Post on 19-Mar-2018
-Digital Shipbuilding-NSRP Advanced Shipbuilding Enterprise Research Announcement, NSRP letter dated March 13, 2014
Submitted by: Huntington Ingalls Industries ,Newport News Shipbuilding
Dennis Jarabak - Project Manager Huntington Ingalls – Newport News Shipbuilding
3D CIC 2016 Golden, Colorado
Huntington Ingalls Industries, Newport News Shipbuilding
General Dynamics Electric Boat
SIEMENS Product Lifecycle Management (PLM) Software
A Collaborative Project on behalf of:
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Project Synopsis 2
The goal of this project is to determine how to best leverage the Product Model to supportintegrated Design, Planning, and Manufacturing for an effective Shipbuilding Data Environment.
The Project Team will improve and integrate current 3D Product Model activities with newprocesses and tool functionality, to include:
•Defining discrete views for Design, Planning, Manufacturing & Execution Data in the 3DShipbuilding Data Environment.
•Defining data privileges by stakeholder roles.
•Identifying Product Manufacturing Information (PMI) requirements and data flow between theproduct model and deck plate, including a consistent format for the delivery of digital workinstructions.
•Establishing an information data architecture to support digital Shipbuilding.
•Determining the CAD and ERP master/slave relationships for Product Model data and workinstructions.
•Developing a transition change management strategy to move trades from a 2D drawing to adigital environment.
The Project will evaluate tools and address the impact to the Shop Floor for a Significant Paradigm change from Drawings to Digital Manufacturing Products.
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Current Assessment 3
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
• ModelBasedEnterprise• IntegratedManufacturing– IntegratedExtendedEnterprise• PrimaryDeliverablesDigitalProductDefinitionPackageandTDPviatheweb
• ModelBasedEnterprise• IntegratedManufacturing– IntegratedInternalEnterprise• PrimaryDeliverablesDigitalProductDefinitionPackageandTechnicalDataProduct(TDP)
• ModelBasedDefinition• IntegratedManufacturing– DisconnectedEnterprise• PrimaryDeliverables3DAnnotatedModelandLightWeightviewableviaPLM
• ModelBasedDefinition• NativeModelCAM– DisconnectedEnterprise• PrimaryDeliverables3DAnnotatedModelandLightWeightviewable
• ModelCentric• NativeModelCAM– DisconnectedEnterprise• PrimaryDeliverables2DDrawingandNativeCADModel
• ModelCentric• NeutralModelCAM– DisconnectedEnterprise• PrimaryDeliverables2DDrawingandNeutralCADModel
• DrawingCentric• DisconnectedManufacturing– DisconnectedEnterprise• PrimaryDeliverables2DDrawing
Level6Level5Level4Level3Level2Level1Level0
Current Assessment 2 – Moving to 3
FORD CLASS
NIMITZ
Project Schedule4
3 Year Project: Currently Entering Phase 3
1) Future State Requirements/Use Cases 2) Code Development 3) Pilot – Integrated TC/NX/ERP
Production Environment Interfaces Test/Development Environment
Phase I -12 months Phase III - 12 monthsPhase II – 12 months
Pilot/Transition Plan
NNS’ PP- Reqmt’s for Drawingless Env.
EB’s RA – Ship Knowledge Management
Supporting NSRP Projects:
NNS’ RA – Product Model Driven Weld Management
Project Duration = 36 months
Project Deliverables:•Requirements Documents•Process Use Cases•System Architecture Diagram•SIEMENS COTs software TC/NX•Pilot results / configuration•Shop Floor Transition plan•Implementation plans
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
System Architecture 5
The Project will Evaluate options for an Effective Shipbuilding Data Environment,and then configure Pilot Environments for testing production impact.
WORKInstructions
BOM/Material
Schedule
ERP/SAP
IntelligentMachines
ShopForeman
“DigitalShipbuilding”Architecture(CurrentState)
Bi-Directional
Integration
3DGeometry
DESIGN EXECUTION
Access/SecurityRoles(NeedtoKnow)
ElectronicData
Documents
2DDwg’s
3DModel
PDM/TC
2DEnvironment 2DDrawings
PLANNING
Dispatcher
Partial Electronic Data Flow / 2D Drawings are Baseline
Replace
Replace
CiWPStandard Process
Instructions(Libraries)
Common Work Assignments,Management & Closeout
(SWIMS)
Visual Product Information &
Digital Shipbuilding
Transition Period
Direct Electronic Data Flow / 2D Drawing Elimination
NEW
NEW
Direct Interface
CiWPStandard Process
Instructions(Libraries)
Common Work Assignments,Management & Closeout
(SWIMS)
Visual Product Information &
Digital Shipbuilding
Full Implementation
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Project Work Completed 6
ü Document Requirementsü Create a comprehensive Drawing Inventory (NSRP 2014 Panel Project
“Requirements for a Drawing-less environment”) ü Identify Drawing content for Key Piping and Structural Drawings ü Identify design/ manufacturing view requirementsü Develop As-is Use Cases for Drawing consumption within work instructionsü Document non-drawing data content required for a work instructionü Document data flow architecture for Digital Shipbuildingü A 10 step data processing pilot has been acceptedü Pilot environments has been established at Newport Newsü Pilot Plan has been developedü System Architecture has been developed
Digital Shipbuilding Phases 1 & 2 are complete & Phase 3 to start 4th Qtr. 2016Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Phase 1 Business Process Analysis
7
Engineering&Design Planning Manufacturing/
Shops Ship/Platen Inspection/Test
PROGRAMS:VCS/ORPCVNRCOH
OVERALLBUSINESSPROCESS
Business Process Mapped to Insure Entire Value Stream is AddressedCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Phase 1 Requirements Definition
8
ENGINEERING&DESIGNE&D RequirementDescription Priority Customer
CommittedRelease
The system will allow for multiple design scenarios and views (concept, arrangement and detailed).
Workflows for design process review, interim steps (working, review, and
approval, complete) and approvals will be incorporated to support the complete Technical Authority process.
The system will allow the separation between the Design (Technical Authority) , Build (Build Authority) and Life Cycle Authority (In Service) model views.
The system shall provide links to reference data, procedures, test documents, specifications, material specs., material and pipe specs, standard part catalogs, and other misc., information required.
The system will link all drawing based information (Ref. Section 2) The system shall be able to link to vendor specific information supplied to
the design agent.
The system shall provide a means to store and retrieve system diagrams. The system should allow for access to product history, reference and other
shipbuilder or vendor information repositories.
The system will provide the capability to develop or link to ship scantling drawings that are developed internally or in an external system.
The system will provide the shipbuilder specific layer and color options (by
system, material etc.).
The system shall allow for the development for a user specific ships’ reference grid system.
The system should provide the ability to add parts from a common part
catalog.
The system should allow for the development or link to the Engineering Bill of Material.
The system should have the capability for populating shipyard specific
forms (joint occurrence, penetration, weld, inspections etc.).
Over 1,000 Requirements Identified – Comprehensive Value Stream AnalysisCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Phase 2 System Configuration
9
10/20
MR2 MR3
6/28
MR4
9/20
Phase 2 Completion
9/30
MaturityReviews
MR Topics Products/Versions
Status
MR1 Design Engineering Tc 10.1.1, NX 9.0.1.3
Completed
MR2 Planning MBOM Tc 10.1.5/Vis 10.1.5, NX 10
Completed
MR3 Planning Work Package Tc 11, NX 11, EWI 3.x
Completed
MR4 Execute and Inspect Tc 11.x, NX 11.x Completed
MR5 Change Control Tc 11.x, NX 11.x Completed
Pilots Digital Shipbuilding Complete Project
Tc 11.x, NX 11.x 2017
MR5
9/20
Pilot Results
9/1
1/30
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
2017
2016
Phase 2 System Configuration
10
Manufacturing Planning MBOM (Build Authority) Processes
Process Step AnalysisCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Phase 3: Pilot Goals and Objectives
The objective of the pilot is to demonstrate and end to end processfrom BOM creation to issuance of the work package including visualwork instructions and model views. The major objectives are:
• Production implementation to support drawing-less build processesfor CVN new construction.
• Reduce man-hours by eliminating manual steps for producing visualwork instructions and associated work packages.
• Increased Technology Readiness Level (TRL) – pilot will increaseTRL from 3 to 4
11
Goal: An integrated Solution
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Pilot Process 12
A Ten Step Solution
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Phase 3 Pilot Activities 13
Phase 3. Pilot/Prototype q Develop use cases for fabrication and
assembly processesq Plan detailed Pilot activitiesq Load Test Dataq Extract CAD/ERP data to mfg. systemsq Analyze resultsq Develop full scale implementation planq Develop training requirement
Pilot the ProcessesCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Pilot Roles & Responsibilities
14
Participants RoleNNS Pilot Team • Project Lead – successful Systems Engineering/Project
Management Processes.• Develop use cases and execute pilot; evaluate and report
out results.• Technology Transfer Partner – transitioning pilot into
production.Siemens • TeamCenter/NX developer and maintainer – implements
requirements into future deliveries of their products andindustry
NNS IT • Ensure test environment and interfaces are configured andoperable. Provide NNS environment technical support.
General DynamicsElectric Boat
• Develop uses cases and assist in pilot execution.
All Inclusive Project Support TeamCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Phase 3 Use Cases 15
UC # Use Case Requirement1.0 Build mBOM (PBOM) based on a previously released model or eBOM.
2.0
Develop manufacturing processes using previously developed PBOM.
• Authorprocessesandsub-processestobuild/assemblyunit/product• Authoroperationsteps• Assignconsumedpartstooperations• Addresources(toolsandfixtures)• Define sequence of events
3.0
Create Product Views to Support Manufacturing
• Create views• Add PMI
4.0
Author textual work instructions
• Add additional work instructions as required
5.0
Add operational instructions including links to weld procedures, manufacturing notes etc.
• Addreferencetodrawing• Addspecificproceduresetc.
6.0
ExecuteChangeManagementProcess• Updatethelinkstotherequiredinformation• Redesignorchange/addaparttoexistingunit/product• ReissuetheeBOM/mBOM(PBOM)• Updatetheproductviewfortheaffectedarea• Updatethetextualworkinstructions
7.0
Output information to the MES system
• Electronic transfer or simulated data between systems.
Comprehensive End to End Use CaseCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Pilot Schedule 16
Scheduled Activities Allow for Additional WorkCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Task Start Date End Date
Environment Configuration 9/1/2016 9/30//2016
Load Test Data 9/5/2016 9.30/2016
Siemens Test and Demo and User Training 10/1/2016 10/31/2016
User Acceptance Testing 11/1/2016 11/30/2016
Pilot Execution 12/1/2016 9/30/2017
Pilot Demonstration 8/15/2017 9/15/2017
Final Report 9/1/2017 9/30/2017
Pilot Implementation Plan 9/1/2017 9/30/2017
Metrics/Benefits 17
Category Measurement description
Target metric Acceptable range of values
Business goals Develop work instructions and other documents to fully allow the building of a ship unit.
Completion of pilot units Successfulcompletion
Business Goals Compare time to existing methods; the process should allow for a reduction of approximately 30% when compared to existing methods.
30% reduction 20-30%
Technology Readiness Level (TRL)
3 – Analytical and experimental critical function and/or proof of concept.
4 – Component validation in laboratory environment
Demonstrate capability in Pilot with ship data
The Pay Off : Man-hour and Schedule ReductionsCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
NX 11/Tc11 Pilot Environment
18
Siemens Center of Excellence (COE) Environment• Development Servers: Virtual Machine, CPU Size
– 2800, RAM 2GB, 4GB, 6GB, and 16GB, • Workstation 3: CPU Size – 3.20Ghz, RAM 12GB• Workstation 8: CPU Size – 2.93GHz, RAM 12GB• Workstation Dell M4800 laptop: CPU Size –
2.40GHz, RAM 32GB• Recommended: Graphics Card > 8MB• Operating System: MS Windows • Product Data Location: Siemens NX11.x/TC 11.x• Pilot Base A Assembly Units – Ford Class Carrier• Pilot Dates: 10/1/2016 – 9/30/2017
Hardware and SoftwareCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Planned Technical Reviews/Reports
19
Description Location Date
Siemens Test, Demo and User Training Newport News 10/31/16
User Acceptance Testing Newport News 11/30/16
Pilot Results and Demonstrations Newport News 8/30/16
Planned Technical Transfers and ReportingCopyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
Project Quarterly Reporting• Technical Report: Progress, Schedule etc.• Business Report: Cost, Resources Issues etc.
Digital Shipbuilding 20
A Glimpse of the Future
Digital Ship Video
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved
21
“Maximize Value Realized Through Integrated Digital Shipbuilding”
Model Based Enterprise
ConceptualDesign
ProductionPlanning
Fabrication,Assembly
ManufacturingEngineering
ShipDeliveryMaintenance
&Repair
ShipDecommission
Test&Inspection
In-serviceOperations
Requirements
DetailDesign
ArrangementDesign
3D ModelEBOM
CAE Analysis
PMI PBOMWork
PackageVisual Work Instructions
Requirements Validation
Close-Out Work CertificationAvailable
Work Package (AWP) Availability
Planning
Technical Manuals/Documents
“Information Digital Thread”
DisposalWork Package
Copyright 2016 Huntington Ingalls Industries Inc. All Rights Reserved