Logistics Modernization
Program
Integrating Product Data from the Top Floor to the
Shop Floor
Logistics Modernization
Program
Integrating Product Data from the Top Floor to the
Shop Floor
Dr. Raj Iyer
Director, Data Management/ TACOM LCMC Data Czar TACOM LCMC LMP Deployment
Army Logistics Automation Transition Plan
Path to Single Army Logistics Enterprise (SALE)
LMP Enterprise Model – the
world’s largest ERP!
Acquisition and Distribution
• Army Search Matrix and Penetration Logic • Real-time Global
Available-to-Promise • Back order Processing • MILSTRIP sales order
processing
Industrial Base Operations
• Acquisition
• Manufacturing and Remanufacturing Resource Requirements Planning • National Maintenance Management • Base Operations and Plant Maintenance • Quality Management • Human Resources • Inventory Management • Warehouse Management • Single Stock Fund • Environment, Health,
and Safety
• Distribution Planning
• Long Term and Material Requirements Planning
• Project Systems • Budget Planning • Demand Planning
Supply Chain Planning
Order
Management Acquisition Distribution
Make Fix
Budget and Finance
• Cost Accounting • Budget Formulation Material Master Management
• Ammunition Support • Bills of Material • General Accounting DFAS and
Funds Management
• Cost Management and Real Estate (Facilities) Management
• Provisioning • Cataloging
• Packaging and Freight • Maintenance Engineering Data and Reporting Army Army Reserves National Guard Other DOD • AF • Navy • Marines • DLA Other Government • Federal • State • Local Foreign Armed Services Commercial Contractors
Army Industrial Base
• Depots • Arsenals Other DOD • DLA Customer Returns Suppliers Customers
LMP Deployment Sites
L
T
Acquisition (PEOs)
Logistics / Industrial Operations (ILSC) Technology (RDECs) A PEO GCS •Warren, MI (HQ) •Picatinny, NJ •Huntsville, AL PEO CS&CSS •Warren, MI (HQ) •Rock Island, IL •Huntsville, AL •Natick, MA PEO Soldier •Fort Belvoir, VA (HQ) •Picatinny, NJ •Huntsville, AL
A
Enterprise Partners •TARDEC - Warren, MI •ARDEC - Picatinny, NJ •NSC - Natick, MAT
ILSC •Warren, MI (HQ) •Rock Island, IL •Natick, MA •Philadelphia, PA ILSC Industrial Base•Rock Island, IL (RIA) •Watervliet, NY (WVA) •Anniston, AL (ANAD) •Texarkana, TX (RRAD) •Herlong, CA (SIAD) •Lima, OH (LIMA) Acquisition Center •Warren, MI (HQ) •Rock Island, IL •Picatinny, NJ
L
TACOM will deploy LMP in October 2010 TACOM will deploy LMP in October 2010
TACOM LMP Data Management –
Key Tenets
• Data and Business Processes are
Inseparable
• Reuse OEM data via partnering in lieu
of new
• Use LMI as System of Record (SOR)
for Supportability Requirements
• Use of Windchill as SOR for
Configuration Management and Master Data Management
• Data quality based upon documented
“Data Standards” using authoritative sources
• Six Sigma based metrics for data
quality
• Ensure accurate and current data is
used by depots and arsenals that truly reflects system configuration
LMP is a TACOM transformation initiative – it is not an ERP software deployment!
LMP is a TACOM transformation initiative
PLM and ERP
•
Most industry ERP implementations include standardized product data
management functionality
• PLM system manages product configurations and associated master data
needed for ERP
• PLM system ties downstream data back to engineering product baselines
• Typically implemented outside ERP using Product Lifecycle Management
(PLM) software
•
Product data is created and managed as part of the systems
engineering process
• Logistics Support Analysis (LSA) process used by OEMs to develop
supportability requirements early in system development phase – not all data delivered to Govt.
• Logistics Management Information (LMI) results from LSA process and
defines logistics product baseline
LSA Data Flow and System
Engineering Interface
- Tools - Test Equipment - Calibration Equipment - Maintenance equipment - FMECA -LORA -RCM -Provisioning -Cataloging -Spares -RPSTLLSA Provisioning Tech Pubs Training MRO/MES Aggregate LMI Data Lifecycle Cost
Analysis Maintenance TaskAnalysis
Recommended service plan Maintenance task definition Manpower requirements Facilities requirements
Support equipment requirements Spare part requirements Recommended service intervals Level of repair analysis/ Economic LORA
Reliability Analysis FMECA RCMA FMEA Design Artifacts Engineering BOM Provisioning Spares stocking Serviceable BOM Spare parts list
Tech Pubs Training MES Maintenance Manual IETM/IETP Operators Manual Maintenance Procedures Maintenance Tasks Valid configurations Actual service procedures
As Maintained configuration of BOM Job cards / Work orders
Service Records Utilization Training courses Engineering BOM CAD Specifications Facilities Data Tool Library Manpower Maintenance task definition Spares requirements Corrective & preventative maintenance tasks
Integrated Logistics Support
Process and Data Re-use
Need for integrated BOMs
across the enterprise
BOMs created by ILSC, depots, arsenals and RDECs are disconnected and
Supply/ Wholesale Action ILSC Repair Action/Depot Manufacturing Action/ Arsenal Engineering Action RDECOM PBOM PBOM TM/IETM TM/IETM RPSTL RPSTL DMWR/ NMWR DMWR/ NMWR Work Centers Work Centers Available Resources Available Resources Routing Routing EBOM EBOM Engineering Changes Engineering Changes Drawings & Models Drawings & Models Specs & Standards Specs & Standards Process Plans Process Plans
PEO/PM
PEO/PM
OEM
OEM
As-maintained Configuration Field/ Tactical LMI RBOM MBOM TDP
PM – total lifecycle systems
integration responsibilities
PM is responsible for data integrity and accuracy through formal change control PM is responsible for data integrity and accuracy through formal change control
process
Supply/ Wholesale Action ILSC Repair Action/Depot Manufacturing Action/ Arsenal Engineering Action RDECOM PBOM PBOM TM/IETM TM/IETM RPSTL RPSTL NMWR/ DMWR NMWR/ DMWR Work Centers Work Centers Available Resources Available Resources Routing Routing EBOM EBOM Engineering Changes Engineering Changes Drawings & Models Drawings & Models Specs & Standards Specs & Standards Process Plans Process Plans
PEO/PM
PEO/PM
OEM
OEM
Configuration Management LMI RBOM MBOM TDPClosed Loop Product Lifecycle
Management
PM is the Lifecycle
Manager
Product
Development Product Support
Customer Requirements Product Optimization Design & Development Release To Manufacturing Technical Documentation Systems Engineering Service Optimization Service Program Definition Upgrades & Overhauls Service Record Management Service Planning Scheduled Maintenance Line Maintenance Service Performance Analysis Equipment Utilization & Performance Analysis Design for Sustainment Reliability & Qualification Testing
LMP is expected to transform and revitalize the PM’s role as the lifecycle system LMP is expected to transform and revitalize the PM’s role as the lifecycle system
Integrated Product Baseline
The Integrated Product Baseline (IPB) is TACOM’s approach to implementing a single master BOMThe Integrated Product Baseline (IPB) is TACOM’s approach to implementing a single master BOM
The IPB integrates –
• As-designed baseline – EBOM
• As-supported baseline – PBOM
• As-manufactured baseline – RBOM and MBOM
The IPB integrates –
• As-designed baseline –
EBOM
• As-supported baseline –
PBOM
• As-manufactured baseline –
RBOM and MBOM
The IPB will be configuration controlled in Windchill PLM and changed permitted only through a strict configuration
management process
The IPB will be configuration controlled in Windchill PLM and changed permitted only through a strict configuration
management process
A single master BOM with multiple views is the recommended industry best
practice for master data – however not implemented in LMP
Engineering Change Requests Engineering Change Requests Design Change Design Change Drawing Change Drawing Change
Changes gathered by Engineering
Engineering Change Notice Engineering Change Notice EBOM
Engineering throws ECN over the wall To other functions
Other functions receive ECN with time delays
PBOM RBOM MBOM
Manufacturing Supply Repair
Changes are made to respective BOMs and unsynchronized
As-Is Change Control Process
Current change control process is engineering centric. Other functional stakeholders are notified of decisions made and held responsible for making changes to their Current change control process is engineering centric. Other functional stakeholders
All BOM users within the enterprise can request changes to Master BOM
Configuration Control Board consists of all functional users BOM Change Request BOM Change Request CCB approves/ rejects request
Changes made to Master BOM
MBOM PBOM
RBOM
Changes to Master BOM Automatically updates other
derivative BOMs
All users notified of changes
To-Be Change Control Process
Proposed BOM Change control process is expected to be controlled by a truly cross-functional Configuration Control Board. Changes will be made to the master
Proposed BOM Change control process is expected to be controlled by a truly cross-functional Configuration Control Board. Changes will be made to the master
Manufacturing Execution System
– the final missing link
Basis for model is MESA eleven functions
Product Data Integration
Architecture
Windchill PowerLog-J EMS LMP Materiel Master Materiel Master OEM DLAEnterprise Business System
Configuration Management
Master BOM Management Document Management
Collaboration CAD/ Drawing Management
Tech Loop Process Workflows
Serial Item Management IETMs TMs RPSTLs NMWRs DMWRs Operator Manuals Windchill – ERP Interface Data Deliverable Data Federation SOA-based Data Federation Training Task Analysis Provisioning 2LM RCM LORA FMECA
SAP Netweaver ESB “MES”“
“MESMES””
AIT
Part 1 Part 1 Part 2 Part 2 Wheel Assy Wheel Assy Support Support System PBOM System PBOM Arm Arm Part 3 Part 3 PBOM (NSN) PBOM (NSN) Part 1 Part 1 Part 2 Part 2 Support Support Sub-Assy Sub-Assy System MBOM/RBOM Part 8 Part 8 Part 9 Part 9 Equivalent MBOM/RBOM MBOM/RBOM (Part No/ NSN) (Part No/ NSN)
3. Depots/ Arsenals re-use global PBOM/ EBOM data to create RBOM/ MBOM
4. Create Routings/ Process Plans 5. Allocate parts and resources to routing
6. Create for each Operation: Illustrations, Animations, 2D/3D Drawings, in-process machining state
Documents Documents Illustrations Illustrations 7. Dynamically generate Work Instructions Time Breakdown Time Breakdown Textual Description Textual Description Op 025 Op 030 Op 010 Op 040 Op 020 Builds Routing Routing
...
Plants Work CentersTools Machines Skills Process material Performed with Consumed Resource List Resource List Part List Part List Resources Resources Operated on 8. Send to LMP: BOMs Parts (Material Masters) Routings Work Centers Work Instructions Document Links Windchill
Linking product configuration
data to the shop floor
Part 1 Part 1 Part 2 Part 2 Wheel Assy Wheel Assy Engine Engine System EBOM System EBOM Arm Arm Part 3 Part 3 Part 4 Part 4 EBOM (Part No + CAGE Code) EBOM (Part No + CAGE Code) 1. PBOM developed through LMI or cleansed from CCSS 2. PBOM linked back to EBOM if available
Data integration validation pilot
on small arms
Windchill (Integrated Product Baseline) SAP ECC 6 ILSCSmall Arms Item Manager Armaments R&D Engg. Center -Rock Island JMTC - Rock Powerlog-J LMI Parts Tasks Packaging P-BOM+ Material Master Attributes Intralink E-BOM Configuration Management CAD models MACPAC CAPP TAMMS M-BOM, Workcenters OEM Validation (GD Armaments) DMWR Tasks Co m p on en ts O n ly M2 Machine Gun
PTC Test Facility, Union Town, PA
Acronyms: LMI – Logistics Management Information ILSC – Integrated Logistics Support Center PBOM – Provisioning Bill of Material EBOM – Engineering Bill of Material MBOM – Manufacturing Bill of Material
RBOM – Repair Bill of Material SDS – Standard Depot System DMWR – Depot Maintenance Work Requirement
DTAVS – Depot Total Asset Visibility System JMTC – Joint Manufacturing Technology Center SASI – Small Arms Serialization Interface CAPP – Computer Aided Process Planning
TAMMS – Tool and Asset Management System
