CTMA Project #: 140412

Problem: The CTMA Product Lifecycle Management (PLM) for Six Sigma Quality – Phase I project demonstrated the capability of creating solid models with granularity and associated intelligence down to a part feature level.  This ability to capture drawing and specification characteristics and display it in an AS9102 format to facilitate First Article Inspection Reports (FAIR) real time via the Internet will reduce quality escapes, reduce efforts, and reduce lead times.

The PLM for Six Sigma Quality project targeted parts where drawing data was in UGS NX native format.  This project extends the benefits to legacy parts where part data is in one of the raster image formats, including the DoD’s JEDMICS drawings.  Technology from this project provides a means of adding intelligent data about engineering requirements to a JEDMICS part file without modifying the configuration controlled master drawing file in any way.  The result is that existing JEDMICS part files can be enhanced with intelligent manufacturing data without impacting data ownership, an important factor when dealing with legacy data that predates more modern data acquisition policies.

Within the aerospace industry the majority of this data is extremely sensitive and falls under the Export Control Act of 2002 (ITAR and EAR) and company-specific policies.  Esta­blishment of a secure collaborative environment is required to ensure proper ID certification, accreditation and verification.

The key business drivers of the Legacy Data Lifecycle Management project are:

  • Management of security privileges
  • Identity management based on open standards
  • PLM
  • Legacy data extraction
  • AS9102 Compliance: Real-time OEM/Supplier FAIR exchange and approval
  • AS9103 Compliance: Real-time OEM/Supplier monitoring of on-going production process capability
  • Digital requirements management architecture.

Benefit: The following qualitative list of anticipated benefits from the Legacy Data Lifecycle Management project applies most directly to defense OEMs and DLA, the entities that interface most often with suppliers:

  • Reduced cycle time to implement a new program through a reduction in the time required to qualify manufacturing processes for parts
  • Improved communication between suppliers and OEM
  • Improved quality and delivery metrics
  • Reduced lead time of product change
  • Reduction in human errors via electronic characteristic flow-down from design engineering through the FAIR
  • Ability to share data real-time improving communication between OEM personnel and their suppliers
  • Reuse of legacy data throughout the supply-chain.

Anticipated quantitative benefits to OEM, DLA, and to depot interface with suppliers are as follows:

  • Reduction in missed or misinterpreted engineering requirements of 20%
  • Reduction in supplier qualification time (the FAIR process) of 15%.

Depots will use the technologies to address issues other than those of the supply chain.  The PLM Pathfinder at OC-ALC, for example, is migrating legacy F101 engine data to the Teamcenter™ PLM system.  Most F101 engine part data today is raster images in JEDMICS.  Adding intelligence to part data without impacting data rights and then configuration managing the whole brings to legacy data the same benefits estimated for 3D data used in the PLM for Six Sigma Part Quality project.

Solution/Approach:

  • Conduct a pilot project to demonstrate information technology (IT) solutions that are adopted by industry governance boards
  • Demonstrate the ability to comply with export control company regulations while working real time in a secure environment
  • Develop ballooning strategy for Rolls-Royce data types (NX, Vector and raster drawings, include approaches for first pass, adding intelligence, batch ballooning, etc.)
  • Develop ballooning strategies and enhanced data storage methods for depot and DLA raster data (JEDMICS)
  • Share web-enabled First Article Inspection Report (FAIR) and characteristic accountability data via AS9102 format throughout the Rolls-Royce supply chain
  • Share web-enabled process capability data via AS9103 format throughout the Rolls-Royce supply chain.

Impact on Warfighter:

  • Faster turnaround on qualification of new suppliers for spare parts equates to shorter maintenance cycles, increased availability of air fleet
  • Shorter maintenance cycles equate to cost avoidance savings

DOD Participation:

  • U.S. Air Force (OC-ALC)
  • Defense Logistics Agency (DLA)
  • U.S. Army (Letterkenny)
  • U.S. Navy (FRC East)

Industry Participation:

  • Rolls-Royce
  • BCT Technology
  • Imaginestics
  • Net Inspect
  • Renaissance Services
  • NCMS

Final Report