Business Improvement Through Complex Enterprise Migrations
BUSINESSIMPROVEMENTTHROUGH COMPLEXENTERPRISEMIGRATIONSKevin PowerBusiness Development Manager, PLM Solutions Tata Technologies
BUSINESS IMPROVEMENTTHROUGH COMPLEXENTERPRISE MIGRATIONSHow to Scale the Migration MountainKevin PowerBusiness Development Manager, PLM Solutions Tata TechnologiesLarge organizations that develop complex products accumulate huge amounts of product lifecycledata that has lifespans measured in decades. In addition, the business cannot stop; productdevelopment is a vital part of an organization’s continued success. With that in mind, an enterpriseis occasionally faced with the seemingly impossible task of migrating from one product lifecyclemanagement (PLM) platform to another. At first glance, these migrations face insurmountableobstacles; large data volumes, complex and varied information, incompatible systems and last butnot least, the possibility of significant business disruption. This whitepaper details how a complexenterprise data migration can be effectively executed with confidence and does not have to be alimiting factor in business improvement.Business Improvement through Complex Enterprise Migrations3
ABOUT THE AUTHORKevin Power has worked as a solution architect, accountexecutive and electrical engineer with Tata Technologies overthe last fifteen years. During this time, he has helped manyclients with their PLM journey through teaching, consulting,authoring best practices and roadmap planning.Currently, Power holds the position of Business DevelopmentManager for the PLM solutions group at Tata Technologies. Heis responsible for ensuring that customers are provided with thecorrect technical solution to solve their problems.Power also held the position of Lead Electrical Engineer at TataTechnologies and has been responsible for the design of electrical systems for automotive programsand BEV power trains.Power holds a bachelor’s degree in Electrical Engineering along with various professional qualifications.This whitepaper was authored with Ron Fasbinder, a PLM Migration Solution Architect and Jeff Stong,a PLM Migration Program Manager, both who are no longer working for Tata Technologies.4Business Improvement through Complex Enterprise Migrations
CONTENTSCan We Scale the Mountain?. 6Planning the Ascent. 8Pick Your Path: Big Bang or Slow Roll. 8Test Your Ascent. 9Degrees of Migration.10Accelerators.11The Support Team.12i MIGRATE IT.12An Example.14Summary.15Appendix – The Tata Technologies Process.16Business Improvement through Complex Enterprise Migrations5
CAN WE SCALE THE MOUNTAIN?Consider an organization that relies on technology for competitive advantage. In such an organization,PLM installations may play an important part in maintaining such an advantage. However, technologyimproves at breakneck speed and yesterday’s successful PLM implementation may be today’s whiteelephant. An established institution with this type of business imperative is the perfect setting foran enterprise PLM migration. So what are the problems associated with complex enterprise PLMmigrations? Why do some organizations balk at attempting to scale the mountain of migration? Beloware some factors that must be investigated when assessing a large scale PLM migration.Business Considerations Business Disruption – On the top of the list for any migration exercise is the issue of businessdisruption. Volume of Data – In an organization that has a mature PLM implementation, the volumes ofdata associated with existing databases can be staggering. Raw vault data can be measured interabytes, computer-aided design (CAD) models can be counted in hundreds of thousands andestablished workflows number in the hundreds. Data Security – PLM data by its very nature is an integral part of a company’s intellectualproperty, hence the data must be protected via multiple security mechanisms at all times. People and Organizations – In relation to data security, the access of the PLM users, sometimescalled roles and groups, must be preserved. Business Processes – A PLM system always supports vital business processes. Some examplesinclude engineering change processes, requirements management, project or programmanagement, manufacturing release, etc. These processes have to be maintained, re-engineeredor improved. External Collaboration – Large enterprises rely on extensive supply chains to support theirproduct design activity. Because of the requirements for speed, this information is often tightlyintegrated into the PLM system and updated in real time. This integration must be preserved. Master Information – A migration will always result in two separate PLM systems that coexistfor a period of time. In this scenario, decisions have to be made regarding which system containsthe master data and which contains the following (non-modifiable) data.Bill of Materials Attributes and Metadata – PLM systems include vital data regarding each component making upa product definition. Examples include part numbers, cost, weight, supplier, etc. Product Structure – A product structure defines the relationships between componentsand often underlies a complete bill of materials (BOM) description. Structures are intimatelyassociated with CAD representations and can include multiple levels of indent. Configurations and Variants – Large organizations with complex products always useconfiguration capabilities in a PLM system to keep track of complex product variants.6Business Improvement through Complex Enterprise Migrations
CAD Data Assembly and Modeling Tolerances – Accuracy standards,used to define geometric data, are fundamental to CADmodeling technology. In a migration scenario, the sourceand target CAD systems can have differing standards, whichhave to be considered during the migration process. Corporate CAD Standards – This specific considerationrefers to how CAD standards (start models, layerconventions, etc.) are mapped from source to targetCAD systems. Spatial Positioning – In a three-dimensional (3D) CAD world,the components of a product are positioned in assemblies.DataThis information can reside at various levels in the softwareand must be preserved during the migration process. CAD File Linkages – CAD technology allows for theCADpossibility of linking separate files together. This technologyallows for rapid updating of representations (e.g. update adrawing in response to a 3D geometry change) and oftenneeds to be maintained.Metadata Lightweight Representations – Large CAD assemblies thatrepresent complex products are often presented to users ina lightweight format to improve performance and responseStandardstimes. These are stored in the PLM system and requiremigrating or regenerating during a migration.Enterprise IntegrationsTolerances Enterprise Resource Planning (ERP) Integration – At somepoint in a product development and manufacturing process,information gets transferred from a PLM system to an ERPBOMsystem. A new PLM system necessitates a new integration. Financial Integration – A PLM system almost alwaysIntegrationcontains the master BOM during a product developmentprocess. Therefore, some degree of integration must existbetween an organization’s financial system(s) and the PLMsystem.SecurityVisualization Warranty and Service – Systems that underpin the serviceand support of a product in relation to customer useeither rely on significant input from the PLM system or aremaintained in the same database.The Migration MountainThe above is certainly exhaustive and it’s no wonder thatorganizations can only see the insurmountable ahead of them.Business Improvement through Complex Enterprise Migrations7
PLANNING THE ASCENTHow do you climb a mountain? One step at a time. Attempting the task of migrating from one PLMsystem to another is no different.This whitepaper shows how through an innovative and unique program, companies can take a costeffective, low risk approach to tackling the migration mountain.Some of the techniques that have been successfully deployed by Tata Technologies are detailedbelow. These methods allow organizations to achieve an effective migration with minimal risk.PICK YOUR PATH: BIG BANG OR SLOW ROLLThere are three fundamental approaches to a migration. The exact methodology that is applicableis dependent on the organization’s situation and the type of new technology that has been or will bedeployed. The three approaches are described as follows:1. Big BangPLM System 2PLM System 1End of Life (EOL)In the big bang approach, a planned switchover is executed in a short space of time (typically over aweekend). Thus all users would arrive at work on a Monday morning and immediately begin workingin the new PLM system.2. On-demand Migration (Small Bang)PLM System 2Active DataPLM System 1Inactive DataEOLPLM System 1In the on-demand scenario, only active data is transferred over a weekend and all users would beginworking in the new system. Thereafter, an on demand pull can be made from the legacy system whenrequired, but no new data is created in this system.8Business Improvement through Complex Enterprise Migrations
3. Phased Migration (Slow Roll)PLM System 2PLM System 1PLM System 1PLM System 1EOLIn the phased migration approach, the PLM systems exist concurrently and a two way data exchangeis maintained. Generally, new product programs are started in the new system and existing ones arecompleted in the legacy system.The trade off between the three approaches is risk against cost. Tata Technologies can advise on thebest approach to suit each customer’s unique requirements.TEST YOUR ASCENTBefore scaling a mountain, experienced climbers attempt a test ascent to prove their approach. Thesame goes for a large scale migration. In order to eliminate risk, Tata Technologies has developedmultiple implementation approaches, which are designed to validate all the activities required beforethe production migration. One example of this type of approach is shown below:Data MigrationPlanningAnalysis, SolutionDesign andDevelopmentReleased DataMigrationActive Data andUser MigrationMockMigrationPilotMigrationInactive DataMigrationPost MigrationActivitiesSmall BangThe details for each step include: Data Migration Planing – Develop the migration strategy and approach, and define the scope,schedule, resource plan, technical requirements and detailed execution plan.Business Improvement through Complex Enterprise Migrations9
Analysis, Solution Design and Development – Create migration routines; validate businessrequirements and analyze historical data; and develop mappings, referential integrity and scripts. Mock Migration – Conduct dress rehearsals for each planned release. Mock migrations may bepartial or complete end-to-end cycles to verify migration procedures and benchmark the cycletimes for each migration task. Pilot Migration – Complete an end-to-end migration in the pilot environment. Make sure tocoordinate with the business users for data validation, and to verify and evaluate the controlmechanisms and metrics. Production Migration (Released Data Migration, Active Data and User Migration, Inactive DataMigration) – Execute the full-scale migration into the production environment. Follow the ondemand migration approach. Post Migration – Follow through and prepare the legacy system for end of life.DEGREES OF MIGRATIONOne of the most common mistakes made with any migration process is to insist on full migrationof all the data. Usually this is driven by end users who are fearful that they will not have enoughinformation in the new PLM system or by a “belt and braces” mentality.It is of paramount importance that degrees of migration be agreed to before the process starts andusers are challenged to classify data according to what they need to use the migrated data for. Rigorin this approach can result in significant time and cost savings.As an example, consider the migration of geometric data from one CAD software to another. Onecan insist on a full feature translation for all files, but this is usually not required. Instead it is better todefine degrees of conversion to suit the usage. Possible degrees along with usage are shown below:FullFeature Geometrical definition with history and parameters Assembly information and file linksDesign Geometrical definition without history Assembly informationReference Tessellated representation Additional data such as GD&T or surface definitionInterrogateBREPRichLightweight Tessellated representation onlyLightweight10Business Improvement through Complex Enterprise MigrationsView
ACCELERATORSIn any large scale migration process, considerable speed and accuracy gains can be realized by theintroduction of customized software tools or accelerators. Because the details of migration projectsare unique to every situation, these tools have to be developed on a case by case basis.An example of such tools applied to a PLM to PLM migration is illustrated below:Source PLMTarget aStructure3D Geometry2D DrawingsStagingAreaIn this example, the extractors and injectors are custom automation routines (accelerators) that havebeen authored for the migration from the source PLM system to the target PLM system. It is assumedthat no CAD translations are required, but that PLM migration is the goal.The function of the extractor is: Receive input on a part or product assembly number from the source PLM system. Extract all data associated with the required part or assembly number using the applicationinterface or database calls. This may consist of .xml files and actual CAD files, along withlightweight representations and drawings or images. Place the data in a staging area ready for further processing.The function of the injector is to: Examine the data in the staging area for correctness and integrity. This would includeverification of part numbers, completeness of metadata, etc.Business Improvement through Complex Enterprise Migrations11
Create entries in the target PLM system, once the data integrity is verified, which correspond tothe required part or assembly. Store data in the database or vault corresponding to the entry. Verify that the creation is complete.Notice the diagram shows a two way communication for the injector. This takes into considerationthe possibility that the injection process could result in errors (e.g. duplicate part numbers). In thiscase, the accelerator will abort the process and report the error.THE SUPPORT TEAMOne of the methods that can be used to mitigate the costs associated with large migrations is to usea support team, such as offshore resources. The following is a proven model that can be used for themigration process.ONSITEOFFSHOREONSITEData in sourcePLM systemData download fromFTP siteData download fromFTP siteData extract usingextractor acceleratorper translation request;Added to migrationtrackerData processing/migrationExamine data and reportData transfer to offshorethrough passwordprotected FTP siteValidate data integrityData validation withrespect to input dataPrepare delivery reportStore data in targetPLM system usinginjector acceleratorData and reportreturned via FTP sitei MIGRATE ITTata Technologies has developed a tool to help with migration projects, which puts the processinto the hands of the users. It is a useful addition to this kind of project and facilitates on-demandmigration of critical data.12Business Improvement through Complex Enterprise Migrations
The i MIGRATE IT tool is an on-demand solution for any manner of migrations and translations. It isconfigured for a given situation and allows a user to specify what data needs to be migrated and inwhat format.From a user perspective, a typical workflow would be as follows:1. User logs into the tool. The configuration of the tool and their assigned role would determinewhat that specific user can do (examine only, examine and migrate, etc.)2. The user searches for the data that needs migration. Based on the search result, the userchooses the exact data set required and specifies what must be preserved during the migration(full geometrical feature definition, BREP only, metadata only, etc.)3. Once this is completed, the user would submit the job for processing. At this point, i MIGRATE ITwould take over and run the necessary background tasks required to complete the request.Depending on the nature of the systems, the job could take some time to complete (e.g.overnight batch process). The user has access to a dashboard that shows the status of thepending jobs and historical jobs.4. If the job fails (for example the requested data has already been migrated), the user is alertedwith an error message which can be used to determine a future course of action.Business Improvement through Complex Enterprise Migrations13
This tool has several advantages for migration and translation problems:1. Only data that is required by the users is migrated. This can reduce the cost of a completemigration.2. By providing options, the most efficient process is applied as determined by those who know.3. After a period, usage will drop and the tool can eventually be phased out.4. Data remains secure throughout the process.AN EXAMPLETata Technologies undertook the design and execution of a large and complex migration for a majorcustomer. The project started in August 2010 and continued until the end of 2012.In order to provide a cost effective solution to the customer, Tata Technologies set up an offshorePLM migration factory that was capable of handling all the use cases required for the migration.Examples of the conversion processes are given below:Full-feature Migration Process Full-featured, parameterized geometry Customer requests specific files for full-featured conversion Existing models are locked during migration process Parameterized features, that reside in existing models, are re-created in the target system (linksare maintained) All existing part files that contain 2D drawings will have a 2D drawing created and linked in thenew format (2D/3D association is maintained) Newly migrated data is validated back to the existing original model before uploading to targetPLM systemUsing this process, approximately 3,500 full-featured models, complete with drawings, wereconverted in less than 18 months. The bulk of the work was carried out by the offshore team.A more detailed flow chart associated with this process is given in the Appendix.BREP Migration Process This process creates boundary representation (BREP) data or, alternatively stated, nonparameterized geometry By default, all files requested in the structure are generated as a BREP BREP process converts the final part as solids and surfaces Once converted, the migration factory validates the BREP output back to the original model toensure an accurate conversion14Business Improvement through Complex Enterprise Migrations
All parts converted that fall outside of a defined tolerance are referred to customer for approval,and are flagged in the process and quarantined accordingly Once approved, data is uploaded to the target PLM systemThis process has been used to complete approximately 90,000 conversions over a period of 18months. Because of the automated nature of the process, only three resources were required to doall the data validation.Assembly Drawing Migration Process Customer requests specific parts to have full-featured assembly drawings 3D data is validated, which includes full-featured and BREP components A drawing is created representing a one-for-one match against the existing drawing Completed assembly drawings are approved by the customer and uploaded to the target systemMore than 200 large assembly drawings have been completed using this process.SUMMARYIn this whitepaper, we looked at the problems associated with a complex enterprise data migrationand identified specific areas that require attention; then suggests that a planned and coordinatedapproach can make the task manageable. Tata Technologies has developed unique PLM migrationprograms that have proven ability to mitigate risks and obstacles. Through innovation and processimprovement, PLM migration programs can help many corporations move their PLM data atminimum cost and with no business disruption.Business Improvement through Complex Enterprise Migrations15
16Business Improvement through Complex Enterprise MigrationsPassedData Post-processingValidation (Onsite)FailedLinked toTargetData Import toTarget PLMRequires Manual CompletionData InteractivelyMigratedDeliver Datato PLMDataPackagingResolvedMigration SpecialistsMML/PRJ/GeoData IssuesDataPre-processingReviewed fromSourceUnresolvedPDM DataExtractData Submitted toEnterprise Batch Managerfor AutomationBackground ProcessingData Processed 3DGeometry BREPData ReturnedOnsiteData ValidatedModel CompareMigration Validation/CheckerRequires NoManual EffortData Processed 3DGeometry Full-featuredMigration Manager – Batch ManagerData Sent toMigration TeamAPPENDIX – THE TATA TECHNOLOGIES PROCESS
ABOUT TATA TECHNOLOGIESTata Technologies, founded in 1989, enables ambitious manufacturing companies to design and build better productsthrough engineering services outsourcing and the application of information technology to product development andmanufacturing enterprise processes.With more than 7,900 professionals, Tata Technologies focuses on the manufacturing industry – covering every aspectof the value chain from conceptualization and manufacturing to aftermarket and maintenance repair overhaul support.Tata Technologies supports clients through engineering services outsourcing, product development, enterprise ITservices and product lifecycle management solutions.engagements that offers a unique blend of deep, local expertise integrated with 17 global delivery centers acrosswww.tatatechnologies.com. 320M USD7,900 CONSOLIDATED PROFESSIONALSREVENUETHE COMPANYWE KEEP7,900 EmployeesRepresenting 28 nationalities/TataTechnologiesAEROSPACEOEMS3 MACHINERYOEMS17 Global Delivery CentersAPAC, EU, NAUSA – Troy, Detroit and others Europe – Warwick (UK),Gothenburg (Sweden), Brasov, Craiova & Iasi (Romania),Gaimersheim (Germany) and others India - New Delhi, BlueRidge & Hinjawadi - Pune, Bengaluru, Thane and others China Shanghai (China) SEA - Tokyo (Japan), Bangkok (Thailand),Singapore, Vietnam (Hanoi)/TataTechnologies/TataTech News/TataTechnologiesASIA PACIFICEUROPE25 Rajiv Gandhi Infotech ParkThe European Innovation andNORTH AMERICA6001Cass Avenue,Hinjawadi, PuneDevelopment Centre (EIDC)Suite 600, Detroit MIIndiaOlympus AvenueUSA411057Tachbrook Park, Warwick, UK48202CV34 6RJTel. 1 248 426 1482Tel. 91 20 6652 9090Tel. 44 (0) 8443 759685
Data Migration Planning Analysis, Solution Design and Development Mock Migration Pilot Migration Released Data Migration Active Data and User Migration Inactive Data Migration Post Migration Activities Small Bang The details for each step include: Data Migration Planing - Develop the migration strategy and approach, and define the scope,
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