What is Moog ECAD? - theiiom.org · What is Moog ECAD? Moog ECAD ... (such as firmware, FPGA code). The benefits of these parts may not be realized. ... stock details and PCNs are

0 Global Technology Conference 2011

What is Moog ECAD?

Moog ECAD (Electronic Computer Aid Design) system;

– Common design tools to enable easy transfer of

design data among different sites and enhanced

resource sharing

– Common libraries of supporting parts data to

maximize the reuse of previous design efforts

– Simple and straight-forward access to help EE

designers find the data they need

Obsolescence Management System (OMS)

Development & its benefits to

Moog Programs

IIOM International Conference 2017

Author: V V Siby

Thursday, June 29, 2017

June 20-22, 2017

http://www.moog.com/

Agenda

1 IIOM International Conference 2017

About Moog Inc.,

Motivation and challenges: OMS Development & its benefits to Moog Programs

Summary

Acknowledgments & References

Acronyms


About Moog Inc.,


• Founded in 1951 by Bill Moog

• Headquarters in East Aurora, NY

− Over 300 Acre Facility

• Global Company

− 5 Groups, 50 Locations in 27 Countries

• Precision Control Systems Solutions

and Component Provider

• Over 11,000 Employees Worldwide

• USD $2.47 Billion in Revenue (FY 2016)

• Listed on NYSE Bill Moog


Motivation and challenges

Have you had a problem and challenges in defining a proactive solution to

Obsolescence Management…. ?

Moog has experienced;

Customer Expectations

Skyrocketing costs of today’s avionics systems coupled with the accelerated pace of

technological change are creating expectations from customers for product support far

beyond the typical component lifecycle.

Tracking Product Change Notifications (PCN)

Redundant process & efforts

Programs are Notified Individually

Communication isn’t across multiple programs & sites

Effects of Discontinued Tin\Lead Parts:

“Supply Chain Group” or “Contract Manufacturer” are unable to purchase parts

Limited Resources

No dedicated resource to monitor, notify, and manage the closure of action items

Choosing right tools to analyze, monitor and to notify

Not consistent, repetitive Obsolescence Management process that can be used at all sites

during all phases of the program execution including aftermarket support



4

Obsolescence Impact

Obsolescence is an increasing concern

Moog products are being used outside the components life cycle [1]

Moog products >30 years – Component Life < 8 years

Critical electronic components become obsolete before the system has been released

Commercial off the shelf (COTS) Parts life cycle

REACH/RoHS/WEEE increasing the elimination of products

Obsolescence impacts can be astronomical

US NAVY estimates obsolescence issues cost up to $750 million annually [2]

Few Moog programs affected by obsolete part across multiple boards [1]

MOOG estimated over $1.5 million for redesign and requalification

Considerable schedule impact

Component obsolescence is inevitable and cannot be avoided.

The only way to manage it cost effectively is to put a ‘systematic plan’ in place

that will lead to better product design and extend life.



5

Benefits of Obsolescence Management System

OMS will provide early warning of obsolescence

Taking a proactive approach to obsolescence allows for minimization of obsolescence costs, while

maximizing the gain each time a design is revisited.

Allow for life time buy decisions to prevent redesign, requalification, schedule impacts

Known obsolescence issues during proposals to account for additional cost and schedule

Based on the life cycle of Components, Diminishing Manufacturing Plan can be provided at proposal

and technology refresh can be planned ahead of the time.

Include future enhancements

With enough warning, obsolescence of a key part and the need to replace it, can lead to product

enhancements to be implemented that were not in the original design. [6]

Improve product performance

In many cases, higher performance parts can be form, fit, and function compatible with the

existing design, but without system changes (such as firmware, FPGA code). The benefits of

these parts may not be realized. With a planned approach, the decision to do a design change

can be made based on return on investment-not whether it will impact immediate production

schedules. [6]



How did we develop?

6

Items Past Issues Obsolescence Management System

Resource

No dedicated resources for :

Monitoring, Notifying, and Managing

Action Closure of Obsolescence Parts

Full Time Dedicated expert resources for:

Monitoring, Notifying, and Managing

Action Closure of Obsolescence Parts

Notification Inadequate Warning for

Obsolescence Provides Early Warning for Obsolescence

Database No Centralized Database Centralized Database

Approach Reactive / Adhoc Approach

Predictive, Pro-active & Strategic

Approach:

• Sends Periodic Health Analysis

Reports

• Sends Critical PCN, EOL & Errata

Alerts

• Provides Obsolescence Forecasts

• Supports the data for Strategic refresh

planning [3]



7

Our Approach


Robust process for Electronics

Obsolescence

Moog OMS provided the ‘Health

Analysis Reports’ to multiple

development, production and

Legacy programs for the last

several years

Moog has joined the CALCE

(Center for Advanced Life Cycle

Engineering) and working to develop a

consistent, deliberate and cost

effective strategic refresh strategy

using MOCA. [4]

Pro-active Strategic

MOOG

Obsolescence Management System MOCA

Mitigation of Obsolescence Cost Analysis

Figure 1 – Pro-active Figure 2 - Strategic


8

Obsolescence Management System

OMS is an enterprise system provides web-based

obsolescence analysis and tracking tool that provides

users with supportability assessments, predicative

obsolescence forecasts and it supports globally

across various Moog locations

Provides a Cost-effective, Customized obsolescence

Management tool to help you minimize the impacts to your

systems before problems turn into crises


Predictive, Proactive Obsolescence Management through ‘OMS’

Figure 3 - OMS


9

OMS Process

Component Engineering (CE) analyzes part inputs from various sources and the validated

data are uploaded to OMS

Data distributed/accessible to program users through web-based OMS tools

Formatted reports and other analysis data available online

Periodic reviews /updates to data on OMS by Component Engineering


Figure 4 – OMS Process


10

OMS Process-Cont’d

The OMS tool consist of 3 components: Data management tool

Health analysis reporting

Obsolescence notifications (Critical Alerts – Product Change Notifications, Errata, etc)

It supports in the mitigation of electronic component obsolescence By proactively analysing and distributing part obsolescence data

Information on recommended alternates to the respective program teams from a

centralized location


Recommendation Report

Figure 5 – Alternate Report


11

Health Analysis Report (OMS)


Parts are classified into 6 different categories based on estimated availability

Individual ‘CCA level’ and ‘Program Level’ reports can be generated

RoHS/Tin, REACH equivalents are listed wherever applicable

Alternate recommendations, stock details and PCNs are provided

Critical Errata are notified to the Program team and to the Software Engineer

Periodic OMS Reports are distributed to program team for review and action

The ‘comments‘ are provided with suggested actions for ‘obsolete’ or ‘High Risk’ component.

PCNs and Errata documents are stored

Status & Color Code Characterization

Discontinued No longer in production by OEM

Discontinued with replacement No longer in production, but equivalent replacement

part available

High Risk >0 & <1 yr

Medium Risk >1 & < 5 yr

Low Risk >= 5 yr

Not Available Invalid part number Figure 6 – OMS Report


12

PCN – Product Change Notification (OMS)


PCN process ensure the close loop path for all the critical alerts

Figure 7 – PCN reports

Closure Resolution

Determination Notification Identification


13

Obsolescence & PCN Statistics (OMS)


PCN alerts reviewed for 2016 (sample data)

CE team continuously track, monitor & notify the parts status

Figure 8 – Obsolescence report -2016

Figure 9 – PCN report - 2016

Obsolescence reviewed for 2016 (sample data)


14

Obsolescence Strategy Overview


Output for Lowest life cycle cost is a Refresh in 2022 and 2031

MOOG

OMS

MOOG

Product

Database

OBS Mitigation & RoHS

PCN Alerts

Production Forecasts

Reliability Predictions

Inventory

Cost to hold Inventory

Inflation rate

Refresh NRE Scenarios

Constraints

Analysis Example

CALCE

MOCA

Runs

hundreds

of scenarios

and produces

lowest life

cycle cost

optimization

plans

The best plan is typically ‘bridge buy’ with

planned design refresh date

Health Analysis report

Input

Data

Pro-active Strategic

Figure 10 – OBS Overview

Moog always aim to have high standards, robust process, tools and database to establish the Center of Excellence in Obsolescence Management


15

OMS (Success stories - Example)


Program : Various Programs

Part Description : ( IC CMOS EPROM 1.3MX1 3.3V )

( IC CMOS EPROM 559KX4 3.3V )

Supplier : XILINX

Issue Description : Product Discontinuation and No Direct Replacement

Resolution : OMS health analysis reports and part status monitoring service identified and notified to program

team. Early notification and details enabled the Program Management to evaluate & take action

plan.


Part Description : (IC CMOS FPGA 1M GATE)

Supplier : QUICKLOGIC

Issue Description : Product Discontinuation and No Direct Replacement

Resolution : OMS health analysis reports and part status monitoring service identified and notified to program

team. Early notification, online review and approval systems enabled the Program Management to

evaluate & take action plan


Part Description : (IC CMOS SRAM 128KX36 7.5NS 117MHZ 3.3V SMD 100TQFP)

Supplier : GSI TECHNOLOGY

Issue Description : Periodic health analysis report with highlighted the obsolescence of the part

Resolution : Product engineering has taken further feedback from the OMS team and worked on resolution.

Program : Multiple

Issue Description : Existing Moog BOMs has historic part numbers, which are prone to sourcing risks, higher

cost and obsolescence

Resolution : BOM health reports suggested suitable alternates , RoHS/Tin equivalents for these

historic part number which were later implemented in next BOM revisions


16

Summary & Conclusion

1. Systematic, Proactive & Strategic approach to obsolescence management with easy to use

centralized database

2. Collaboration of information from part suppliers and predictive tools combined with Moog’s

knowledge and expertise for efficient problem identification and resolution

3. Alternate part recommendations, access to critical PCNs and other additional details to

support efficient mitigation plan provided by an integrated PCN Notification System

4. Allow quick decision for life time buy and Refresh plan to prevent redesign, requalification

and schedule impacts

5. A dedicated team with more than 50 years of cumulative experience on part management,

obsolescence management and related areas

6. System and process in line with Diminishing Manufacturing Sources and Material Shortages

(DMSMS) frame work as outlined in SD-22 [5]

7. An established and proven process which compliant to AS9100 C quality requirements.



17

Acknowledgments & References

1. Siby V V, Y. Kim, “Obsolescence Management system development” MOOG Global Engineering

Technology Conference – Jun 2013.

2. Adams, Charlotte, “Getting a Handle on COTS Obsolescence,” Avionics Magazine – May 2005.

3. P. Singh, P. Sanborn, “Obsolescence driven design refresh planning for sustainment-dominated

systems” Eng Econ 51– Jun 2006.

4. P. Sandborn, “MOCA User’s Guide, V.2.6,’’ MOCA manual – Oct 2013

5. “SD-22 - Diminishing Manufacturing Sources and Material Shortages (DMSMS)” – Jan 2016.

6. M.Pugh, “Proactive obsolescence management” – Apr 2015.


References

Acknowledgments

I take this great opportunity to thank Moog Management for permission to present this paper at IIOM

conference 2017. Also I would like to thank my team members, Moog program team, Moog IT & Software

team for excellent support & feedback during the OMS development.


18

Acronyms


Acronyms Description

CE Component Engineering

CCA Circuit Card Assembly

COTS Commercial Off-The-Shelf

CALCE Center for Advanced Life Cycle Engineering

DMSMS Diminishing Manufacturing Sources and Material Shortages

EOL End of Life

MOCA Mitigation of Obsolescence Cost Analysis

NRE Non Reoccurring Expense

OMS Obsolescence Management System

OBS Obsolescence

PCN Part Change Notifications

ROHS Reduction Of Hazardous Substances

REACH Registration, Evaluation, Authorization and Restriction of Chemicals

WEEE Waste Electrical and Electronic Equipment


19

Thank you!


V V Siby Direct : +91 80 3372 8606

Email : [email protected]

For more information, please contact:

Web : www.moog.com


Documents

What is Moog ECAD? - theiiom.org · What is Moog ECAD? Moog ECAD ... (such as firmware, FPGA code). The benefits of these parts may not be realized. ... stock details and PCNs are