1. 11 The Ultimate Upgrade Nicholas Garcia Bell Helicopter Textron

2. 2 Agenda  Who am I?  What are we doing?  Why are we doing it?  How are we doing it?  Are we going to do this again?  Questions

3. 33 Who am I?  Nicholas Garcia  Bell Helicopter Textron  IT CAD/CAM  Fort Worth, TX  ngarcia@bellhelicopter.textron.com ngarcia@bellhelicopter.textron.com  (817) 280-6484

4. 44 Who am I?

5. 5 What are we doing?  Upgrade from NX 1 to NX 5  Upgrade from Teamcenter Engineering 9.1.3 to Teamcenter Engineering 2007  Migrate workstations from AIX Unix to Windows XP  Migrate from 32-bit to 64-bit  Migrate servers from AIX to Windows  Decommission Multi-site

6. 6 Why are we doing it? Current Environment  ~200 AIX 5.3 Workstations  NX 1 on AIX  Teamcenter Engineering 9 on AIX and Oracle 9i  2.5 Terabytes of NX Data  Multi-site for WAN

7. 7 Why are we doing it?

8. 8 Issues  Loading times unacceptable  Multi-site sync issues  NX 1 “no patch” issues  No disk space for growth  “View” only capabilities  Users want to be current  No-support/EOL on current software versions

9. 9 Why are we doing it? Future Environment  ~200 Windows XP 64-bit Workstations  NX 5 64-bit on Windows  Teamcenter 2007 on Windows  4 Terabytes total disk space  2-tier for “local” sites (DFW Area)  4-tier w/Site Cache for remote sites  No Multi-site!!!

10. 10 Why are we doing it?

11. 11 How did we do it? Background  Oct 2006 Project initiation  Upgrade from TCe 8 to TCe 9  Move from HP-UX to AIX  NX 3 or NX 4?  What are the real issues?

12. 12 How did we do it? Review Current Environment  Users  ~200 Users  4 Sites  Data  2.4 Terabytes  Multisite between sites  Very large assemblies that do not open

13. 13 How did we do it? Review Current Environment  Processes  Over 70 customizations in NX  10 Customizations in TCe  Hardware  AIX Servers  AIX Storage  Oracle Database

14. 14 How did we do it? Review Solutions  NX 3 vs NX 4 vs NX 5 (remember this was around July 2007)  Begin testing of Windows 32/64-bit vs AIX 32/64-bit  Compare NX 4 and NX 5 (NX 3 decided to be outdated)  Test everything with TCe 9

15. 15 How did we do it? Decisions  October 2007  Loading capabilities with Windows showed to be greatly improved  NX 4  Teamcenter 9  How do we rollout?

16. 16 How did we do it? Rollout options  Upgrade to NX 4 on AIX then migrate to Windows as needed  Migrate to Windows with NX 1 then upgrade to NX 4  Mix environments with some users on Windows and some on Unix  Final Decision: Full Migration to NX 4, TCe 2005 and Windows in one weekend

17. 17 How did we do it? Getting Started  Current skillset and past experiences (NX 1 upgrade) showed that we needed assistance  INCAT contracted to provide technical expertise, coding upgrades and training  CSC supports Bell infrastructure  Goal was for Mid-year 2008 rollout, which changes the targets

18. 18 How did we do it? Moore’s Law  12+ months since project first started  NX 5.0.1 was available  Teamcenter 2007 was available  New Hardware (Quad Core) for Windows PC’s All this means change in scope!

19. 19 How did we do it? Hardware Definition and Acquisition  Compare 64-bit CAD compatible PC’s  Define and order  Servers  Disk Storage  Workstations

20. 20 How did we do it? PC Workstations  New at Bell  Windows XP 64-bit  Dual Quad Core Intel  8 GB Memory  2 x 250 GB Raid 1 Hard Drive (great for caching)

21. 21 How did we do it? Now for the fun stuff  Customizations  Server installation  Client installation  Training  Testing  Results?  Go Live

22. 22 How did we do it? Customizations  Needed before any testing can occur  Gather all source code (very little in source control)  Give to Incat to upgrade and migrate  Answer lots of questions about purpose, functionality and processes  Some don’t work because no longer on AIX  How do we handle these?

23. 23 How did we do it? Server Installation  3 Environments  Sandbox (Development)  Test (Full copy of production, during project only)  Production  Multi-site Decommission  Stop creation of new parts at external site  Migrate all data back to single site (not an easy task)

24. 24 How did we do it? Server Installation Sandbox  Proof of Concept  Functionality only testing  Limited dataset  Use of existing desktop for immediate rollout

25. 25 How did we do it? Server Installation Test  Production server hardware  Full copy of production  Data migration  200GB Limit for backup/restore  4TB at 200GB = 20 different mounts  2 weeks to migrate data from Unix  Database migration

26. 26 How did we do it? Server Installation Test  Install Teamcenter 9 to verify database connections  Install Teamcenter 2007 on Server  Perform upgrade to Teamcenter 2007  NX 5 data upgrade? On the fly upon opening

27. 27 How did we do it? Client Installation  Create similar share on Windows  Installation process automated as much as possible with batch files, which reduced install time from 2 hours to 25 minutes  Small quirks are annoying  NX installation warning  Adding user id to XML install file  No silent install for patches

28. 28 How did we do it? Client Installation  150 PC Workstations ordered, imaged, and delivered  60 were “refreshes”  2 months to rollout  All were ready prior to go live

29. 29 How did we do it? Training  Outsourced, onsite training  6 weeks, 3 locations, 150+ users, 32 hours each  Pilot training class with Super Users in Engineering and Manufacturing  Courses available online after classes  Documentation, CAST, I.GET.IT for additional functionality

30. 30 How did we do it? Testing  Basic Functionality performed by core team  Sandbox used for code verification  Test system used for performance, load and timing tests  Pilot training class users asked to do “real” work in test system  Refresh of test system with production data

31. 31 How did we do it? Testing  Printing and Plotting changes  New functionality  Non-Project related issues  Moving to Windows  Downstream processes  64-bit  Integrations with other systems  How to support Windows

32. 32 How did we do it? Results P/N Load & Save Times (s) NX1 (UNIX) (baseline) NX5 - 1st (Initial load in Windows) NX5 - 2nd (Same w/s - cached) DFW Part 18223 Part 223048852 Part 324262996 Part 4536698173 Part 5874627352 Part 6827706191 Part 731209 AMA Part 1412510 Part 21258705281 Part 31057656255 Part 4 1255537 Part 7828153

33. 33 How did we do it? Go Live  2 Dry Runs to ensure timing  Perform “sync” between production and test system volumes  Copy production database to test  Perform upgrade and ensure timing is correct  Everything is ready prior to go live

34. 34 How did we do it? Go Live  June 16 th  Friday 3:30 pm – Monday 6 am  Coordination across 5 Plants, 2 cities  Coordination between 3 companies: Bell, CSC, Incat  1 Team to make it happen

35. 35 How did we do it? Lessons Learned  Get help if needed  Hardware migration is hard  Dry Runs are useful for timing  64-bit migration may have issues  Hardware/software changes quickly

36. 36 What did we do again?  Upgraded NX 4 versions  Upgraded Teamcenter 3 versions  Migrated from Windows to Unix on Clients  Migrated from Windows to Unix on Servers  Migrated from 32-bit to 64-bit All in one weekend!

37. 37 Are we going to do this again? NO

38. 38 Are we going to do this again?  Install Patches  Review new releases of TCe and NX  Review new hardware  Continual process improvements

39. 39 Questions? Nicholas Garcia ngarcia@bellhelicopter.textron.com (817) 280-6484 ngarcia@bellhelicopter.textron.com