1. © 2003 D. N. Frank Associates Configuration Management in Aerospace and Defense presented by Donald N. Frank BSEE, CFPIM, CIRM D. N. Frank Associates PO Box 295 Florham Park, NJ 07932 Tel: (973) 377-6782 Fax: (973) 514-2148 Email: dfrankasso@optonline.net

2. © 2003 D. N. Frank Associates Our Focus Configuration Management defined Specific A&D issues and concerns CM and the Product Life Cycle CM v Engineering Change Some lessons learned Conclusions

3. © 2003 D. N. Frank Associates Evolution of Standards ANCI/EIA-649 National Consensus Standard for Configuration Management 1998 EIA-836 Data Interoperability and Configuration Management 2002 MILSPEC 1940s ANCI/EIA-748 EVMS 1998 DFARS 252.242 MMAS 1989

4. © 2003 D. N. Frank Associates WSB9806E - Rev C The Enterprise View Phase I Sales Management Order Svc Mgt Asset Management Purchasing Inventory Management Accounts Payable Accounts Receivable General Ledger Mfg Cost Control CRP MRP Master Scheduling Shop Floor Control Shipping & Receiving Warehousing & Distribution Payroll Services Human Resources Mgtt Information Technology Services Project Management Product Design Product Data Management CM really didnt have a home here

5. © 2003 D. N. Frank Associates Definitions

6. © 2003 D. N. Frank Associates Definition of Configuration Management* Applied over the life cycle of a product Provides visibility and controls of its performance, functional and physical attributes Verifies that a product performs as intended Is identified and documented in sufficient detail to support its projected life cycle * Abstracted from EIA-649

7. © 2003 D. N. Frank Associates Configuration Management Data Exchange And Interoperability* Facilitates the interoperability and exchange of configuration management data To be most effective, the capabilities of the process, tools or systems, should embody the CM principles in ANSI/EIA-649 in conjunction with the business objects and data element definitions in EIA-836 Provides a set of standard definitions and business objects that can be used by XML frameworks in interfacing the content elements among one or more systems or databases. The extensible markup language (XML) facilitates data sharing and exchange among different systems The level of interoperability between dissimilar systems is determined by trading partner agreement * Abstracted from EIA-836

8. © 2003 D. N. Frank Associates The Configuration Continuum EOJ RFI, RFQ, RFP Propose Project YBID? N R&D Y Propose Products & Services N MRO Req'd EOJN A Y Capture Configuration, Cost, Schedule & Performance Do Required R&D Ship and Bill Award R&D Plan & Execute Prod

9. © 2003 D. N. Frank Associates Aerospace & Defense Environment

10. © 2003 D. N. Frank Associates CFG028 - Rev. B Aerospace and Defense Functional Needs Managing massive bid activities –FAR, DFARS, CAS, EIA, ANCI/EIA etc. Managing massive design activities –Program and project management –Work Breakdown Structures (WBS) Managing manufacturing operations –Many, many open work orders –Constant engineering change Government reporting requirements –MMAS –Cost/pricing disclosure –Etc., etc., etc. Configuration management –The As-Something Syndrome

11. © 2003 D. N. Frank Associates CFG028 - Rev. B Aerospace and Defense Specific Constraints Government oversight Design/Engineer to order Project oriented activities –R&D –Devices Deep Bills of Material Constant engineering change Long (30+ years) product life cycles Legacy mindsets –Both Government and Contractors

12. © 2003 D. N. Frank Associates Product Life Cycle Phases

13. © 2003 D. N. Frank Associates As Quoted Program Management Paper Parts List File Cabinet RFI, RFP, etc. More or less informal Spreadsheets?

14. © 2003 D. N. Frank Associates As Accepted Program Management WBS database Negotiated Contract Deliverables and Schedule Committed R&D Hardware Software Ancillary Activities Project Management

15. © 2003 D. N. Frank Associates As Designed Engineering Printout or Screen CAn PLM EBOM databases CAn Part Definition CSM PDM Workflow & Red Lining EBOM Release(s) to Manufacturing Engineering Changes

16. © 2003 D. N. Frank Associates As Planned Materials Management Printout or Screen ERP MBOM IM databases MBOM Resource Planning Procurement Manufacture Ship Absorb Engineering Changes

17. © 2003 D. N. Frank Associates As Built Manufacturing Printout or Screen ? Effectivity By Date By Lot Number By CLIN By Serial Number ?BOM

18. © 2003 D. N. Frank Associates As Documented Configuration Management Printout or Screen ? All Deliverables Hardware Software Test & Inspection Data Certificates Pack-up Data

19. © 2003 D. N. Frank Associates As Maintained Field Service Printout or Screen ? Individual Unit History Maintenance Echelons Deployment Schedules Skills Material Documents Upgrades

20. © 2003 D. N. Frank Associates ENG9003A1 - Rev C Where is the Source Document? Printout or Screen CADCAM Parts List File AS DESIGNED Engineering Printout or Screen Mfg BOM File AS PLANNED Matls Mgt Paper Parts List File Cabinet AS QUOTED Program Mgt Printout or Screen ? AS BUILT Mfg Printout or Screen ? AS DOCUMENTED Config Mgt AS MAINTAINED Field Svc Printout or Screen ? WBS database AS COSTED Program Mgt Engineering Change Notice Who Owns the Configuration?

21. © 2003 D. N. Frank Associates EMBOM9808D Who Owns the Bill of Material Engineering Program Management Manufacturing Accounting Purchasing Planning None of the above All of the above A short quiz

22. © 2003 D. N. Frank Associates CM v Engineering Change

23. © 2003 D. N. Frank Associates The Configuration Continuum EOJ RFI, RFQ, RFP Propose Project YBID? N R&D Y Propose Products & Services N MRO Req'd EOJN A Y Do Required R&D Ship and Bill Award R&D Plan & Execute Prod ECN Main Focus Just the tip of the iceberg Wheres the Baseline

24. © 2003 D. N. Frank Associates ERM-114 - Rev. D What is an Engineering Change Changing the Product Structure (BOMs) –Adding a part –Deleting a part –Changing the quantity per assembly Changing the Part Itself –Changing specifications –New Part Number? –Changing approved sources Changing the Routing (?) –Changing the process –Changing the process sequence Do all Engineering Changes affect form, fit or function?

25. © 2003 D. N. Frank Associates BOM0404 - Rev. B The 4F Principle Function:What does it do Form:What does it look like Fit:How does it interface Fee:What do we charge for it Too many of us forget the 4th F

26. © 2003 D. N. Frank Associates BOM0405 - Rev. C What must the ECN Do Tell us WHAT to change Show us HOW to make the change Tell us WHEN –Effectivity Tell us WHO –Define tasks Show us WHERE –What documents Tell us WHY –Really explain the reasons

27. © 2003 D. N. Frank Associates BOM0414A - Rev. B Revision Letter Concepts Assigned To The Physical Item The Engineering Drawing The Part Master Record (?) The Bill of Material Record The Routing Record (?) All Customer Order Line Items All Work Order Line Items All Purchase Order Line Items How well do we do this?

28. © 2003 D. N. Frank Associates BOM0414B- Rev. A Revision Letter Concepts Attributes Has an associated ECN Document Has an Unique ECN Number Has an ECN Initiation Date Has defined Effectivity Suggested Formats –Numerical prior to manufacturing release –Alpha after Manufacturing release Omit I, O, Q, S, X, Z After Y, to to AA, AB, etc. MIL-STD-100 is a good guide How well do we do this?

29. © 2003 D. N. Frank Associates BOM0415 - Rev. B Effectivity of Change By Revision Letter –Engineerings preference By Dates –Do not use before, do not use after –Most manufacturing software does this Other methods (needs) –Use to depletion of old part –Lot (batch) Number –Project (contract) Number –Customer Number –Purchase Order Number –Serial Number Engineering and manufacturing have differing views of effectivity

30. © 2003 D. N. Frank Associates Some Lessons Learned

31. © 2003 D. N. Frank Associates BOM0417- Rev. B Effectivity of Change Revisited Engineering traditionally manages changes via Revision Letter upgrades Engineering change systems do not always consider Effectivity Manufacturing software systems do not do a good job of managing change by Revision Code Effectivity dates are subject to change Ways to close the gap –Put an ECN Czar in charge of bridging the gap –Only allow manufacturing BOM maintenance via an ECN screen with restricted access, requiring Revision Letter update and Effectivity statement Change impact must be communicated to manufacturing … quickly

32. © 2003 D. N. Frank Associates BOM0409 - Rev. A The Triage Principle Engineering Change Priority Planning AStop work and fix –The sun will not set before preliminary action is taken BDefine Effectivity and schedule into the manufacturing planning and execution process –Plan for least disruption and part obsolescence –No more than 2-3 working days until preliminary release CAggregate and hold for product upgrade –Batch release no less often than quarterly The business side of EC processing

33. © 2003 D. N. Frank Associates Reference Designators REF60616D E1 E2 E3 E4 E5 CR1 CR2 T1 L1 + C1 + C2 R1 R2 P/N A284756-002 - Rev F Krarfnod Mfg Co. - Mfg Bill of Material - Sheet 1 of 1 as of: 950715 ____________________________________________________________________________ Part No: A2874756-002 Desc: Pwr Supply 15V 20A Rev: F Lot Size: 1500 Lead Time: 10 Days Planner: Joe Knarf ____________________________________________________________________________ Item Ref Part NoRevDescription QtyUMEff ____________________________________________________________________________ 1A1 A2874756 CPC Card Power Supply1.0000EA950105 2C112345ACap Tant 25MF, 20 V1.0000EA 960102 3C228475Cap Tant 50 MF, 20 V1.0000EA000000 4CR179687Diode Rectifier 30A 200V1.0000EA000000 5CR279687Diode Rectifier 30A 200V1.0000EA000000 6E148576Terminal Swage 0.125D 0.5H1.0000EA000000 7E248576Terminal Swage 0.125D 0.5H1.0000EA000000 8E348576Terminal Swage 0.125D 0.5H1.0000EA000000 9E448576Terminal Swage 0.125D 0.5H1.0000EA000000 10E548576Terminal Swage 0.125D 0.5H1.0000EA000000 11L168473CSwing Choke 25H, 25A1.0000EA950725 12R194375-004Res Fixed WW 1000 20W 5%1.0000EA000000 13R294375-007Res Fixed WW 2500 20W 5%1.0000EA000000 14T168794BXformer 115/27V 300W1.0000EA960602 15157682 Assembly DwgA/REA000000 Links Dwg, Schematic and Parts List Is there another Bill of Material here?

34. © 2003 D. N. Frank Associates Diced Board Part A 1 up Panelized Circuit Card UOM Issue SCI9701B1 Raw Board B1 4 up Loaded Board Part B2 4 up Level 0 Qty=1.00 UOM=EA Level 1 Qty=0.25 UOM=EA? Level 2 Qty=1.00 UOM=EA Part A Part B2 Part Populated Part 4 Up Part A Part A Part A Part A Part B1 Purchased Part Raw Board 4 up Part A Part A Part A Part A

35. © 2003 D. N. Frank Associates The Total Supply Chain CC a CC b CC n CaCa CbCb CnCn Our Enterprise SaSa SnSn SS a SS n Demand Supply Whose Master Schedule should we use? Who controls the product configuration C = Customer CC = Customers Customer S = Supplier SS = Suppliers Supplier

36. © 2003 D. N. Frank Associates Conclusions

37. © 2003 D. N. Frank Associates PUR9505N The Old Way Engineers dont Understand Manufacturing Manufacturing doesnt Understand Engineers

38. © 2003 D. N. Frank Associates 95-029-Rev.C How We View Each Other

39. © 2003 D. N. Frank Associates Quick BOM Quiz How many bill of material systems do we have? How many bill of material systems do we need? EMBOM9904C

40. © 2003 D. N. Frank Associates EMBOM9904D The View from the Foxhole Oh EBOM is EBOM and MBOM is MBOM, and never the twain shall meet, Til Earth and Sky stand presently at Gods great Judgment Seat; But there is neither Designer or Planner, border, nor breed, nor birth, When two strong [people] stand face to face, though they come from the ends of the earth! Stolen from Rudyard Kiplings Ballad of East and West

41. © 2003 D. N. Frank Associates ERP9807E - Rev G The Enterprise View Phase II Interoperability Area Interoperability Area Shared Resources The Data Vault Manufacture Quality Distrib- ution Financials Sales & Mktg MRP II HRM ERP Part Master BOM Config Mgt CSM Concurrent Eng Management Reporting WBS Project Mgt CAE CAM ECAD MCAD Workflow Redline PDM Design Eng Doc Mgt EAI EAI = Enterprise Application Integration (Middleware) GERM APS CRM B2B ? Routing Work Ctr Bill of Material Routing Work Center Part Master Bill of Material Routing Work Center Part Master

42. © 2003 D. N. Frank Associates ENG9003A1 - Rev D Now who owns the Configuration Printout or Screen AS DESIGNED Engineering Printout or Screen AS PLANNED Matls Mgt Printout or Screen AS QUOTED Program Mgt Printout or Screen AS BUILT Mfg Printout or Screen AS DOCUMENTED Config Mgt AS MAINTAINED Field Svc Printout or Screen Enterprise BOM Configuration Mgt Process Enterprise Change Notice Printout or Screen AS COSTED Program Mgt Now we have a source document

43. © 2003 D. N. Frank Associates EMM9807C - Rev. A The Germ of a New Idea Understanding ERP is not enough Doing Concurrent Engineering is not enough Understanding PDM is not enough Understanding SCM is not enough These initiatives are only parts of the 21st century unified approach Global Enterprise Resource Management A New FLA

44. © 2003 D. N. Frank Associates EMM9807D - Rev A Prerequisites Engineering –Accept the Single BOM concept –Assume cradle to grave data integrity responsibility –Understand configuration management implications on the Master Schedule –Willingness to be an enterprise team player Manufacturing –Accept the single BOM concept –Participate in configuration management activities –Understand Master Schedule implications of configuration management –Willingness to be an enterprise team player Management –Be the champion of the GERM process

45. © 2003 D. N. Frank Associates EMBOM9808G Ten Steps to the Single BOM 1. Understand that the design objective is to provide effective documentation for manufacturing 2.Manufacturing and planning participate in the design process 3.Document the bills of material into the manufacturing database 4.Use the master schedule to show design status 5.Start As-Planned early in the design process

46. © 2003 D. N. Frank Associates EMBOM9808H Ten Steps to the Single BOM (cont) 6.Document the design for manufacturing the first time out 7.Use the Single BOM to capture drawing numbers and revision status 8.Use the Single BOM to maintain the As- Something status 9.Use the Single BOM for customer and/or Government reporting requirements 10.Use the Single BOM as the catalyst for engineering/manufacturing integration

47. © 2003 D. N. Frank Associates A Final Thought If we consider the bill of material as a living document that migrates from one phase to another, –We could measure the quality of the quotation against the accepted configuration –We could measure the quality of the design against manufacturing being able to build from the engineering documentation … directly –We could measure manufacturing performance against the baseline configuration –We can capture the as-maintained and compare to any as- built for effective maintenance and upgrade –We could measure the enterprise performance against what the customer really wanted

48. © 2003 D. N. Frank Associates BOM8905L - Rev. B In over 25 years, Ive never found a real reason for more than one Bill of Material system Franks 15th Law 35 40

49. © 2003 D. N. Frank Associates PUR9505P - Rev B The New Way Teamwork produces amazing results

50. © 2003 D. N. Frank Associates CTN0003 - Rev. A The Kiss Principle If your solution is overly complicated... You probably do not understand the problem

51. © 2003 D. N. Frank Associates BOM0101P - Rev. E BOM System Evaluation Quiz Score 1 to 5, where 5 is high Does your BOM system meet real needs Is it simple and easy to understand Does it have flexibility for future growth Does it really describe the manufacturing process Are BOM functions & responsibilities focused Is there good feedback of BOM effectiveness Is the BOM a good communicator of information Is BOM maintenance simple and effective Is the BOM System cost effective Does Management participate in BOM decisions Is there only one enterprise BOM system Email responses to dfrankasso@optonline.net Ill share results with all responders

52. © 2003 D. N. Frank Associates Our Focus Configuration Management defined Specific A&D issues and concerns CM and the Product Life Cycle CM v Engineering Change Some lessons learned Conclusions

53. © 2003 D. N. Frank Associates WRA9201A - Rev. B Thank You! Questions?

54. © 2003 D. N. Frank Associates Configuration Management in Aerospace and Defense presented by Donald N. Frank BSEE, CFPIM, CIRM D. N. Frank Associates PO Box 295 Florham Park, NJ 07932 Tel: (973) 377-6782 Fax: (973) 514-2148 Email: dfrankasso@optonline.net