a lean soa approach enables “build anywhere” at boeing north american plant-to-enterprise...
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www.mesa.org2008 North American Plant-to-Enterprise ConferenceSeptember 21-23, Orlando, FL
A Lean SOA Approach Enables “Build Anywhere” at Boeing
Bryan ZiglerPLM Engineer
The following Strategic Initiatives of MESA International are associated with
this presentation:
Lean ManufacturingQuality & Regulatory Compliance
Product Lifecycle Management (PLM)Real-Time Enterprise
Asset Perfermance Management (APM)
Boeing SOA Case Study
• Introduction• What was the problem Boeing was facing?• Initial approaches to problem• Lean SOA approach• Benefits realized or expected• Conclusion
Agenda
Introduction
Bryan Zigler – [email protected]
Located in West Hills CA (Los Angeles Area)
10 years with Boeing– MES related Career Highlights
• MES deployment team member at Boeing Rocketdyne (now Pratt & Whitney)
• 787 MES Development• 787 PDM (V5) integration with MES• Boeing MES common process development• Boeing MES SOA development
Boeing Vision “Design Anywhere, Build Anywhere”
BOEINGFACTORY
BOEINGFACTORY
Enable Lean Interoperability betweenDesign and Execution
BOEINGFACTORY
BOEINGFACTORY
SUPPLIERPORTALBPN
Initial Situation
• Boeing has 30+ sites each with a unique MES• No standardization
– Data exchanged– Format of data exchanged– Technology being used to exchange data
• Legacy systems are not “Agile”– Barrier to lean manufacturing
• Limited vision for exchange of 3D Data
App 1
Function 1
App 2
Data 1
App 3
Function 1
Function 2
CustomInterface 1
CustomInterface 2
CustomInterface 3
ClientApp A
CustomInterface 1
ClientApp B
CustomInterface 2
CustomInterface 3
Initial ArchitectureSituation
Data 1
Data 1
Typical non-SOA Interfaces• Application focus
• Evolved via requirements of the day
• Custom Point to point• Redundant Data• Redundant Functions
• Arbitrary limitations• Limitations baked into interface• Hard to expand/extend• Can't easily combine in new ways
• Not stable• Impacted by internal changes• Impacted by external changes
Boeing Process improvement Program is called “Lean+”
The Lean+ initiative aims to continue existing Lean practices and move them beyond the factory floor into offices back shops, and across supply chain
How do we apply Lean+ to solving our IT integration issues?
Service Oriented Architecture+ (SOA+) is Lean+ for IT
How to Move Forward ?
• Sort – Process Modeling– Sort business processes and activities operate value
streams• Simplify – Common Processes
– Simplify things and derive potential services– Eliminate unnecessary complexity across the value stream
• Sweep – Identify Services– Derive patterns, models to help with solution
• Standardize – Standard Service Definition – Define, declare standard services– Register them, apply governance
• Self-Discipline – SOA Leaning Curve– Cultural/knowledge transfer– Indoctrinate people (change the mind set)
SOA+ is consistent with 5S(Foundation for Lean)
Identify Business Process:Create Shop Order
The “Create Shop Order” Business Process is in the “Production” part of the Boeing Product Lifecycle
RequirementsDefinition
Boeing PLM
Create Shop Order
ReceiveDemandTrigger
GetPlanning
Data
CreateOrder
Design FirstArticle Production Support
MES
ProcessPlanningSystem
Identification of “Services”
• Identify Application Types that support the process
• Identify Services Provided
Planning System provides “Planning Data” Service MES provides “Create
Shop Order” Service
ReceiveDemandTrigger
GetPlanning
Data
CreateOrder
Request
PlanningSystem
Request Request
ERP
Response
MESMES
Business Process provides “Order Create”Service
MES
ProcessPlanningSystem
Process Model Mapped toIT Infrastructure
• Business Process hosted by Enterprise Service Bus (ESB)
• Business Process is exposed as a Service in ESB
ReceiveDemandTrigger
GetPlanning
Data
CreateOrder
PlanningSystem MES
MES
Enterprise Service Bus
ERP
Connect Applicationsto the ESB
For an application to be accessible by the business process, theapplications must expose the specific Service required by the business process
• Service Definition defines a standard input and or output (amongother things)
• In order for the business process to be application independent,the data flowing through the ESB must conform to a standardized information model
• This methodology keeps the ESB LEAN– Standard process– Standard data definition in information model
Process Model Mapped toIT Infrastructure
• An Adapter exposes one or more Services for a given application
• Adapters are external to Enterprise Service Bus (ESB)
MES
ProcessPlanningSystem
ReceiveDemandTrigger
GetPlanning
Data
CreateOrder
PlanningSystem MES
MES
Enterprise Service Bus
ERP
Adapter Adapter Adapter
Adapter ArchitectureStandardized
Application
APIWeb Service
Adapter
Web Service
Request Response
1. Adapter Receives standard web service Call via web service
2. Adaptor Maps standard business process request into appropriate application specific messages
3. Application functionality Accessedthrough one or more exposed API’s
4. Adapter Maps application response into appropriately formatted standard web service call response
Request Response
Receive DemandTrigger
GetProcess Plan
Data
CreateOrder
Enterprise Service Bus
Just-in-Time Binding
At Run Time…Business process must “find” the required adapter
Services are registered in the Index of Services (Universal Definition Discovery Index: UDDI)
At Run Time…Business process binds with appropriate Service
Just-In-Time Binding Example
MES 1
UDDI Service
AdapterService
AdapterService
1. Services are indexed in UDDI
2. Create Order step retrieves binding information from UDDI
3. Create Order step uses appropriate Service to complete business process
ReceiveDemandTrigger
GetPlanning
Data
CreateOrder
Enterprise Service Bus
MES 2
What is Realized?
Use of Lean concepts as applied through SOA+:
• Common simple business process
• Standard Services with standard inputs and outputs
• Adapters exposing applications with similar capability through a standard Service
• At Run Time… Ability to use business logic to bind to Service “Just-in-Time”
Conclusions
Process Modeling– Must model with the end in mind– Many iterations requires to expose services
Adapters– Use the language of the native application– Externalize mapping definition as a configuration– Adapters are Critical for SOA implementation and transformation
into a legacy environment
Service Definition– Use Open Standards if available– “Right” granularity is determined case by case– Reuse is where the value is!!!
Vendor Implications
• Use of open standards makes vendors more likely to engage
• Standards allows vendors to develop without interacting directly (IP issues)
• Use of Private standards may be appropriate considering:
– Agility– Intellectual Property concerns