Life Cycle Baseline Reconciliation A System Overview and Description of the Basic Configuration Verification System (BCVS) ACDM 15 th Annual Technical Conference March 2010 Ram White, Integrated Support Systems, Inc. 1

Life Cycle Baseline Reconciliation Basic Configuration Verification System (BCVS) Presentation Agenda: The Basics/Fundamentals –Product Life Cycle, Bills of Material, Data/Documentation, Baselines and BL Comparisons, Audits and Reconciliation The BCVS Business Values The System Environments –Functional Systems Architectures –Communications (point-to-point or Standards) Data Object Modeling (The devil is in the detail) Data Mapping Strategies –XLS/CVS, XML, Standards & Direct Integration ISS/InSync Proposed Solution Supporting the DD 250 Process The Back Story: Boeing’s SI/BCA & P-8A 2

3 As-Authorized (_________) As-Designed (_________) As-Committed (_________) As-Planned (_________) As-Delivered (_________) As-Maintained (_________) As-Built (_________) As-Purchased (_________) As-Tested (_________) Cost Estimating Capacity Planning & Assessment Specifications Master Schedule Work Breakdown Structure Budgets Sales Orders Cost Accounts Effectivity Baseline Release Document Control Product Definition EBOM Bill of Routings Effectivity (Eng.) MBOM Effectivity (Manf.) Bill of Routings/Resources Master Production Schedule Proposed Capacity Planning MRP/CRP/Procurement Work Order Release Receiving/Inspection Receiving Instructions Dock-to-Stock Inventory (WIP) Lot Code / Serial Numbering Shop Floor Control Labor Collection Work Measurements Process Instructions Test Procedures Test Results CM Status Accounting As-Built Snapshot CM Reconciliation CM Status Accounting Lot Code / Serial Numbering Deviations / Waivers Field Return / Retrofit Field Service CM Reconciliation Lot Code / Serial No. CM Status Accounting As-Built History Product’s Life Cycle Management (Basic Life Cycle Process) As-Disposed (_________) Storage, Salvage To-Become (Recycle) CM Reconciliation Lot Code / Serial No. CM Status Accounting As-Was/Is History

Concept Definition Detailed Development Pre- Production Deployment/ Operation Design Upgrades Disposal As- Authorized As- Committed Product Life Cycle Management As- Designed As- Planned As- Built As- Disposed As- Delivered As- Maintained 4

As-Authorized Authorize Data As-Committed Schedule Data As-Designed Design Data As-Planned Plan Data As-Built Build Data As-Supported Support Data Authorized Baseline Scheduled Baseline Design Baseline Planned Baseline Built Baseline Supported Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Comparison Reports Comparison Reports Comparison Reports Comparison Reports Comparison Reports Traditional Life Cycle Reconciliation 5 Multiple Manual Methods – The Usual Configuration Audits Configuration Audits Configuration Audits Configuration Audits Configuration Audits

Concept Definition Detailed Development Pre- Production Deployment/ Operation Design Upgrades Disposal Master Data Repository/Vault (IDs, Baselines, Changes, CSA, Audits, Etc,) As- Authorized As- Committed As- Designed As- Built As- Planned As- Tested As- Disposed As- Supported As- Delivered As- Maintained Product Life Cycle Management 6 Configuration (Audit) Reconciliation

As-Authorized Authorize Data As-Committed Schedule Data As-Designed Design Data As-Planned Plan Data As-Built Build Data As-Supported Support Data Configuration Reconciliation Accounting and Audit Process Authorized Baseline Scheduled Baseline Design Baseline Planned Baseline Built Baseline Supported Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Comparison Reports Comparison Reports Comparison Reports Comparison Reports Comparison Reports Generic Life Cycle Reconciliation Bills of Material (BOMs) Configuration Reconciliation Accounting and Audit Process (CRAAP) 7

As-Authorized (_________) As-Designed (_________) As-Planned _________) As-Maintained (_________) As-Built (_________) EBOM Structure MBOM Structure OBOM Structure RBOM Structure Retrofit Processes Routings Resources Tooling Serial Number Lot Code QA/MRB As-Built History Repair/Refurbish Records Operational Processes Routings Resources Tooling Serial Number Lot Code QA/MRB Service Records Manufacturing Material Catalog Processes Routings Resources Tooling Engineering Material Catalog Processes MarketingContracts WBS Budgets Sales Orders Computer-Aided Engineering Configuration Audit(s) Reconciliation Engineering Release As-Disposed (_________) Disposed Processes Resources Serial Number Lot Code As-Was/Is History Storage, Salvage Disposal Records Recycling DBOM Structure Product’s Life Cycle Management (Basic Configuration Reconciliation Process) As-Committed (_________) 8

Basic Configuration Verification System Business Values: Ensure Released Drawing Defined Parts are in the As- Designed. Ensure the As-Designed Parts are in the Manufacturing Plans and Orders. Ensure the As-Designed Parts in the Manufacturing Orders and applicable serialization is identified. Ensure applicable Change information is related to the life cycle views of the product definition. Enable Part Restriction Documentation and Evolution to be managed and maintained. Provide a common infrastructure to report and review “Configuration Verification Action Items” in the various life cycle states. 9

Fielding Life Cycle Generic System Architecture CAD & PDM System (__________) CAE Schedule System (________) Program Mgmt. System (________) CLS System (__________) Part Test & Certification System CSAR CSA Reports Legend: CAPP - Computer-aided Process Planning BOM - Bill of Material SFC - Shop Floor Control NCM - Number Control Machine CA - Corrective Action CAD-E - Computer-aided Design Electrical CAD - Computer-aided Design PDM – Product Data Management Computer-aided Engineering CLS - Contractor Logistic Support Engineering CAPP System (__________) BOM System (__________) SFC System (__________) NCM System (__________) CA System (__________) As-built (Orders) As-planned (Planning) Manufacturing As-supported (Parts/Locations) As-authorized (Contract & Changes) CAD-E System (__________) As-designed (Electrical) As-designed (Parts & BOM) As-committed (Schedules)

Fielding Life Cycle Generic System Architecture As-designed (Electrical) As-committed (Schedules) As-supported (Parts/Locations) As-designed (Parts & BOM) As-authorized (Contract & Changes) CAPP System (__________) BOM System (__________) SFC System (__________) NCM System (__________) CA System (__________) As-built (Orders) As-planned (Planning) CAD & PDM System (__________) CAD-E System (__________) CAE Schedule System (________) Manufacturing Program Mgmt. System (________) CLS System (__________) Part Test & Certification System CSAR CSA Reports Legend: CAPP - Computer-aided Process Planning BOM - Bill of Material SFC - Shop Floor Control NCM - Number Control Machine CA - Corrective Action CAD-E - Computer-aided Design Electrical CAD - Computer-aided Design PDM – Product Data Management Computer-aided Engineering CLS - Contractor Logistic Support Engineering Point to Point Data Exchange

Life Cycle Generic System Architecture As-designed (Electrical) As-committed (Schedules) As-supported (Parts/Locations) As-designed (Parts & BOM) As-authorized (Contract & Changes) CAPP System (__________) BOM System (__________) SFC System (__________) NCM System (__________) CA System (__________) As-built (Orders) As-planned (Planning) CAD & PDM System (__________) CAD-E System (__________) CAE Schedule System (________) Manufacturing Program Mgmt. System (________) CLS System (__________) Part Test & Certification System CSAR CSA Reports Legend: CAPP - Computer-aided Process Planning BOM - Bill of Material SFC - Shop Floor Control NCM - Number Control Machine CA - Corrective Action CAD-E - Computer-aided Design Electrical CAD - Computer-aided Design PDM – Product Data Management Computer-aided Engineering CLS - Contractor Logistic Support Engineering Data Exchange Standards Data Management Exchange Standards Fielding

Functional Environment (Program Management / Engineering / Manufacturing / Fielding) Functional System(s) Architectures 13 System ASystem BSystem CSystem D

Data Object Modeling Objects: Drawings Documents Specs/plans/orders Parts Software Changes (Effectivity) Request/Orders/events Etc. Object -1 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects 14 The Devil’s in the Detail Location / Representation Media (format) Storage (located) Application (used by) Protocols (exchanged) Operating System Database (related) Meta-data (about) Characteristics, Attributes, & Features One to One One to Many Many to One Many to Many

Data Object Modeling Object -2 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -1 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -4 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -3 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -6 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -5 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects 15

Data Object Modeling Object -2 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -1 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -4 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -3 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -6 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -5 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects 16

Data Object Modeling Object -2 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -1 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -4 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -3 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -6 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Object -5 Identification: ID#/Name,/Owner Attributes: Size Qty Relationships: To-From Up-Down Other Objects Export/Import XML Files. XLS/.CVS Files Standards Files Direct Integrate 17

Data Mapping Strategies System ASystem B Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify 18

XML Files. XLS/.CVS Files Standards Files Direct Integrate Data Mapping Strategies 19 System ASystem B Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify

XML Files. XLS/.CVS Files Standards Files Direct Integrate Data Mapping Strategies 20 System ASystem B Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify Mapping Verify/Certify Costs

As-Authorized Authorize Data As-Committed Schedule Data As-Designed Design Data As-Planned Plan Data As-Built Build Data As-Supported Support Data InSync Authorized Baseline Scheduled Baseline Design Baseline Planned Baseline Built Baseline Supported Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Baseline Compares Comparison Reports Comparison Reports Comparison Reports Comparison Reports Comparison Reports Basic Configuration Verification System Concept 21 STEP AP 232GEIA 836

ISS Use of Standards In Life Cycle Supportability Engineering Data: Drawing, Model, Metrics… DESIGNENGINEERING Design Data/Structure R & M Data Feedback Product Structure Data, Specs and Parameters Delivered Product Data Definition Initial Product/ Support DefinitionMANUFACTURING/PRODUCTION ‘ ‘ Delivered Data/Structure ERP Data IN-SERVICE/ SUPPORT Serialized Part Data: Maintenance ‘ ‘ ‘ In-Service Data/Structure One-Two -Way Data Flow Two-Way collaboration, reconciliation, coordination Asset Management Process/ Product/ Process/ Cost Improvements LSAR/ LMI Supportability Analysis Analysis Supportability Data Feedback IETMs, Condition-Based Maintenance, etc. Tech Pub/ IETM Data Training Data IPB / IPC/ IPL Data and Graphics Spares Ordering, Inventory Mgmt, Obsolescence Planning, … STEP AP 203 / 232 / pdm schema STEP AP 232*, pdm schema B, (STEP AP 239) ASD 2000M (STEP AP 239) STEP AP 232*: Not used in conjunction with Life Cycle Supportability, today,

IP Plan/Fab Plans 1 Assembly, PN The Mechanisms & Processes (Basic Configuration Reconciliation Process) As-DesignedAs-PlannedAs-Built Parts Planned (IP Plans) Parts Defined (Dwgs/PLs) Parts Ordered (Fab. Orders) End Item 1 Assembly, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 2 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 2 Assembly, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 2 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 2 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN IP Plan/Fab Plans 2 Assembly, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 2 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN Fab. Orders 1 Assembly, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 2 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN Fab. Orders 2 Assembly, PN 1 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 2 Sub Assy., PN 1 Component, PN 2 Component, PN 3 Component, PN 23 As-Designed Baseline BOM for Parts & Assemblies Manufacturing Planning for Parts & Assemblies Fabrication Orders for Parts & Assemblies

Validation & Verification Cycle (Configuration Verification Action Items) 24 CVAI: Configuration Verification Action Item Analysis Cycle Analysis Cycle Plans Orders Parts List Final Reconciled Reports CVAI: Configuration Verification Action Item

25 As-Authorized (_________) As-Designed (_________) As-Planned (_________) As-Built (_________) Product’s Life Cycle Management (Basic Confirmation Process) As-Committed (_________) Installation Plan (IP) (Planning for final assembly) In Work Completed Approved Inspected Delivered Make Parts – Fabrication/Assembly (Planning for Fabrication/Assembly) In Work Completed Approved Inspected Stocked to Inventory Buy Parts - Purchase (Planning for Buy) Purchase Request Purchase Order Received Inspected Stocked to Inventory Engineering Design (Perform engineering design) In Work Completed Approved Released Commitment Scheduling (Commitment to schedule) In Work Completed Approved Released Authoring Engineering (Authorizing parts design) In Work Completed Approved Released DD 250 Reporting Audit Trail Was the installation right? Was the purchase right? Was the fabrication right? Was the design right? Was the commitment right? Was the authorization right? All’s Right Not Right Waivers Deviations DD Form 250 CSA Reports

As-Authorized (_________) As-Designed (_________) As-Planned (_________) As-Maintained (_________) As-Built (_________) EBOM Structure MBOM Structure OBOM Structure RBOM Structure Retrofit Processes Routings Resources Tooling Serial Number Lot Code QA/MRB As-Built History Repair/Refurbish Records Operational Processes Routings Resources Tooling Serial Number Lot Code QA/MRB Service Records Manufacturing Material Catalog Processes Routings Resources Tooling Engineering Material Catalog Processes MarketingContracts WBS Budgets Sales Orders Computer-Aided Engineering Configuration Reconciliation (InSync) Engineering Release As-Disposed (_________) Disposed Processes Resources Serial Number Lot Code As-Was/Is History Storage, Salvage Disposal Records Recycling DBOM Structure Product’s Life Cycle Management (Basic Reconciliation Process) As-Committed (_________) DD250 26

27 STEP Data Exchange (The Back Story – SI/BCA) Enterprise Supplier

Type Design Data/Process Flow Type Design Data PDM Output STEP Files OS Vaults - Reports (XML, PDF) - STP - PS - PKG Vista Reporting PKG Files PS Files Other Files Translated Files Generated XML* Files Imported Files Formatted PDF* Files InSync InSync/SI Processing InSync Screens Browser View - “Generated XML” - “Formatted PDF” - Formatted HTML - Multi-Level - XML File Compare Non-Vaulted “Work” ERP or other Systems * Interface / Integration with other data systems may be implemented as a “push or pull” transaction process or as a “web service.” * 28

ISS’s Integrated Support System Supplier Integration (SI/BCA) 29

As-Authorized (ECCM) As-Designed (DCAC) As-Committed (DM2000) As-Planned (MES) As-Delivered (InSync) As-Maintained (OOMA) As-Tested (ALRMS) As-Built (MES) Cost Estimating Capacity Planning & Assessment Specifications Master Schedule Work Breakdown Structure Budgets Sales Orders Cost Accounts Effectivity Baseline Release Document Control Product Definition EBOM Bill of Routings Effectivity (Eng.) MBOM Effectivity (Manf.) Bill of Routings/Resources Master Production Schedule Proposed Capacity Planning MRP/CRP/Procurement Work Order Release Receiving/Inspection Receiving Instructions Dock-to-Stock Inventory (WIP) Lot Code / Serial Numbering Shop Floor Control Labor Collection Work Measurements Process Instructions Test Procedures Test Results Part and System Restrictions CM Status Accounting As-Built Snapshot CM Reconciliation CM Status Accounting Lot Code / Serial Numbering Deviations / Waivers Field Return / Retrofit Field Service CM Reconciliation Lot Code / Serial No. CM Status Accounting As-Built History As-Disposed (????) Storage, Salvage To-Become (Recycle) CM Reconciliation Lot Code / Serial No. CM Status Accounting As-Was/Is History 30 Product’s Life Cycle Management (Boeing MMA P-8A)

As-Authorized (ECCM) As-Designed (DCAC) As-Planned (MES) As-Maintained (OOMA) As-Built (MES) EBOM Structure MBOM Structure OBOM Structure RBOM Structure Retrofit Processes Routings Resources Tooling Serial Number Lot Code QA/MRB As-Built History Repair/Refurbish Records Operational Processes Routings Resources Tooling Serial Number Lot Code QA/MRB Service Records Manufacturing Material Catalog Processes Routings Resources Tooling Engineering Material Catalog Processes MarketingContracts WBS Budgets Sales Orders Computer-Aided Engineering Configuration Reconciliation (InSync) Engineering Release As-Disposed (????) Disposed Processes Resources Serial Number Lot Code As-Was/Is History Storage, Salvage Disposal Records Recycling DBOM Structure Product’s Life Cycle Management (Boeing MMA P-8A Reconciliation Process) As-Committed (DM2000) 31

Life Cycle Baseline Reconciliation A System Overview and Description of the Basic Configuration Verification System (BCVS) ACDM 15 th Annual Technical Conference March 2010 Ram White, Integrated Support Systems, Inc. 32 Questions & Comments

Life Cycle Baseline Reconciliation A System Overview and Description of the Basic Configuration Verification System (BCVS) ACDM 15 th Annual Technical Conference March 2010 Ram White, Integrated Support Systems, Inc. 33