THE DATA MANAGEMENT MESS

As I was working with Kubotek and the release of the Verification Tool, I thought why in the world do we need a tool like this. Of course we do things a bit different today; we design in 3D solid models.  Now we can create a drawing from that model, but it seems like it would be a lot easier to just send the model out with a couple of critical dimensions and material specifications. But there are problems with maintaining that data. Each CAD program has a PDM (Part Data Management) system, there are even third party programs to track changes in the parts and assemblies. From the input I get from my associates and customers this new system is causing some very serious problems.

PROVEN ENGINEERING PRACTICES

When I went to work as a draftsman for Boeing there were engineering practices that had been in place for Decades.  We did the drawings; they got checked by a drafting checker for fit, form, function and standard drawing practices.  They were marked up in yellow for correct and red for the errors.  The drafter did the pickups and then they were rechecked, until the checker was satisfied.  Then it was taken for review and signatures from stress engineering and manufacturing, with a final signature from the lead engineer.

DRAWING/DATA ACCESS

The drawings were scanned into the microfiche system with the notes.  Many hours were spent looking for all the drawings that made up the assembly configuration that you were going to modify or redefine as a new configuration.

DESIGN CHANGES

The drawings were then released to manufacturing to create their planning procedures. Planning actually created their own drawings on how to install or rig the parts/assemblies.  As they establish an assembly line, they had liaison engineers to help solve any problems.  When there were problems the liaison engineer would resolve the problem and create a rejection tag.  This rejection tag would go to the responsible engineering department and an ADCN (Advance Drawing Change Notice) was created or they directly revise the drawing with a DCN (Drawing Change Notice).  When the drawing accumulated many ADCN’s they were incorporated them into a new revision with a DCN or Revision.

TODAY’S ENGINEERING PRACTICES

Years ago Pro/E was released.  This had a part, an assembly and a drawing.  All separate files. That is when the trouble started. You had to maintain all of those files, PDM came into being. You have to manage all those files. Now this is not really a problem with a small company where you have 3 or 4 designers or engineers and they are in close proximity. The problem starts when you have people in different locations accessing the data.  Then add vendors and you have a new problem of implementing a massive program of standardization.  From sending a folder with some clearly defined drawings to now having to make sure the user has all the necessary software to evaluate and use the data.

DRAWING/DATA ACCESS

When we talk about data management what are we talking about.  The part model, of course, the assembly, the DRAWING, oh yes the drawing.  Even if you don't do a drawing you have to include specifications, such as material, GD&T data for inspection, processes, etc.  If you use a Pro/E paradigm program you have at least 3 documents to maintain with each part or assembly. These documents or files have to be available to manufacturing to create and inspect the part or assembly.  Now we add an inspection document.  Adobe Acrobat 8 3D can sort and maintain this data.  Catia has a program call Enovia that does this also. I am sure Pro/E and UGS have their programs, and I know there are many 3rd party programs available also.  Now the problem is that you need software to read this.  And now you have to coordinate with your vendors to make sure they have all the programs to make sure you can utilize the data.  Now you can imagine the initial and ongoing costs added to manufacture these parts.

A drawing is basically an inspection document, but offers much more than that. It offers an incredible check on design from the designer as he creates the drawing.  At this time we focus on mating surfaces and disregard the rest of the part.  But I have detailed a many of these parts and I can personally tell you that if they were detailed the part would have been much easier to manufacture.  Much of the non-related features were very difficult to make.  The drawing becomes a design tool and check.  In the past we had drafters doing the design with an engineer managing multiple projects.  Now they dump an engineer on a CAD system and let him work on one part at a time, when a drafter has the experience necessary to communicate the data to manufacturing.  I feel this is an incredible waste of talent and experience.

DESIGN CHANGES

How do we do changes in today’s Engineering practices?  Today we are using the solid model as the authority for the part. That means that part or assembly has to be kept up to date and available to manufacturing. Manufacturing has to have the tools to evaluate and use the data.  This has become a nightmare. A drawing takes no more than 2 to 4 hours to detail from a solid, of course there are more complex parts but most can be done in that time frame.  Yes we have to maintain the drawing. But if we made the drawing, as in the past the authoritive document, we would not need all the confusing PDM software.

This change in focus has caused a multitude of problem.  Let’s go back to the ADCN.  How does the liaison engineer fix the part and notify the originating engineering department.  No drawing to modify and needs special software to view the part.  So he has to have a way to do this and fix the error and get that fix to engineering.  Now they have to modify the part, and get it into the system as soon as possible.  We since we have no drawings we have to work directly on the part and make the new part available to manufacturing so no incorrect parts will continue to be made.  Now here is where things can get very tough.

THE PROBLEM WITH HISTORY BASED CAD 

The rejection tag gets back to the originating engineering department.  The original designer has quit, fired, retired, transferred, etc., so one of the other designers has to rework the part.  I have worked on history based parts systems like Pro/E and it can take 2 to 4 hours just to figure out how the original designer made the part.  Then he can modify the part as required.  Many times some actually rework the part; imagine how dangerous that would be.  If some other important features was missed.  This can become a horror show.  This is where the drawing is so important.  It is a picture in stone, or at least in a PDF. 

Let’s say we only need to change a few fillets.  On a drawing we just create an ADCN, going to the correct locations and show the change. No need to remodel the part.   That can be done later when you incorporate the ADCN or do a revision to the part as we have done in the past.  Manufacturing gets the ADCN and modifies the part.  Modifies the part, now how do they do that?  Do they have the correct CAD software, probably not, but with the focus on hybrid or direct face editing they can easily make the changes.  Using the drawing they can now be sure to be creating the correct part.  Even with this assurance of the correct information you could use the Verification Tool to make sure that the part had only the required change.  The Verification Tool could also be necessary in the design departments to see that the changes were implemented correctly.

SOLUTION!

We need a product that can include all the information in one file. There are a few CAD products that can do Assemblies in one part file but have external drawings. The only CAD product that can do it all is KeyCreator.

Yes, KeyCreator. With its single 3D space you can smoothly design parts in the same part/assembly file, separating parts by levels, even sub levels for tracking our part creation (KeyCreator's form of history).  KeyCreator offers an easy to use integrated wireframe/solid/surface modeling system that can create any part without any design limits. You can even create reference parts for your assemblies for common used parts. But those parts even though separate still carry the drawing and any specification in the same file.  KeyCreator is by far the King of Hybrid modelers, and has the all of the standard translators, such as Dxf/Dwg, Step, ASIC, Parasolids, IGES, but also most of the native translators available for the most popular programs, such as Solidwork, Autocad, Pro/E, UGS and Catia.

Now how could a switch to KeyCreator to benefit your data management problems.  History based solid modeling is a very good design system and many of us enjoy using it.  But programs like Solidworks, Pro/E (who just purchased CoCreate) and other programs are fast learning they need hybrid (direct face editing) to get the job done. KeyCreator has been on this track for a very long time and has proven it can virtually take any data, 2D/3D wireframe, surfaces and solids and utilize it.  So you could translate or have KeyCreator take the native data and create the drawings in one part file.  KeyCreator can not only create drawings in that part file but keep track of all revisions with the ability to create multiple drawings, thereby having the history of the part in one file.

Kubotek offers a very good viewer called spectrum.  There are two versions one available at no cost and can read Keycreator part files and another version that reads all the standard translators plus native files from Pro/E, UGS and Catia 4.  With this add on anyone that needs to look at the part or drawing has access, and can print the drawing and mark up the parts.

But imagine how easy it would be, one master file available to everyone.  KeyCreator is very inexpensive solution for the engineering to standardize.  It is easy to use and offers incredible unlimited flexibility.