PLM for the US Army Dr. Raj Iyer Team 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

Systems Supporting Army Readiness PRODUCT LINES SUPPORT MAGNITUDE 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 Capital Value of TACOM Equipment $81.7B 141 Allied Countries own TACOM Equipment 2993 Fielded Systems Supported All Army Parent UICs Contain TACOM Supported Equip > 26,000 Components This chart helps illustrate the magnitude of TACOM’s mission. The middle column shows the product lines that TACOM supports. We support these product lines throughout their life cycles, from the development of new technology for tomorrow’s Army to the final disposal of obsolete equipment. The left column highlights a number of our activities. The Total Capital Value of TACOM equipment is approximately $82B, and we currently have approximately 3000 systems being sustained in the field. The right column serves to demonstrate the impact TACOM has on defense of this country. There are 141 allied counties who own TACOM equipment and we continue to provide support for that equipment. Plus Technology Development for the Objective Force The Army’s Lead Systems Integrator April 22, 2005 PDE2005

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 April 22, 2005 PDE2005

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

Standards vs. Point-to-point Solutions SAP Teamcenter MatrixOne CMStat Enovia Windchill STEP Standards   April 22, 2005 PDE2005

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

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

Architecture for the TACOM Lifecycle Management Command Soldier & Ground Systems Collaborative Gateway (ACMS + ACE) STEP Standards Program Executive Offices OEMs TACOM GSIE DLA (BSM) PLM+ TARDEC FCS - ACE Interface to SALE STEP – STandard for Exchange of Product data ACMS – Automated Configuration Management System ACE – Advanced Collaborative Environment PLM+ - Product Lifecycle Management Plus SALE – Single Army Logistics Enterprise April 22, 2005 PDE2005

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

Data Exchange Workflow STEP Part 21/28 File STEP AP214 Translator for Teamcenter EPM Windchill 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 Automatic Import Export User searches for part using ACMS Federation Windchill Adapter Federation Teamcenter Search for part inside Teamcenter Data Exchange Workflow April 22, 2005 PDE2005

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 metal die planning & design AP 214 – Automotive mechanical design processes Design Analysis AP 209 – Composite & metal structural analysis AP 237 – Computational Fluid Dynamics Manufacturing AP 223 – Design & manufacturing of cast parts AP 224 – Machining features for process planning AP 238 – Computer numerical controllers AP 240 – Process plans for machined parts AP 219 – Dimensional inspection for parts Data Management AP 214 cc6 – PDM Schema AP 232 – Technical data packaging AP 239 – Product lifecycle support April 22, 2005 PDE2005

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

PDM Schema April 22, 2005 PDE2005 Systems Engineering (AP233) Design Life-cycle Support (AP239) Analysis (AP209) STEP-PDM SCHEMA Supply chain (AP232) Life-cycle April 22, 2005 PDE2005

April 22, 2005 PDE2005

EXPRESS Data Manager Software April 22, 2005 PDE2005

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

EPM Model Migrator Mapping Software April 22, 2005 PDE2005

Federation-based Product Data Synchronization Fxml Federation Server 1 Server 2 ADAPTER (TEAMCENTER) GROUP (WHAT) SCHEDULER (WHEN) MAPPER (CONVERSION) TRANSPORT (SECURE) ADMIN (DASHBOARD) DELTA ANALYZER (CHANGES) (WINDCHILL) April 22, 2005 PDE2005

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 April 22, 2005 PDE2005