Neutral BOM Management and the Impact on Physical Structure

James Batka
Software Product Consultant

http://plmworld.org/

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Teamcenter MRO Challenges

Neutral BOM requirements Creating a neutral BOM for services Managing neutral BOM for services Exporting and Importing data Change Management Data Quality

Some Neutral BOM requirements conflict!

Services must manage SBOM Engineering must maintain independent of Engineering control of design BUT Must include all service parts Remain manageable in size
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Teamcenter MRO Why use MRO? Report describing engine test failure from the 1980s Turbine engine disk failure during testing A disk fragment flew ~ mi, through ceiling of office buildings ceiling Landed on desk of the test program lead engineer Hot disk fragment (probably 700 800 F) burned the engineers desk top and bounced onto the floor

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Teamcenter MRO Why use MRO? Incident investigation found: Disk failed due to improper heat treatment Heat treatment failed due to bad thermal sensor Other disks created using the same process were in flight in both military and commercial aircraft The engine company had to track down and remove all defective engines from vehicles and inventory MRO: Tracks all serial parts entered into the system Tracks production lot membership Tracks the location of both serial and lot parts What took the engine company weeks or more of time in the 1980s could be accomplished in a few minutes with Teamcenter MRO!

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Teamcenter MRO Neutral Structure versus Physical Structure Engineering Design & Development Production Delivery & Support

Neutral

Physical

Authorized
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Actual
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Why use MRO? Complexities of managing physical structure

ED&D

eBOM
Rev A

eBOM
Rev B
Upgrade Brake Rotor

eBOM
Rev C
New Brake Pad

eBOM
Rev D
Upgrade Strut

Rebase

Hull-50

Hull-40 Production & Delivery

Hull-30

Hull-20 Sustainment

Hull-10

Modification
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Retrofit
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Neutral BOM Management for MRO Service BOM Service BOM What is it? Requirements Part Selection Managing SBOM Other Considerations

HD User Experience
Intelligently Integrated Information Future-proof Architecture

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Service BOM What is it? Neutral Structure used by Physical Structure As template: As reference:
Used to generate physical structure Used to highlight missing, extra to design, deviated, and differences between design & reality

A correct Service BOM is critical to MRO!

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Service BOM What is it? Service BOM differs from the Engineering BOM!

EBOM

SBOM

How do you determine what should be included / excluded? How do you manage differences?
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Service BOM Requirements and Recommendations Requirements: Must (eventually) include: Options & Variants Substitutes Upstream BOM changes must propagate to SBOM Ability to add parts to BOM for services use (e.g. customer & vendor parts) Recommendations: Created and managed by services organization Manage changes with formal change management process

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Service BOM Parts to include in SBOM Rules for including / excluding parts from SBOM DoD Guidelines: DoD Instruction 5000.64 (IUID Guidelines) Part acquisition >= $5000 All serially managed parts Controlled inventory parts Mission essential parts (e.g. essentiality codes 1, 3, 5, 6, & 7) DoD Instruction 4130.1-R (SMR Code) Reparable parts Plus any parts required by customer Plus any assembly higher in the product structure which contains any of these parts regardless of whether it satisfies these requirements
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Neutral BOM Management for MRO Managing SBOM Service BOM Managing SBOM Multi-Structure Manager Independently managed BOMs 150% BOM Other Considerations

HD User Experience
Intelligently Integrated Information Future-proof Architecture

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Managing SBOM Teamcenter Multi-Structure Manager MSM assists in managing perspectives of single BOM Plusses: Recommended method of managing multiple BOMs by product development Organizations less dependent upon cooperation Minuses: Requires MSM licenses Our team lacked experience with this method Requires disciplined changed management Multi-Structure Manager

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Managing SBOM Independently Managed BOMs Duplicate parts created to represent a single part Plusses: Organizations not dependent upon cooperation No Teamcenter licenses required Best method for dealing with vendor parts Minuses: Most prone to data errors Most duplication of effort Requires disciplined change management
EBOM SBOM

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Managing SBOM 150% BOM

EBOM + SBOM BOM which combines parts into single BOM Plusses: No Teamcenter licenses required Changes within service parts do NOT require engineering authorization Minuses: Requires cooperation between organizations Requires disciplined change management Other: Use part types to enable different security and searches for EBOM/SBOM parts Changes to design require engineering authorization good for highly regulated environments
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Neutral BOM Management for MRO Other Considerations Service BOM Managing SBOM Other Considerations Maintenance Planning Data Export / Import Change Management Data Quality

HD User Experience
Intelligently Integrated Information Future-proof Architecture

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Other Considerations Maintenance Planning Thoughts on Maintenance Planning: For military and highly regulated industries, technical manual and maintenance planning MUST share source of task information Neither Content Management nor Maintenance Planning can currently output maintenance planning detail into technical manuals

Military required to follow most recent technical manuals even when they are known to be out of date

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Other Consideration Data Export and Import S1000D PLMXML Existing Teamcenter capability Existing industry standard Intended for the exchange of: Can export & import Service tasks Service actions Service BOM Service BOM Physical structure Physical Structure Related data Related data USAF & Army already receive maintenance data in this format MIL-STD-3031A, DEPARTMENT OF DEFENSE STANDARD PRACTICE: ARMY A&D companies already deliver BUSINESS RULES FOR S1000D maintenance data in this format BUT Teamcenter cannot (yet) parse S1000D XML Teamcenter cannot (yet) produce S1000D documents
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Other Considerations Change Management and its role in MRO Forward Change Process results in deployment of new designs to existing systems Retrofit new capability to existing systems Upgrade or rebuild system to new standards Determines when to update physical structure to new design reference (rebase) Reverse change process (Service Discrepancy -> Problem -> Change Request -> Change process) can be used to heal data errors such as: Physical structure mistakes Physical structure referencing incorrect SBOM Previously undocumented substitute and alternate parts
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Other Considerations Data Quality All downstream processes affected by quality of Engineering data SBOM Problems SBOM require fixing only two structures: Physical structure problems require correcting EBOM, SBOM, and ALL physical structures referencing the affected SBOM Correcting errors in the EBOM/SBOM is extremely difficult Each correction must propagate through the enterprise change management process EBOM & SBOM Which could be dozens or more! Cant modify released revisions of a part! This could bog the process down

Spend time correcting your EBOM / SBOM prior to deploying MRO It will pay back your investment many fold over time!
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Teamcenter MRO Aerospace and Defense Sector Customer Benefits

Increased productivity Contract Compliance

Integrated Logistics Greater efficiency

US Army requirement: Using Computer-Aided Know precisely the current Production Planning to status of each vehicle capture and configuration standardise the best Use MRO to economically practices manage vehicle fleet

US AF Developing logistics system tying Launch Reduced MRO with Cycle ERP, PLM, From 36 Management, to 30 months Document 17% reduction and Systems Engineering US

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MRO Neutral BOM Management Summary

Serialized part traceability throughout system life at a cost Automates the tracking parts ideal for regulated industries Source of Engineering data for change process feeds reliability, usage, et al into Engineering

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MRO Neutral BOM Management Related Sessions 502 Teamcenter Change Management Overview Wednesday / 9:30 AM 228 MRO Overview Wednesday / 1:00 PM 62 I Need it NOW, I Need it CORRECT Wednesday / 1:45 PM 702 Birds of a Feather Wednesday / 4:10 PM

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MRO Neutral BOM Management Related Materials

Sample US AF Technical Order (AFI)

http://www.ngbpdc.ngb.army.mil/pubs/21/afi21-105_angsup_I.pdf

S1000D
http://www.s1000d.net/ http://www.everyspec.com/MIL-STD/MIL-STD+%283000+-+9999%29/MIL-STD3031A_32065/

DoD IUID (DoD Instruction 5000.64)

http://www.acq.osd.mil/dpap/pdi/uid/index.html http://www.dtic.mil/whs/directives/corres/pdf/832004p.pdf

http://www.acq.osd.mil/dpap/UID/attachments/UIDfaq_extended.doc

DoD SMR Code (DoD 4130.1-R)

http://www.dtic.mil/whs/directives/corres/pdf/414001r.pdf

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Thank You!

Siemens PLM Connection 2012 Las Vegas, NV May 7-10

http://plmworld.org/

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