Configuration Management in the Aircraft Industry

Configuration Management in the Aircraft Industry

ProSTEP iViP Symposium 2009 H. Pitthan

2

A Joint Diehl Thales Company

Configuration Management in the Aircraft Industry

•

Company

•

Initial Situation

•

PLM Project

•

Configuration Management

Company Overview - Diehl Aerospace

An der Sandelmühle 13 D-60439 Frankfurt am Main

Donaustraße 120 D-90451 Nürnberg Alte Nußdorfer Straße 23

D-88662 Überlingen (Headquarters)

51%

49%

Staff:

1200

Sales:

205 M€

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A Joint Diehl Thales Company

Overview military portfolio

EUROFIGHTER TORNADO A400M

DAs System responsibility

Legend:

Multifunction

Head-down Display Flight Control Computer

Stick Sensor and Interface Control Assembly Fuel Computer Enhanced Lighting Controller Landing Gear Computer

Control and Display System

AFDX End System Integrated Modular Avionics

Doors Control and Monitoring System ECR Computer Symbol Generator Digital Engine Control Unit 2020 Command Stability Augmentation System Video Switching Unit Electronic Warfare Indicator Instruments Turbine Blade Temperature

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A Joint Diehl Thales Company

Allocation of Discipline parts

C o c k p it u n d D is p la y s y s te m e F lu g s te u e ru n g T ri e b w e rk s re g e lu n g K a b in e n s y s te m e D u rc h s c h n it t Mechanik Hardware Software 0 10 20 30 40 50 60

Starting Point: Analysis

•

Forschungszentrum Informatik (Karlsruhe), Vector Consulting and

Siemens IT Services were commissioned to perform a study on:

– the potential of PLM-Solutions available on the market

– their possible impact on harmonizing processes and tools across sites

– achievable benefits based on the current state of affairs

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Resulting PLM focus areas and recommendations:

1. Configuration Management 2. Change Management 4. Engineering Processes Design 3. CAD Tool Harmonization 5. Engineering Process Implementation 8. Manufacturing and Service Integration 7. EDM Tool Integration 6. Document Flow 9. Partner Collaboration

2007

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A Joint Diehl Thales Company

Launch of the PLM Introduction

Mission:

•

By introducing Product Lifecycle Management (PLM) at Diehl Aerospace

all relevant product information as well as information pertaining to their

generation and use will be kept in a central data repository throughout the

entire product lifecycle. This will ensure that the correct information is

made available where it is needed exactly when it is needed.

Goals:

•

Improve the efficiency within the company, specifically of the NPI process.

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Strengthen process assurance and subsequently minimize costly

deviations.

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Reduce tool & process support cost and provide greater flexibility in

resource allocation to projects across sites.

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Facilitate an effective partner management.

PLM Introduction in Phases

Central DB

(incl. DMS)

Configuration

Management

(Baselining)

Change

Management

CAD

Integration

Workflow

Integration of

Doors,

Clearcase,

Clearquest

Digital

Signature

Data

Exchange

with

Development

Partners

Integration

of Legacy

Data

Process

Portal

Integration

of Production

and Service

Data

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A Joint Diehl Thales Company

Data Concept – Lifecycle Support

Pre.Dev. Concept

Quotations

Contracts

Comos

Reports

Metrics

IBPM,…

Mails

eCAD

mCAD

DRL

Legacy

Documents

EMS Data

Service Bulletin,

CMM, …

Supplier

Portal

Customer

Portal

Require

-ments

Norms

Standards

Soft-ware

SAP PLM

Definition Implementation Qualification Production Service

Changes

(CR, DCR,

CL, EDES)

Mfg.

Records

Iterative Development

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A Joint Diehl Thales Company

PLM

Configuration Management Baseline

Initial situation and goal

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Initial situation

– All relevant data of a baseline are collected manually from the respective authoring system and are documented in the Configuration Index Document (CID).

– Material from SAP partslist

– Documents from SAP EASY DM

– Drawings and models from SAP DVS – Standards and additional data from

Project Servers

– Test means documentation from SAP, Project servers und partially from Excel lists

•

Goal

– The goal of the PLM Project is to collect and manage all relevant data centrally in a database

DRL

Changes

(CR, DCR,

CL, EDES)

mCAD

Software

Require

-ments

Configuration Management (CM) Baseline (BL)

Meta data of the baseline

Part-, Document-and

Tool list and drawing list Team definition

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A Joint Diehl Thales Company

CM BL Part Cockpit

4. Detail screen for changes,

documents, attachments, …

CM BL Document Cockpit

Document checklist based on templates

• Boeing 747 Std

• Airbus Gress CAM 10

Handling status

Notification of version

•green: last and released version •yellow: new version available

•red: new and released version avail.

Creation or allocation of DIS

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A Joint Diehl Thales Company

CM BL Tool List and Means Cockpit

Tool list based on templates

Configuration of test means

CM BL Drawing List

List of all linked documents allocated to the top material (Filtered

according defined document types)

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A Joint Diehl Thales Company

CM BL Configuration Index Document (CID)

CID Document is automatically generated

(Tools: create documents)

CM BL CID Release

Team definition based on role definitions acc.

CMMI

Release cockpit

Query of user name und password to document

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A Joint Diehl Thales Company

CM BL CID Release workflow

Workflow members are generated according

team definition

Workflow and actions are predefined

(Templates)

Usage of SAP Business Workplace functions

and notification per Notes mail

CM BL CID release shown in the document

Release acc. project record implemented in

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A Joint Diehl Thales Company

Configuration Management Change processes

Initial situation and goal

•

Initial situation

– The change processes are handled different at each location.

The processes are normally “paper“ based.

– Long duration cycles.

•

Goals

– To create, to monitor an to realize the changes centralized and paperless in

SAP.

– Reduce the cycle time to 50%

– Improve the inventories significant

PLM e-m ail e-mail e-m ail e -m a il Engineering Change Request CAD Drawing Layout BOM Serial process …. parallel process ….

CM Change Control Processes

CCR

CPR

PR

Event

CLx

CL

CR

CCB

Internal Problem phaseSerial

Development phase Subcontractor

CE

and Costing Decision CCB

Customer release

Implemen-tation

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A Joint Diehl Thales Company

Change Request (CR) in

ECM

Change processes role based views

Meta data

ECM Cockpit

Validation of changes

Inventory of material

e.g. Production orders per material

Validation of each position

Detail Screens for Attachments, parts list,

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A Joint Diehl Thales Company

CR Template generated automatically

CR Template generated and filled

automatically and filed at linked

objects

Meta data of Change Request

Checklists and templates

Cost summary based on templates

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A Joint Diehl Thales Company

CR Workflow

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Questions, please?