mark it, track it, share it - spec 2000 · spec2000 bar code taskforce functional and data...

Parts Marking for TraceabilityParts Marking for Traceability

Jon AndresenPresident, Technology Solutions, Oakland, CA

Technical Director, Center for AutoID –Ohio University

SPEC2000 - An Industrial Standard for this Millennium

Orlando, FL 10 October 2002

Mark It, Track It, Share It

Who Am I ?Who Am I ?

Here to tell you: forget the darn bar code !

(I’m really the Data Guy!)

What is What is SPEC2000 SPEC2000 ??

ØØ A specification to exchange information:A specification to exchange information:

-- Purchasing transactions Purchasing transactions

-- Repair Order transactionsRepair Order transactions

-- Aircraft and Engine warrantyAircraft and Engine warranty

-- Reliability Data Collection and Exchange Reliability Data Collection and Exchange

-- Bar Coding / Direct Part Marking

ØØ System for buying and selling aircraft parts and repair serviceSystem for buying and selling aircraft parts and repair servicess

-- Defines data for business transactionsDefines data for business transactions

ØØ Established network of suppliers and airline operators Established network of suppliers and airline operators

ØØ Established and very well supported EDI formatEstablished and very well supported EDI format

-- used for 40+ years used for 40+ years -- started as ATA Spec200started as ATA Spec200

In Summary:

SPEC2000 is a data standard and an eBusiness standard.

Electronic Data Interchange

EDI Standards

File Transfers

Bar Codes

Purchasing / InvoicingRepair Order Admin.Warranty Claims

Customer

MFR / Supplier / Repair Agencies

Marketplace Databases

Bar Coded Shipping LabelsPerm. Bar Code ID on Parts

1000+ companies involvedWorldwide !

Tools, Test, & Ground Equip.Manufacturer Prices / Lead Times

Repair Agency Capabilities / PricesSurplus Parts Availability

Reliability DatabaseProvisioningDelivery Configuration

Inventory Consumption DataLead Time Performance Data

Reliability Data

SPEC2000 OverviewSPEC2000 Overview

Customer/Supplier InterchangesCustomer/Supplier InterchangesRequirements Specification for new part (documents, diagrams, etc.)

Design Data (performance specs, visuals, CAD drawings, etc.)

Commercial negotiations (discussion documents, contract drafts, etc.)

Progress Monitoring/updates (letters, phone calls, documents, etc.)

Initial/replenishment Purchasing Transactions (POs, expedites, etc.)

Parts Shipments Involving New, Repair, Warranty, & Exchange Parts

Trading Transactions (quotes, warranties, invoices, etc.)

Engineering & Maintenance Information (manuals, graphics, training, etc.)

Customer Support & Service Bulletins (documents, photos, graphics, etc.)

Customers

Suppliers

Parts Traceability : mfgr, install, remove, repair, store, ship, scrap, etc.

Why SPEC2000 ?Why SPEC2000 ?


Customer A Supplier 1

Is this your business model ?

…because of this !…because of this !

Customer A Supplier 1

Customer D

Customer C

Customer B

Customer E

Supplier 4

Supplier 5

Supplier 2

Supplier 3

It is too costly to do business 25 (or 2500) different ways !


SPEC2000SPEC2000Business ArchitectureBusiness Architecture

Customers and SuppliersCustomers and SuppliersBuild A Piece as It’s NeededBuild A Piece as It’s Needed


SPEC2000 Bar Code TaskforceSPEC2000 Bar Code Taskforce

Functional and Data ArchitectureFunctional and Data Architecture

Permanent Bar Code Identification of Parts

Legend: Existing Standards

‘In-Process’ Standards (June 2002)

Future Standards

Jon Andresen, President,

Technology Solutions

Rev: August 2002

The Foundation is laid!(giving parts a Social Security Number)







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These business function have been in place for years !







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The FAA wants this piece !







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These are being currently worked !

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Primarily the OEMs issue !(which Part # should go in there?)

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This is the hardest one !(which Serial # is actually in there?)

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These will happen in the future !

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Functional and Data ArchitectureFunctional and Data ArchitectureC

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ØØ Historically, real parts traceability is done poorly and is Historically, real parts traceability is done poorly and is very expensivevery expensive–– Most parts tracked by Serial # within Part # it hasn’tMost parts tracked by Serial # within Part # it hasn’t worked ! worked !

–– Three logic flawsThree logic flaws»» Airlines/operators invent their own numbering systems for partsAirlines/operators invent their own numbering systems for parts

»» When form / fit / function changes When form / fit / function changes -- new Part # requirednew Part # requirednn this effectively loses the ability to track itthis effectively loses the ability to track it

»» No control between companies of Part Numbers assigned, no legal No control between companies of Part Numbers assigned, no legal ‘teeth’ regarding bogus parts‘teeth’ regarding bogus parts

Tracking Parts Tracking Parts -- the Problemthe Problem

The business problem we’re trying to solve is one of Part identification and traceability.


2000

x !

Cost to make an error

Cost to fix an error

2000

How much does it cost you to make an error?


Benefits of Bar Code Technology

Time Accuracy Time Accuracy

Manual Data Entry Bar Code Data Entry

1) Touch typists average 1 error every 30 characters

2) Bar code errors occurs once every 3 million characters !How many touch typists in your production areas ?


263265930

What’s this ?

This is a NAKED number with no intelligence whatsoever !


Part Number

? Serial Number ?

Employee Number ?

Location ?

Order Number ?SSN without the dashes ?Who knows ???

Example of an Intelligent NumberSerial Number showing the Text Element Identifier (TEI)

SER 263265930

spac

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TEI

4 characters

Serial Number

1à15 characters


Simple, plain text, WYSIWYG, easy for people - easy for computers

Tracking Parts Tracking Parts -- the Solutionthe SolutionSPEC2000 Permanent Bar Code IDSPEC2000 Permanent Bar Code ID

What is it?§ A universal ‘Social Security Number’ for serialized parts

§ Only 2 rules:1) unique Serial # within CAGE Code2) label or mark lasts the life of the part

Easy to understand, Easy to communicate


§§ Every piece of data is intelligentEvery piece of data is intelligent§§ the electronic data (quotes, orders, adv. shipping notice, etc.)the electronic data (quotes, orders, adv. shipping notice, etc.) and the bar coded data and the bar coded data

(shipping labels, perm. bar code ID) both use the same data iden(shipping labels, perm. bar code ID) both use the same data identifier tifier

§§ Bar coded data and HRI allows for business transitionsBar coded data and HRI allows for business transitions§§ Human readable data allows for existing business systems to contHuman readable data allows for existing business systems to continue, and allows for inue, and allows for

more advanced companies to benefit from Auto ID savings.more advanced companies to benefit from Auto ID savings.

§§ Bar coded data and HRI allows for manual failBar coded data and HRI allows for manual fail--overover§§ Human readable data is included with all bar codes to allow manuHuman readable data is included with all bar codes to allow manual processes to al processes to

continue when technology failscontinue when technology fails

Benefits of SPEC2000 Implementation


What is SPEC2000 Perm. Bar Code ID?What is SPEC2000 Perm. Bar Code ID?§§ It is an ISO TS21849 specificationIt is an ISO TS21849 specification§§ It is used by 1000+ international companiesIt is used by 1000+ international companies§§ It is adopted by the Aerospace Industries It is adopted by the Aerospace Industries

Association (AIA)Association (AIA)§§ It is adopted by the railroad industryIt is adopted by the railroad industry§§ It is used in some automotive companiesIt is used in some automotive companies§§ It is used in several military programsIt is used in several military programs§§ C17, CH47 Helicopter, torpedo markingC17, CH47 Helicopter, torpedo marking


So why do we want to mark parts ?So why do we want to mark parts ?1. We have too much money and we need to spend it.

2. We want to look busy for the rest of our careers.

3. We are mentally unstable.

The common identification and tracking of the part has ALL the benefits !


SPEC2000 Part Marking DataSPEC2000 Part Marking Data

nn How much ? What kind of data ?How much ? What kind of data ?–– For new parts, 3 pieces of data required:For new parts, 3 pieces of data required:

»» MFRMFR Code Code –– manufacturer’s CAGE Codemanufacturer’s CAGE Code»» SERSER # # -- unique Serial # within the CAGE Codeunique Serial # within the CAGE Code»» PNRPNR # # -- manufacturer’s Part #manufacturer’s Part #

–– How does SPEC2000 Data Dictionary define these?How does SPEC2000 Data Dictionary define these?»» MFRMFR = 5 characters, A/N, assigned by the DoD = 5 characters, A/N, assigned by the DoD onceonce»» SERSER = 1= 1àà 15 characters, A/N, dash (15 characters, A/N, dash (--) is only special char.) is only special char.»» PNRPNR = = 11àà 15 characters, A/N, dash (15 characters, A/N, dash (--) is only special char.) is only special char.


DMF 082000DMF(Conditional Data Element)

PNR F100F200(Conditional on DPM Applications)PNRPNR

USN USN 12345ABC123oror

USN (= MFR+SER)

MFR 12345 MFR 12345 SER ABC123 (see Note)SER ABC123 (see Note)

Encoded in Data Matrix Encoded in Data Matrix MFR 12345/SER ABC123 MFR 12345/SER ABC123

Note:Human Readable Interpretation does NOT include embedded slash “/” but the data does include it.A Carriage Return is not embedded in the 2D Data Matrix

MFR / SERMFR / SER

2-D Data Matrix(Preferred on Direct Part Marking)

1-D Linear Barcode(Preferred on Data Plates)

Data Elements

MFR 12345

SER ABC123

USN 12345ABC123

PNR F100F200

DMF 082000

For New Parts:For New Parts:SPEC2000 - An Industrial Standard for this Millennium

Example of SPEC2000Example of SPEC2000--Formatted Formatted PERMANENT ID DATAPLATEPERMANENT ID DATAPLATE

Permanent

Identifier

“Current”

Part #


SPEC2000 - An Industry Standard for this Millennium

For very small parts,2D Data Matrix bar code symbology

was approved in June 1998

MFR 12345 SER ABC123PNR 100200300400A


Direct Part Mark (DPM) TechnologiesDirect Part Mark (DPM) Technologies

nn Dot PeenDot Peennn Laser EtchLaser Etchnn Laser BondingLaser Bondingnn Chemical EtchChemical Etchnn Micro MillingMicro Millingnn InkjetInkjet



0.1”


Examples ofExamples of

Square and Rectangular Data MatrixSquare and Rectangular Data MatrixDot Peen TechnologyDot Peen Technology


Examples ofExamples of

Laser EtchingLaser Etchinghigh quality, very small bar codes on a pin headhigh quality, very small bar codes on a pin head


SPL / UCN(Used for In-Service Serialized Parts)

UST 54321123ABC

Other data elements shown above may also be included.

UST 54321123ABCor

UST (= SPL+UCN)

SPL 54321UCN 123ABC (see Note)

Encoded in Data MatrixSPL 54321/UCN 123ABC

Note:Human Readable Interpretation does NOT include embedded slash “/” but the data does include it.A Carriage Return is not embedded in the 2D Data Matrix

2-D Data Matrix(Preferred on Direct Part Marking)

1-D Linear Barcode(Preferred on Data Plates)

Data Elements

SPL 54321

UCN 123ABC

Other Data Elements

For InFor In--Service Parts:Service Parts:SPEC2000 - An Industrial Standard for this Millennium

nn Confused about what makes up a SSN ?Confused about what makes up a SSN ?

New SSN:New SSN: MFR xxxxxMFR xxxxx SER yyyyyy…SER yyyyyy…

InIn--Service SSN: Service SSN: SPL xxxxxSPL xxxxx UCN yyyyy…UCN yyyyy…

PNR is the PNR is the currentcurrent, manufacturer’s Part #, manufacturer’s Part #DMF is conditional on New Parts, doesn’t apply for InDMF is conditional on New Parts, doesn’t apply for In--Service PartsService Parts

Data SummaryData Summary

CAGE Code of the company marking the part

Unique Number within the CAGE Code


SPEC2000 Part Marking DataSPEC2000 Part Marking Data

nn How can you tell what data is where ?How can you tell what data is where ?–– CAGE Code is always first 5 charactersCAGE Code is always first 5 characters–– Whatever remains is the unique Serial #Whatever remains is the unique Serial #

nn Pros and cons ?Pros and cons ?–– Good for very small parts; not good for long numbersGood for very small parts; not good for long numbers–– Harder for people if typing; slightly harder for systemsHarder for people if typing; slightly harder for systems

nn Is there another way to mark parts ?Is there another way to mark parts ?–– Yes, the same Yes, the same DATADATA can be concatenated into one # called a can be concatenated into one # called a

Universal Serial NumberUniversal Serial Number»» USN = the CAGE Code + Unique Serial #USN = the CAGE Code + Unique Serial #nn Example: MFR 2D67AExample: MFR 2D67A

SER 1234567SER 1234567USN 2D67A1234567


nn See addendum in printed documentSee addendum in printed documentnn Questions:Questions:

–– How complicated is this?How complicated is this?–– Won’t the data rules restrict the Serial Numbers?Won’t the data rules restrict the Serial Numbers?–– Won’t we run out of numbers?Won’t we run out of numbers?–– Won’t we need a centralized system to control all the numbers ?Won’t we need a centralized system to control all the numbers ?–– Sequential Serial #s are important to use for our warranty ?Sequential Serial #s are important to use for our warranty ?–– We have always serialized within the Part #. How can we move We have always serialized within the Part #. How can we move

forward without discarding everything ?forward without discarding everything ?–– Our Serial #s are randomly assigned and out of my control. How Our Serial #s are randomly assigned and out of my control. How do I do I

handle that ?handle that ?–– What about company mergers? Won’t that cause duplicate Serial #sWhat about company mergers? Won’t that cause duplicate Serial #s ??

Questions about Unique Serial #sQuestions about Unique Serial #sSPEC2000 - An Industrial Standard for this Millennium

ØØ Forget the bar code !Forget the bar code !–– create a unique Serial Number system firstcreate a unique Serial Number system first

ØØ TheThe preferencepreference for Serialized Part Markingfor Serialized Part Marking–– LabelsLabels : : Data Plates or Polyester Labels, if appropriateData Plates or Polyester Labels, if appropriate

»» Data:Data: CAGE Code, unique Serial #CAGE Code, unique Serial #, Part # on 2, Part # on 2ndnd label label

»» Bar code: on existing data plate using Code 128 symbologyBar code: on existing data plate using Code 128 symbology

–– Direct Part MarkingDirect Part Marking»» Data:Data: CAGE Code, unique Serial #CAGE Code, unique Serial #, Part # in 2, Part # in 2ndnd bar codebar code

»» Bar code: 2D Data Matrix symbology using laser etch/dot peenBar code: 2D Data Matrix symbology using laser etch/dot peen


So how So how shouldshould I mark my parts?I mark my parts?

We’re aiming at lowest cost, most ubiquitous use of the data !


Permanent Bar Code ID on Parts – Benefits - WIIFM- parts can be tracked from cradle-to-grave

- easy, error-free data entry to improve tracking

- social security number for every company to use: OEM, airframer, airline, repair shop, distributor

- no clearinghouse to allocate serial numbers

- works for In-Service parts as well as new parts

- meets FAA/JAA regulations and Best Commercial Practice

- works in today’s “open systems” world

-allows industry to share data: - e.g., traceability, reliability, composition, supply chain collaboration

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Functional and Data ArchitectureFunctional and Data ArchitectureC

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TRACEABILITY Database Example Min. Traceability Standard Your Information (optional) “Social Security Number”

CAGE Code

Serial Number

Current Part #

Action Action Date

Action company

OEM Original Serial #

Aircraft Number

Condition Code

Internal Location

Etc…

61G49 1234567 P7DTR26 RMV 23/11/99 83PH4 Collins T52D611 UA3482 UNS Shop 141 91673 83H6290 459873L8 INS 23/11/99 83PH4 Collins 83H6290 UA3482 SRV UA3482 91673 SS12932 9J9846 SCP 24/11/99 83PH4 Honeywell H12933 UNS 1283S 836 LPY67FF INS 29/11/99 83PH4 Lucas UA5534 SRV UA5534 91673 9943 28374-22 OVH 30/11/99 83PH4 Boeing SRV Shop 180 83845 489GD5 938475-1 SLD 01/12/9 83PH4 P&W 489GD5 SRV Delta 83845 MR32121 -

143 P9475-503 OVH 5/8/00 83PH4 Lucas 75463 UA2234 SRV StkRm C

81979 TS1-5221 7109783H MRK 6/29/00 81979 EIA 591783 UA1731 UNS Shop 142

Action Codes: Condition Codes: MFG - manufactured SRV - Serviceable MRK - marked (initialized) unit UNS - Unserviceable SHP - shipped INS - installed RMV - removed RPR - repaired OVH - overhauled EXC - exchanged SLD - sold SCP - scrapped WHR - warehoused


The Near Term Future

Customer C

Customer B

Customer A

Supplier 1

Supplier 2

Supplier 3

Reliability

Database

Internet

Traceability

Database


SPEC2000 Approach to MaintenanceSPEC2000 Approach to Maintenance

Suppliers

TechnicalInformation

MaterialsManagement

MaintenanceOperations

SPEC 2100

Manuals

PartsSPEC2000 Parts

InformationEngineering

Warehouse

Database(s)Key: common data

like SSN


Data

Data

Data

Data

Why SPEC2000 ?Why SPEC2000 ?

nn Only system with a SSN concept for partsOnly system with a SSN concept for partsnn Simple Simple –– unique Serial # within CAGE Codeunique Serial # within CAGE Codenn WYSIWYG WYSIWYG –– good for computer good for computer andand peoplepeoplenn Common data definitions for eBusinessCommon data definitions for eBusinessnn XMLXML--compatiblecompatiblenn Established : 20 years, 1000+ companiesEstablished : 20 years, 1000+ companiesnn It works!It works!


The MRO Issue is Complex in our business…

but it all revolves around Quality Data

Parts

Process

People

Quality

D A T A

SPEC2000 insures quality data and well-defined processes for your people.


Thank YouThank Youfor your attention !for your attention !

www.spec2000.com, click on Bar Coding tab

For more information on Permanent Bar Code ID:

www.SPEC2000.com

Questions?

mark it, track it, share it - spec 2000 · spec2000 bar code taskforce functional and data...

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