Holistic PLM for the development of mechatronic systems Proof of concept: Synchronized Mechatronics Engineering enabled by SOA

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1 Holistic PLM for the development of mechatronic systems Proof of concept: Synchronized Mechatronics Engineering enabled by SOA Dr. Gerd Oelerich Bernd Sartor Hubert Aunkofer Ines Merk Michael Buchholz Frank Weiblen IBM SWG, PLM Solutions IBM SWG,PLM Solutions IBM SWG, Rational IBM SWG, WebShpere PROSTEP IBM SWG, PLM Solutions 2009 IBM Corporation

2 Challenges in development of mechatronics systems and how to deal with Challenges Handle complexity Ensure ability to innovate Increase quality Improve efficiency of development processes Synchronize different lifecycles Integrate different disciplines, cultures and organizations Functions F1 F2 Product B1 B2 B3 Module HW SW EE Aggregates 2

3 Systems Engineering for development of mechatronic systems compliant to requirements Benefits through Systems Engineering: From vertical towers to one system level Synchronize communication, processes, methods and tools Integration and reuse of deliverables Systems Engineering principles: Respects relations and dependencies between elements Integrates work products of different development domains to the synthesis of the whole system Verification and validation of the system to ensure that all requirements are met Requirements Functions System Architecture Mechanics Electronics Software Product/System Integration Test & Validation 3

4 The Solution Approach: Synchronized Change Process Consistent rules and processes applied by all stakeholders Overall status and process information available SW Iterative Process MCAD V Process E/E V Process Mgmt??? SW IBM Software Group Development HW EE Lotus software Assets Assets Assets Collaboration and sharing of results Traceability of artifacts and business objects Change Request SW ECO EE ECO ECO Reuse of artifacts ECR Approval Process HW ECO Continuous validation against requirements on all system levels 4

5 The concept to integrative change within different development domains The concept for developing on a domain-comprehensive basis intends that the change request on the system level is being broken down into requests for the particular domains After the execution: the new baselines of the single domains are being aggregated to a new overall baseline and the change request is being closed Stakeholder Change Request System Baseline 1 System Baseline 2 Master Order Requirement- Baseline 1 Requirement- Baseline 2 Baseline 1 HW Requirements Baseline 2 HW Requirements HW Baseline 1 HW Order HW Baseline 2 Baseline 1 E/E Requirements Baseline 2 E/E Requirements E/E Baseline 1 E/E Order E/E Baseline 2 Baseline 1 SW Requirements Baseline 2 SW Requirements SW Baseline 1 SW Order SW Baseline 2 5

6 Advantages of the integration concept The state conditions within the domains facilitate synchronizing the different development disciplines ongoing visibility for easy monitoring control on Gates or Milestones of the development process Easy navigation into the processes and their work products at domain level end-to-end traceability Within the domains the, development follows specific procedure models and is being executed with specific tools and data managers The EC-interface delivers specific requirements and receives the work result that is relevant for the synthesis of the complete system; sub-components and processes can be managed freely within the domains Developers use solely or predominately their standard tools HW Order Relational Design, CAD and VPLM Master Order E/E Order Design/Layout - Loops SW Order Rational Unified Process, Activity Mgr and CM Tool 6

7 Synchronizing Engineering Changes in Mechatronics Integration Architecture Overview Master Order HW Change Order SW Change Order ECO Management E/E Change Order System Level Mech. BOM E/E BOM SW BOM Federated BOM ECR Process WAS/WID/WPS Integration Level IBM Software Team Data Group Lotus Team Data software ClearQuest MatrixOne SmarTeam ERP ClearCase Build Forge E-CAD Mechanical Authoring Application Level Software Authoring Electrical Authoring Mechanical Authoring BOM 7

8 System Level - ENOVIA Reference architecture Bidirectional PROSTEP Adaplet (Web Services) ENOVIA PROSTEP Adaplet for OpenPDM 8

9 Using modular Web Services for the integration of the SW domain Modular Web Services have been developed which are hosted by MatrixOne and ClearQuest resp. and are used in different phases of the scenario System Link records Link to records ClearQuest MatrixOne Method Name Submit record Provide record state Set record state Update record Create Object Update Object Connect objects Receive number File service, Check in File service, check out Description Create record of given type Provide state of a record Set the state of a record Update meta data of a record Creates an object in MOne Updates attributes of an existing object Connects objects through spec. relationship Receives a new identification number from the MOne numbering generator Upload and check in files, connect to object check out and download files related to objects 9

10 Integrating the mechanics domain We operate a Team Data Manager which is ENOVIA SmarTeam for organizing the engineering procedures in the mechanical domain. The information flow towards SmarTeam goes through the IBM WebSphere Process Server and the ProSTEP OpenPDM gateway. IBM WebSphere Process Sever OpenPDM 10

11 Scenario Overview Analyse Requirements Set up ECO structure Promote Master ECO Mech. ECO, Part SW ECO OpenPDM Perform transfer of ECO and affected part Navigate to affected CAD models, perform change, Rational IBM Software Group Lotus Rational software ClearQuest Set up SW project, assign team, ClearCase Build Forge Perform change Build SW Promote ECO, update ECO in ENOVIA provide new BOM Rational ClearQuest Promote ECO, update ECO in ENOVIA, provide new SW part EE ECO ECAD Check out schematics, Perform change, generate el. BOM Import el. BOM Aggregate system BOM, transfer BOM to SAP, complete ECOs Incorporate material masters and BOM 11

12 State display on system level ECO stateon domain level 12

13 ECO in the mechanical domain system A new ECO is created in the domain data manager and related information is attached. A team leader can use the hyperlink to switch to the system context.. 13

14 ECO in the SW domain system Again, a local ECO is initiated from the system level and related information is forwarded to the SW configuration management tool. Requirements that were assigned to the SW Change Order are forwarded to the domain system for validating the deliverables. 14

15 The federated BOM Root node Electrical parts Mechanical parts SW part 15

16 Values of a holistic Product Lifecycle Management in the mechatronics engineering Reduce development costs through process automation, flexibility and inter-domain collaboration Accelerate development cycles through synchronization, faster feedback and increased reuse of existing solutions Increase product quality through standardized development processes that ensure consistent results improved reuse of approved assets check and test results on all levels against initial requirements Manage complexity through traceability and a single federated system BOM Protect and capitalize investments through leveraging of existing domain specific knowledge and methodologies 16

17 Thank You! 2009 IBM Corporation

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