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PRO J E C T R EPO RT
SCOTT FRYE
UNIVERSITY OF MASSAC HUSETTS AT LOWELL
91.522 OBJECT ORIENT ED ANALYSIS AND DESI GN
FALL 2004
DECEMBER 6 T H , 2004
TA B L E O F C ON T E N T S
Table of Contents ...................................................................... 2
Background ................................................................................ 3
Company ....................................................................................... 3
Process ........................................................................................... 3
Problem Domain............................................................................ 3
Project Plan ................................................................................ 3
Overview ........................................................................................ 3
Opportunity Assessment ................................................................. 4
Design ......................................................................................... 5
Design Issues.......................Error! Bookmark not defined.
Design Issues.............................................................................. 7
Information Model .................................................................... 9
Object Life Cycle Model ........................................................ 10
BA C KG RO U N D
COMPANY
I work for Wyman-Gordon – Grafton (http://www.wyman-gordon.com/) A division of PCC
(http://www.precast.com/). Our plant is marketed as providing Structural Forgings for Military and
Commercial Aircraft; Large Forgings for Industrial Gas Turbine and Aero turbine Applications.
There are many steps in our process but this project is concerned with the forging process.
PROCESS
The process of forging consists of taking a metal shape, heating it in a furnace to the desired
temperature and placing the part in press with a mold, called a forge. Extreme pressures, between
18k and 50k tons are applied to shape the metal into a rough shape. This is referred to as a hit.
Several hits may be necessary sometimes with reheating of the part in between. After a part is
forged, properties are measured. Some are physical dimensions and some are metallurgic properties.
If some of these are not within an acceptable range, the part can often be “hit” again to correct the
problems.
PROBLEM DOMAIN
There are many points where data is collected in the process. This project will concern itself
with the Forge Database but it will touch on other systems as they relate.
The Forge database was written by a co-op Industrial Engineering student in 2002 to store some
process variables about the forging process. The solution was implemented in Access but the co-op
had no database design knowledge and focused on defining the parameters that should be tracked
instead of the database design.
Measurement information about the forging process is stored in a third party application called
Quantum SPC-DC. The application provides a front end that allows data entry and all information is
stored in a MS SQL Server backend. The Quantum SPC-DC application allows for capturing of data
in traditional statistical control chart format. The data is recorded by part, characteristic and time
measured. Each measurement group (of size one in our case) represents a subgroup. Our inspectors
attach a label to each subgroup that tells the Serial Number of the part and other information.
Recently, the engineering group approach the IT group about the possibility of viewing the
Quantum data in a different format that the Quantum SPC-DC program allows. Specifically they
wanted to view the data by part, with a row for each serial number and a column for each
characteristic measured. I created a program called WGPartDataView which did this.
The Engineering group has now requested that the information in the Forge database be
displayed alongside the Quantum SPC-DC data in WGPartDataview.
P RO J E C T P L A N
OVERVIEW
Description
The Forge Database is currently an Access program that stores information about the Forge
operations done in Grafton. The most important information stored is when the serial number is
processed and how long the forging step took.
The current system can be thought of as a prototype. It has evolved instead of been designed. Now
that it is being used by many people in needs to be re-designed to follow good programming
practices.
Who Uses:
Data Production:
The data is entered in the system by a data entry person. The data is retrieved from a variety of
paper documents that are generated in the shop.
Data Consumption:
The data is used by Development Engineers, Design Engineers and Metallurgist to research
problems by looking at product history.
OPPORTUNITY ASSESSMENT
Reason for new system:
 Lack of Extensibility:



o
Access only supports 10 concurrent users
o
According to current opinion in the industry, Access starts becoming unstable at
about 50,000 records. Currently there are over 62,000 records in the SN table.
Lack of Security:
o
Sarbanes Oxley requires change management practices. There is no way to control
changes because everyone has full access to the database.
o
Anyone can add, delete and modify information.
Maintainability
o
Modification to the system take a long time because the system doesn’t follow good
programming practices.
o
There are a lot of unused fields and redundant data in the current schema.
There is a current need to view data in this system along side Quantum data in
WGPartDataView. The modification to the program to make this information useful are
extensive and provide a good time for re-factoring this solution
DESIGN
Domain: Order:
A physical order coming into our system through any number of channels.
Bridge to Syteline ERP system:
All orders are entered and maintained in Syteline
Domain: Syteline ERP System
Mission Statement:
Manages all aspects of the business including order entry, billing, scheduling, shipping.
Bridge to Syteline ERP system:
All orders are entered, tracked and closed in the ERP system
Bridge to Forge Process:
Jobs schedule for Forge process is created by ERP system.
Domain: Viper NDT System
Manages the serial number tracking of each part and certification to quality specification.
Bridge to Physical Order:
Physical orders are entered into the NDT system so their certification can be generated
and tracked.
Bridge to Forge Process:
Certification results of process entered into NDT.
Domain: Forge Process
Physical process of forging the parts
Bridge to ERP system:
Jobs schedule for Forge process is created by ERP system.
Bridge to NDT System:
Certification results of process entered into NDT.
Bridge to Wonder-ware:
Control, switch settings and electronic sensors record data to Wonder-ware system. All
data is stored and Control and Switch settings are manipulated thru Wonder-ware
software.
Bridge to Forge Database Store:
Process Parameters are recorded manually and entered into Forge Database Store
Bridge to Quantum Data Store:
Part characteristics are measured and entered into Quantum Database
Domain: Wonder-ware data store
System that manages the setting of all process parameters for various machines in the
shop (including forge operations) Maintains runtime data of the forge process by
automatically recording physical settings of various machine settings at a given time
index.
Bridge to Forge Process:
Control, switch settings and electronic sensors record data to Wonder-ware system. All
data is stored and Control and Switch settings are manipulated thru Wonder-ware
software.
Bridge to WGPartDataView:
WGPartDataView shows summary information of Wonder-ware, Forge Database and
Quantum information.
Domain: Forge Data store
Summary information about a particular forge that is entered by a user at the end of a
forge run.
Bridge to Forge Process:
Process Parameters are recorded manually and entered into Forge Database Store
Bridge to WGPartDataView:
WGPartDataView shows summary information of Wonder-ware, Forge Database and
Quantum information.
Domain: Quantum Data Store
Stores statistical information about attribute data of a finished forge. Data is stored for
multiple characteristics by subgroup with subgroup size of one. Statistical analysis tools
of the data are available as well.
Bridge to Forge Process:
Part characteristics are measured and entered into Quantum Database
Bridge to WGPartDataView:
WGPartDataView shows summary information of Wonder-ware, Forge Database and
Quantum information.
Domain: WGPartDataView
A querying tool to assist engineers in analyzing a part. Summarizes all data about a part
by serial number.
Bridge to Wonder-ware, Forge Database, Quantum:
WGPartDataView shows summary information of Wonder-ware, Forge Database and
Quantum information.
DESIGN ISSUES
Forge Database must be redesigned such that it is easy to retrieve data for WGPartDataView and is
no harder to ender data into the system than it is today. Additionally, the current data is not
referentially valid. This needs to be corrected.
The Quantum database is a SQL database with an elaborate data structure. This needs to be
abstracted to be easily consumed by WGPartDataView. This can be done through SQL statements
or through software components or through web services.
The Wonder-ware data is stored in flat files organized by year, month and date. Within each file,
the data is stored in comma separated fields with a row for each time sampled. Each row has a time
stamp and a list of values for the characteristic that was measured. An interface needs to be defined
that exposes this information in a way that can be consumed by the WGPartDataview program.
Options are a WebService, a software component, or a Batch File to load this data into a SQL
database periodically.
This project will focus on the Forge Database part of the problem. The data access logic will be
abstracted from the user interface object so that it can be easily modified without affecting the
application.
I N F OR M A T I ON M OD E L
O B J E C T L I F E C YC L E M O D E L