A STEP based Business Process “A Case Study” Bill Marler, Pratt & Whitney January 17, 2001 ® PDES, Inc.

A STEP based business process Objective The purpose for this talk is to review the events of an actual ‘STEP pilot’ based upon the given business condition and summarize the ‘good, the bad, and the ugly’ My expectation is that the issues and answers resulting from this pilot activity will be beneficial for someone developing a STEP based business procedure

…..a little background Experience with ‘homegrown’ translators ~1991 AeroSTEP with Boeing ~ 1994 PowerSTEP project ~ 1995 Turbine pilot with MTU and P&W 1995-99 Current PDES, Inc. pilot: Aerospace Engine Alliance STEPnet and CAx-Implementors Forum test rallies

A STEP based business process ‘The Business Strategy’ Today’s business climate requires international partnering of products to stay competitive in the marketplace Product Design and Manufacturing is out-sourced to partners worldwide A conglomeration of ‘systems’ need to talk to each other to ensure product assembly and integrity The Business Strategy: “Outsource”

A STEP based business process “The Product”

A STEP based business process ….this is the scenario A major Aerospace Engine company, JetJockeys, is providing Digital Mock-up (DMU) Data and Interface Geometry to an Airframe Company , Flybywire, in the US. The Engine company has partnered with 2 Overseas companies Fiazco and LeJette along with another US company, Fans-r-Us Inc., to share in the Design and Manufacturing of the Propulsion system. As Integration manager for the Propulsion System, JetJockeys want to manage the Product Data using UG and Iman. Unfortunately, the other partners are on different CAD and PDM systems creating a Data Exchange dilemma.

A STEP based business process …”The Problem” Multiple CAD and PDM systems involved in the Enterprise Integration team has to ‘manage and integrate’ the partnered product and provide appropriate DMU (Digital Mock Up) and interface information to the customer

A STEP based business process “The Problem-Graphically” Outsource Outsource design and Build Outsource

A STEP based business process “CAD impact of globalization” Company Responsibility CAD Tool PDM Prod. Flybywire JetJockeys Fiazco LeJette Fans-r-Us Air-framer Integrator External components LPT Fan High Spool Catia Cadds UG PTC Enovia Windchill Iman Location Taiwan Islip, NY St.Louis, MO Palermo,IT Bordeaux,FR

A STEP based business process ….“At the Program Level” A ‘Statement of Work’ is prepared for all members of the enterprise to endorse The SOW spells out the areas of responsibilities and their products Program Executives approve the SOW Data Exchange (DEX) IPTs for each alliance member are identified and of course an unrealistic ‘schedule’

A STEP based business process The DEX Planning Phase

A STEP based business process DEX IPTs have face-to-face to... Identify program DEX requirements Agree to a STEP-based DEX process that supports the SOW business plan Assign CAD/PDM responsibilities Identify new ‘tools’ that need to be deployed to meet objectives Document the entire ‘to-be process’ Dry run: walk the process….

A STEP based business process ….the face-to-face realizations Current STEP success ratio < allowable Integrated CAD-PDM data not “RFPT” An effective STEP DEX procedure needs to be put in place at each site Validation criteria needs work DEX business process to be automated Current STEP functionality insufficient

A STEP based business process …some immediate mitigators A pilot process is initiated by all to begin de-bugging the to-be DEX process CAD vendor participation is obtained to address throughput issues Local IT support is obtained Weekly conference calls are scheduled and action lists are maintained STEP experts from PDES, Inc. agree to participate in the pilot

A STEP business process DEX IPT membership structure DMU process owner DMU DEX focal Internal Design Process support Internal IT participation Hotline for CAD vendor(s) PDES, Inc. representatives for STEP support

A STEP based business process The DEX Integration and Deployment phase

A STEP based business process ...results of pilot teamwork Comprehensive requirements document

A STEP based business process ..results of pilot teamwork Comprehensive requirements document More effective STEP DEX process Problem Resolution procedure

A STEP based business process schematic Flybywire “Catia” STEP Exchange JINX “UG” X N Fans-r-us PTC N N Fiazco UG X LeJette CADDS JetJockeys UG PDES, Inc. PDES, Inc. ®

A STEP based business process detailed schematic LeJette Email JetJockeys Methods Process Owner Process Owner Server LeJette data exchange focals Data Exchange focal JJs Send Methods EagleSTEP Server Email Supplier send Firewalls “VPN” environment Supplier Library PDES, Inc. ®

STEP based business process “effective STEP DEX procedure” Complete Model? Best Practices & model quality Native Model Problem Resolution Do Quality Checks Target system capabilities? Create Step File Bspline tolerances Check for Errors Send STEP file Documentation. STEP Log file look ok? Validation OK? Create Target File Contents complete? Validate/heal To heal or not to heal.. Notify Sender & Recipient Archive PDES, Inc. ®

A STEP based business process Pilot effectiveness High Accuracy issues 70 - 75% Success Begin pilot Model Quality Issues STEP Problems Add quality checks Incorporate Healing Low TARGET:90 - 95% successful exchanges Time Production use

A STEP based business process ..results of pilot teamwork Comprehensive requirements document More effective STEP DEX process Problem Resolution procedure Integrated and automated business process

A STEP business process Process Improvements Sending System Visualization Program “Automated Process” Prepare UG file Add Attributes Add CM Val props Run EagleSTEP Check for errors Target Archive & FM Autoname + Send MPA STEP-in validate ftp PDES, Inc. ®

A STEP based business process Process Improvements

A STEP business process Process Improvements Sending System Visualization Program “Automated Process” Prepare UG file Add Attributes Add CM Val props Run EagleSTEP Check for errors Target Archive & FM Autoname + Send MPA STEP-in validate ftp PDES, Inc. ®

Effective STEP exchange “Integration Tools”

A STEP based business process Process Improvements Library Notify Owner Archive & Library Prep CM Template Validate geometry Create CM Data Set Check Log File STEP UG Sending CAD System Receive Send STEP Meta Data PDES, Inc. ®

A STEP based business process “Integration Tools”

A STEP based business process ..results of pilot teamwork Comprehensive requirements document More effective STEP DEX process Problem Resolution procedure Integrated and automated business process Improved validation technique

Upper image highlit part selected for mass property table INSTANCE VPs Upper image highlit part selected for mass property table Lower image shows mass properties for: a) Individual comp. b)CG to parent asm. Here is an example of what differentiates PTC from our competition. Upon import of a STEP file containing validation properties, A log file with a comparison of the as received, as calculated, and a difference value is generated in the working directory. This allows a user to determine if the exchange is VALID within some acceptable range. Future additions to this will be a visible display of the validation properties in the model tree, a user definable % difference for the volume & surface area, a max distance deviation of CG, and RED flagged icons for assembly components outside of this value.

INSTANCE VPs Post process CADDS part with GVP Display results in DXN or browser Checking Instance craig11/l-bracket_asm Mass Properties Check - INSTANCE Centroid STCENTROID = 0.158106E+03, 0.370222E+02, -.750000E+02 CALCULATED = 0.158106E+03, 0.370226E+02, -.750000E+02 CADDS Calculated Centroid location is outside tolerance Here is an example of what differentiates PTC from our competition. Upon import of a STEP file containing validation properties, A log file with a comparison of the as received, as calculated, and a difference value is generated in the working directory. This allows a user to determine if the exchange is VALID within some acceptable range. Future additions to this will be a visible display of the validation properties in the model tree, a user definable % difference for the volume & surface area, a max distance deviation of CG, and RED flagged icons for assembly components outside of this value.

A STEP based business process Ongoing improvements...

A STEP business process Ongoing Improvements More robust translators

A STEP business process Ongoing Improvements 5 Universal Joints in UG are hollow

A STEP business process Ongoing Improvements 5 Universal Joints in Cadds are not hollow

A STEP business process Ongoing Improvements Reflective testing: File processes OK

A STEP business process Ongoing Improvements Problem Solids isolated in UG for translations Problem Solids isolated for STEP translation

A STEP business process Ongoing Improvements Problem Solids in Cadds file are the “inverse” of the actual geometry

A STEP business process Ongoing Improvements CATIA STPCAT ..reads OK into catia!!

A STEP business process Ongoing Improvements STEP file fails to read into ProE!!

A STEP business process ..after much PRP with PDES, Inc. team The problem was solved by identifying “how” the vendors processed the information in the STEP files Some STEP processors handled the two CIRCLEs trimming the SPHERICAL_SURFACE (the 'outer' portion of the bearing) as the two 'tops' of the Sphere; others used the CIRCLEs as the middle of the Sphere Both methods were “valid” according to STEP, but an agreement between the vendors had to occur to avoid this problem in the future Updated Recommended Practices for CAD vendor implementation

A STEP business process Ongoing Improvements Translator improvements Enhanced validation properties

A STEP business process …more STEP functionality CADDS FILE VPD DATA L-Bracket S/A Instance 1 L-Bracket S/A Instance 2 L Bracket L Bracket NAUO NAUO Rod S/A vpd1 x14.59,y20.20,z10.0 Rod S/A vpd1 x14.59,y20.20,z10.0 NAUO Bolt NAUO Bolt Nut/Bolt SubAssy instance 1 Bolt vpd1 x0.0,y0.0,z16.94 Nut/Bolt SubAssy instance 1 Bolt vpd1 x0.0,y0.0,z16.94 NAUO NAUO NAUO Nut NAUO Nut N-B S/A vpd1 x10.0,y7.50,z1.50 Nut vpd1 x10.0,y7.5,z1.5 N-B S/A vpd1 x10.0,y7.50,z1.50 Nut vpd1 x10.0,y7.5,z1.5 Nut/Bolt SubAssy instance 2 NAUO Bolt Nut/Bolt SubAssy instance 2 NAUO Bolt Bolt vpd1 x0.0,y0.0,z16.94 Bolt vpd1 x0.0,y0.0,z16.94 NAUO NAUO NAUO Nut NAUO Nut N-B S/A vpd1 x10.0,y7.50,z1.50 Nut vpd1 x10.0,y7.5,z1.5 N-B S/A vpd1 x10.0,y7.50,z1.50 Nut vpd1 x10.0,y7.5,z1.5 NAUO Bolt NAUO Bolt Nut/Bolt SubAssy instance 3 Bolt vpd1 x0.0,y0.0,z16.94 Nut/Bolt SubAssy instance 3 Bolt vpd1 x0.0,y0.0,z16.94 NAUO NAUO NAUO Nut NAUO Nut N-B S/A vpd1 x10.0,y7.50,z1.50 Nut vpd1 x10.0,y7.5,z1.5 N-B S/A vpd1 x10.0,y7.50,z1.50 Nut vpd1 x10.0,y7.5,z1.5

A STEP business process …more STEP functionality Bracket SubAssy instance 1 Sonbrh Assy vpd1 x92.17,y76.59,z18.0 Bracket S/A vpd1 x16.72,y-50.0,z17.33 C1 Bracket C2 Nut- BoltAssy C3 Nut- C4 Nut- UG FILE VPD DATA Assembly instance 2 Plate Rod Sub Plate vpd1 x90.0,y75.0,z10.0 Rod S/A vpd1 x0.0,y0.0,z100.0 NAUO Rod Nut Nut vpd1 x10.0,y7.5,z1.5 Rod vpd1

A STEP business process …more STEP functionality UG SONBRH ASSY VS CADDS SONBRH ASSY VPD DATA Sonbrh Assy vpd1 CADDS Sonbrh x90.0,y75.0,z18.86 Assembly NAUO NAUO NAUO NAUO Bracket Bracket SubAssy SubAssy instance 1 Bracket S/A vpd1 instance 2 Bracket S/A vpd1 x16.78,y-50.0,z17.30 x16.78,y-50.0,z17.30 Plate Rod Sub-Assy Plate vpd1 Rod S/A vpd1 C of G values x90.0,y75.0,z10.0 x0.0,y0.0,z100.0 do not match Sonbrh Assy vpd1 UG Sonbrh x92.17,y76.59,z18.0 Assembly NAUO NAUO NAUO NAUO Bracket SubAssy Bracket instance 1 SubAssy Bracket S/A vpd1 instance 2 Bracket S/A vpd1 x16.72,y-50.0,z17.33 x16.72,y-50.0,z17.33 Plate Rod Sub-Assy Plate vpd1 Rod S/A vpd1 x90.0,y75.0,z10.0 x0.0,y0.0,z100.0

A STEP business process …more STEP functionality

A STEP business process …more STEP functionality

A STEP business process …more STEP functionality

Instance Validation Properties Upper image highlight part selected for mass property table Lower image shows mass properties for: a) Individual comp. b) CG to parent asm. Here is an example of what differentiates PTC from our competition. Upon import of a STEP file containing validation properties, A log file with a comparison of the as received, as calculated, and a difference value is generated in the working directory. This allows a user to determine if the exchange is VALID within some acceptable range. Future additions to this will be a visible display of the validation properties in the model tree, a user definable % difference for the volume & surface area, a max distance deviation of CG, and RED flagged icons for assembly components outside of this value.

A STEP business process …more STEP functionality UG FILE VPD DATA Sonbrh Assy vpd1 x92.17,y76.59,z18.0 Sonbrh Assembly NAUO Shove-it vpd2 NAUO Shove-it vpd2 NAUO Shove-it vpd2 NAUO Shove-it vpd2 Bracket SubAssy Bracket instance 1 SubAssy instance 2 Bracket S/A vpd1 Bracket S/A vpd1 x16.72,y-50.0,z17.33 x16.72,y-50.0,z17.33 Plate Rod Sub-Assy Plate vpd1 Rod S/A vpd1 x90.0,y75.0,z10.0 x0.0,y0.0,z100.0 NAUO Shove-it vpd2 NAUO Shove-it vpd2 NAUO Shove-it vpd2 Rod Rod vpd1 x0.0,y0.0,z100.0 NAUO Shove-it vpd2 C1 Bracket Nut C1 Bracket C2 Nut- BoltAssy Nut vpd1 C2 Nut- BoltAssy C3 Nut- BoltAssy x10.0,y7.5,z1.5 C3 Nut- BoltAssy C4 Nut- BoltAssy NAUO Shove-it vpd2 Nut C4 Nut- BoltAssy Nut vpd1 x10.0,y7.5,z1.5

A STEP business process Ongoing Improvements Translator improvements Enhanced validation properties Expanded STEP functionality

A STEP business process …more STEP functionality ‘Build to Design using 100% Product Data requires more complete STEP file’ Need Parametrics Lost in STEP exchange Features/tolerances also missing Annotation and text also needed All required to eliminate drawings and obtain full benefit of STEP in Enterprise

A STEP based business process CAx Implementor Forum activities

A STEP business process Summary “Pilot” activity benefits process development efficiency Management buy-in is critical Use PDES, Inc., CAD vendors, and CAx Implementor Forum to help get improvements in process Dedicated team and automated STEP process are keys to success