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 Raj.iyer@us.army.mil
Army Logistics Automation Transition Plan Path to Single Army Logistics Enterprise (SALE) 4/2/2009 2
LMP Enterprise Model the world s largest ERP! Supply Chain Planning Suppliers Commercial Contractors Army Industrial Base Depots Arsenals Other DOD DLA Customer Returns Demand Planning Distribution Planning Acquisition and Distribution Order Acquisition Distribution Management Army Search Matrix and Penetration Logic Real-time Global Available-to-Promise Back order Processing MILSTRIP sales order processing Data and Reporting Long Term and Material Requirements Planning Industrial Base Operations Make Fix Project Systems Budget Planning Acquisition Manufacturing and Remanufacturing Resource Requirements Planning National Maintenance Management Base Operations and Plant Maintenance Quality Management Human Resources Budget and Finance General Accounting DFAS and Cost Management and Real Funds Management Estate (Facilities) Management Provisioning Cataloging Material Master Management Packaging and Freight Maintenance Engineering Inventory Management Warehouse Management Single Stock Fund Environment, Health, and Safety Cost Accounting Budget Formulation Ammunition Support Bills of Material Customers Army Army Reserves National Guard Other DOD AF Navy Marines DLA Other Government Federal State Local Foreign Armed Services 3
LMP Deployment Sites PEO GCS Warren, MI (HQ) Picatinny, NJ Huntsville, AL PEO CS&CSS Warren, MI (HQ) Rock Island, IL Huntsville, AL Natick, MA A PEO Soldier Fort Belvoir, VA (HQ) Picatinny, NJ Huntsville, AL Enterprise Partners TARDEC - Warren, MI ARDEC - Picatinny, NJ NSC - Natick, MA T A L T Acquisition (PEOs) Logistics / Industrial Operations (ILSC) Technology (RDECs) TACOM will deploy LMP in October 2010 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 4/2/2009 4
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! 5
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 Almost all of the material master data required by LMP can be found in LMI 6
LSA Data Flow and System Engineering Interface -FMECA - LORA - RCM - Tools - Test Equipment -Calibration Equipment - Maintenance equipment - Provisioning - Cataloging - Spares - RPSTL 7
Integrated Logistics Support Process and Data Re-use LSA Reliability Analysis Engineering BOM CAD Specifications FMECA RCMA FMEA Corrective & preventative maintenance tasks Lifecycle Cost Analysis Aggregate LMI Data Maintenance Task Analysis 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 Facilities Data Tool Library Manpower Provisioning Design Artifacts Engineering BOM Provisioning Spares stocking Serviceable BOM Spare parts list Spares requirements Maintenance task definition Tech Pubs Tech Pubs Maintenance Manual IETM/IETP Operators Manual Maintenance Procedures Maintenance Tasks Training Training Training courses MRO/MES Valid configurations Actual service procedures As Maintained configuration of BOM Job cards / Work orders Service Records Utilization MES 8
Need for integrated BOMs across the enterprise Supply/ Wholesale Action ILSC Repair Action/Depot Manufacturing Action/ Arsenal Engineering Action RDECOM LMI Work Centers Routing TDP DMWR/ NMWR TM/IETM RPSTL PBOM Available Resources RBOM MBOM Process Plans Specs & Standards EBOM Drawings & Models Engineering Changes As-maintained Configuration Field/ Tactical PEO/PM OEM BOMs created by ILSC, depots, arsenals and RDECs are disconnected and unsynchronized with actual product configuration today unsynchronized with actual product configuration today 9
PM total lifecycle systems integration responsibilities Supply/ Wholesale Action ILSC Repair Action/Depot Manufacturing Action/ Arsenal Engineering Action RDECOM LMI Work Centers Routing TDP NMWR/ DMWR TM/IETM RPSTL PBOM Available Resources RBOM MBOM Process Plans Specs & Standards EBOM Drawings & Models Engineering Changes Configuration Management PEO/PM OEM PM is responsible for data integrity and accuracy through formal change control process 10
Closed Loop Product Lifecycle Management Reliability & Qualification Testing Release To Manufacturing PM is the Lifecycle Manager Technical Documentation Service Record Management Upgrades & Overhauls Line Maintenance Design & Development Design for Sustainment Product Development Service Performance Analysis Product Support Scheduled Maintenance Systems Engineering Customer Requirements Product Optimization Equipment Utilization & Performance Analysis Service Optimization Service Program Definition Service Planning LMP is expected to transform and revitalize the PM s role as the lifecycle system manager consistent with DOD 5000 Total Life Cycle Systems Management (TLCM) 11
Integrated Product Baseline The 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 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 TACOM however Data Strategy not implemented in LMP 12
As-Is Change Control Process Engineering Change Requests Design Change EBOM Engineering Change Notice Engineering throws ECN over the wall To other functions Other functions receive ECN with time delays Drawing Change Changes gathered by Engineering Manufacturing Supply Repair MBOM PBOM RBOM Changes are made to respective BOMs and unsynchronized Current change control process is engineering centric. Other functional stakeholders are notified of decisions made and held responsible for making changes to their BOMs manually. 13
To-Be Change Control Process All users notified of changes All BOM users within the enterprise can request changes to Master BOM BOM Change Request Configuration Control Board consists of all functional users Changes to Master BOM Automatically updates other derivative BOMs CCB approves/ rejects request PBOM RBOM Changes made to Master BOM 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 BOM and automatically propagated to all stakeholders. MBOM BOM and automatically TACOM propagated Data Strategy to all stakeholders. 14
Manufacturing Execution System the final missing link Basis for model is MESA eleven functions of MES 15
Integrating PLM-ERP-MES 16
Product Data Integration Architecture Training OEM Configuration Management Data Deliverable Data Federation RCM LORA FMECA Task Analysis Provisioning 2LM EMS IETMs TMs RPSTLs NMWRs DMWRs Operator Manuals Document Management Master BOM Management Collaboration CAD/ Drawing Management PowerLog-J Windchill Tech Loop Process Workflows Serial Item Management AIT MES Windchill ERP Interface Materiel Master SAP Netweaver ESB SOA-based Data Federation DLA Enterprise Business System TACOM Industrial Base LMP 17
Linking product configuration data to the shop floor 2. PBOM linked back to EBOM if available 1. PBOM developed through LMI or cleansed from CCSS 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 7. Dynamically generate Work Instructions 8. Send to LMP: BOMs Parts (Material Masters) Routings Work Centers Work Instructions Document Links EBOM (Part No + CAGE Code) System EBOM Arm Part 1 Part 2 Wheel Assy Engine Part 3 Part 4 PBOM (NSN) System PBOM Arm Part 1 Part 2 Wheel Assy Support Part 3 Equivalent MBOM/RBOM (Part No/ NSN) System MBOM/RBOM Sub-Assy Part 1 Part 2 Part 8 Part 9 Support Builds Op 010 Consumed Routing Op 020 Op 025 Op 030 Operated on Performed with Op 040 Plants Documents Illustrations Textual Description Time Breakdown Part List Resource List Resources Work Centers... Windchill Tools Machines Skills Process material 18
Components Only Armaments R&D Engg. Center - Rock Island Intralink MACPAC CAPP TAMMS Data integration validation pilot on small arms Parts Tasks Packaging M-BOM, Workcenters LMI E-BOM Configuration Management CAD models P-BOM + Material Master Attributes Tasks Powerlog-J Windchill (Integrated Product Baseline) ILSC Small Arms Item Manager M2 Machine Gun PTC Test Facility, Union Town, PA SAP ECC 6 OEM Validation (GD Armaments) 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 JMTC - Rock Island Arsenal SDS Maximo DTAVS SASI DMWR Anniston Army Depot
Conclusions LMP is transforming TACOM both at the top floor (HQ) and the shop floor LMP is just the first (big) stepping stone on a longer journey TACOM is working towards adopting commercial best practices and solutions Data will be created once and re-used multiple times through the enterprise Initiatives will help TACOM transition successfully to the Materiel Lifecycle Enterprise 19