

Organization Specific

Locked by IT

Coherent

Simplified

Open

IT independent

Process

Data

Inconsistent Terminology

Format dependent

Massive duplication

Islands of IT

Common language

Format “ as required”

Reduced data set

Portable data

Data

Product Life Cycle Support (PLCS)Main activity areas

Develop Single Integrated Data Model based on

Express

NATO CALS NATO CALS PP1 and TLBMPP1 and TLBM

ISO Prelim ISO Prelim Work ItemWork Item

LaunchLaunchPLCSPLCS

Automate Current

Processes

New Integrated Processes

Better , Cheaper

Information

Test and

Integrate

Test and

Integrate

Test and

Integrate

Usage Guides

Industry Testing

Published standardsSubmit to

ISO

Information Requirements

“As is” Scenarios

ExchangeRequirements

Develop Activity Models


Product Life Cycle Support – Activity Model

An IDEF 0 model with 157 activities (boxes) and 220 information exchanges (arrows)

Purpose: 1999/00: to define the scope of PLCS activity 2001/2: to expose data requirements 2003: (current role) to represent the activities and information flows

supported by Application Protocol 239 Future use

Communication the PLCS Vision Charting information exchange boundaries between organizations Identifying and illustrating DEXs

Available as .bp1, .idl, html, xml or pdf.


AP239 Product Life Cycle Support – Activity Model Concepts

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

A deployment environment A support solution requirement

The deployment environment defines: 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:

Continuous optimization of support solution definition through life, based on feedback from use

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


AP239 Product Life Cycle Support – Activity Model Concepts

(Each) Support solution definition includes: 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:

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: point to an existing document point to an SGML document (e.g. an AECMA 1000 Module) be fully “machine readable”

Task specifications may be linked to resources Required resources Resource items (products, people, facilities etc)


APSI and Related Information

Assured Product Support Information comprises PIF scope Description of relevant deployment environments Support Solution requirements Product Definition Information (at least that needed for support) Support Solution Definitions

This full data set is subject to configuration change management (CM = IM?) Related Information may comprise

Test results Manufacturing records History of collected feedback on:

Individual product configuration over time Product state and properties over time Activities, including:

Product use Work done Resource use


AP239 – The information model

Main concepts 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 is a Modular STEP AP

Modules allow common definitions of product data to be reused Extensive re-use of PDM modules

To bring compatibility with design/PDM tools Basic work order/work request process common to change in

design Extended to provide

Life cycle CM Full work management capability Condition based task triggers

All modules feature two levels of model, with mapping User view of information Link to common concepts across all of STEP Full harmonization achieved where needed by common modules

With CAD/PDM via PDM Modules With Requirement Tools


PLCS enables requirement management through life

AP239 will share common modules with AP233 – Systems Engineering:

Text-based Requirements Multiple, related breakdowns, including “System” concept Interfaces

Aim is to support requirements trace from pre-design through to maintenance and disposal

UK MOD has funded demonstration project for this capability with BAE Systems


PLCS provides full history to support optimization and change over time

In the PLCS models it is assumed that any value supplied E.g. a property such as mean time to perform a task

may have multiple values over timewhere each value could have been:

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)


Product Life Cycle Support (PLCS)Life Cycle Configuration Management is a major challenge

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



Conceptand

Assessment

Conceptand

AssessmentDemonstration

andManufacture

Demonstrationand

ManufactureIn Service

and Disposal

In Serviceand

Disposal

Feedback

As ManufacturedConfiguration

As PlannedConfiguration

As DesignedConfiguration

Feedback

As MaintainedConfiguration

SystemRequirementConfiguration


PLCS Core: Life Cycle PDM Capability (1)

PDM Schema already supports automated exchange of Part id and properties Associated documents and files (incl. CAx) Product structure Product (and document) approval status

This is already in production use by US Aerospace and Defence prime contractors (via AP203) German/Swedish/French Automotive sector (via AP214 cc6) Eurofighter Typhoon PDM partners

.. A powerful and proven capability for Configuration Management of a complex product design


AP239 has added: Classification, supported by Reference data libraries Product_as_individual (planned and realized) Product breakdowns (system, physical, functional, zonal and

hybrid) Text based requirements (from AP233) Extended property capability Interfaces Attachment_slot Message, Envelope (similar to ENGDAT) Information Rights

… A powerful capability for Life Cycle Configuration Management of Assured Product and Support Information

PLCS Core: Life Cycle PDM Capability (2)


Activity

ActivityMethod

WorkOrder

WorkRequest

Work Management modules

Work_Definition

Task_Specification

Scheme

ResourcedTask Spec

Required_Resource

Resource_Item

Resource_Management

Support_Provider

Work_order+

Work_request+

Work_record

Resource_as_realized

ProductDefinition

Information

Product State&

Usage

Activity_as_realized

Work Management

Resourced_Activity

Product_as_realized


PLCS uses Reference data

What is it? 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? Because it improves reliability and effectiveness of exchange Because it can be extended:

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


AP239 – Data Exchange Sets

DEXs are: Subsets of the AP239 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

Consistent implementation of AP239 Data consolidation through time

Same DEX Different DEX


Current DEX developments

Product as individual Product breakdown for support Maintenance plan Task set Operational feedback Fault states Work Package Definition Work Package Reporting


Current situation (December 2004)

Activity Model published (available to all) 1750 requirements allocated to ~130 modules Module development completed:

PDM Modules under publication as ISO Technical Specifications PLCS modules under publication as ISO Technical Specifications AP239 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


Product Life Cycle Support (PLCS)Unique Value Proposition

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:

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 VendorsCustomers, Contractors and Software Vendors

working together to develop and implementworking together to develop and implement

a neutral data exchange standard for product supporta neutral data exchange standard for product support


PLCS: relationship to other standards

Looking back AP239 acknowledges a debt to all listed inputs

Current position AP239 can use the data generated by current ILS standards AP239 implementations will need resource to cleanse and

enhance data generated by current standards (it’s not very good!)

AP239 enables, but does not force, much higher levels of data integration

The future AP239, 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

Exploiting the benefits


Implementing PLCS

PLCS (a standardized information model) can be implemented in 3 ways:

As an integration architecture for a new product life cycle support management

system (c.f. PIPPIN, EPISTLE, ISO 15926, NPDM)

As a mapping between systems (APIs) (LITS to RR CM system)

As a standardized data exchange capability (plus compliant software)

STEP technology supports all three and is language independent (Cobol, Java,

C++, XML)

STEP is in production use, with proven benefits, for CAD, CAM and PDM

systems

STEP has mainly been used to standardize data exchange

PLCS can also be used to promote further standardization via Reference Data

(e.g. fault codes, skill grades)


Implementing PLCS on a new program

Use PLCS/STEP formats to capture design information as it is generated in a way that

support engineers can re-use

Develop Support Information in PLCS format

Less duplication – single assured source

Easy to present/deliver in any required form (e.g. Spec 1000D, XML, PDF)

Improved management of effectivity/applicability

Deliver a PLCS enabled maintenance management capability

Automatic upload from single assured source

The right data is available for maintainers (can be tailored to serialized item)

Improved feedback collection (report in the language used to specify, auto-complete)

Better in-service metrics

Faster learning


Identify current information shortfalls or problems

Use the PLCS Activity Model to identify relevant data exchanges (arrows) that cross IT

system boundaries, within and beyond your company

Implement appropriate DEXs, where there is a valid business case

Consider adopting PLCS for new data generated (changes, modifications, upgrades

etc.)

N.B. Most current formats can readily be delivered from a PLCS integrated source.

The latter is cheaper to build and easier to maintain.

What NOT to do – immediately abandon current systems (and standards) that meet

business needs

Implementing PLCS for an existing program


Norwegian pilot - New frigate programme


UK MOD demonstrator

Scenario: Ship damaged by fire Compartment containing mixture of equipment due for

maintenance, due for upgrade, or no longer available Consolidation of planned and unplanned maintenance

requirements into work programme PLCS to link five legacy support applications


Swedish pilot

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 (DEX001 and DEX005). The result of the study will be reported back to the OASIS community.

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.

Future Plans


Standards development and maintenance

ISO TC184/SC4 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 AP239 Resources committed through national standards bodies Also provides clear liaison to Systems Engineering

development


DEX Development and publication

Open-source infrastructure developed Seeking more open participation

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


The OASIS Technical Committee

The purpose of the OASIS Product Life Cycle Support TC is to:

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/SC4 coordinate with relevant OASIS Technical Committees promote the use of OASIS Product Life Cycle Support DEX’s

across industries and governments world-wide


The Challenge

The PLCS consortium has delivered the basic standard, and an infrastructure for exploiting it, and has closed down

Join in an early implementation Join the OASIS Technical Committee to participate in DEX

development

See www.oasis-open.org and select PLCS Contribute to further developments in ISO through your

national standards body

Product Life Cycle Support (PLCS)The Information Backbone for the Enterprise

Questions?

Answers!

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Product Life Cycle Support (PLCS) The Information Backbone to transform the Logistics Enterprise

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