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ATK is a registered

trademark of

Alliant Techsystems Inc.

Chris Anderson – ATK

Sr. Manufacturing Analyst

Bill Baker – ATK

Sr. Software Engineer

October 1, 2014

HMIs Direct the

Manufacturing

Process

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3

Agenda

• About ATK

• Discuss the evolution of HMIs

• Concept Stage

• Prototype Stage

• Release Stage

• Continuous Improvement

• Tangible Benefits

• Reduced (Eliminate) Errors

• Reduced Process Time

• Review Really Cool HMIs

• Process Flow

• System Interfaces

• HMIs

4

Sub-Contractor

38% Prime Contractor

62%

Sales by Contract Type

• Headquartered in Arlington, VA, with approximately

16,000 employees

• $4.8B in sales and $5.8B orders

• Company/customer funded R&D $750M

• More than 60 facilities in 22 states, Puerto Rico and

Internationally

• Representatives in more than 50 countries throughout

the world

• Last 18 months: acquired Savage Arms and Bushnell

Commercial/ International

47%

U.S. Army 20%

NASA 9%

U.S Navy 10%

U.S. Air Force 4%

Other U.S. Government

10%

Sales by Customer

ATK at a Glance- They Made Me Do it

Aerospace Group Defense Group Sporting Group

Results are for the fiscal year ended March 31, 2014

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About ATK – Our Place

Aircraft Commercial Center of Excellence (ACCE)

Located in Clearfield, Utah

Anchor Programs: Airbus A350 / A400M and Roll-

Royce

• Floor Space: 615,000 sq ft

• 100,000 sq ft Clean Room Capacity

• 15,000 sq ft Office Space

• 2,500 sq ft Freezer Capacity

• Automated Stiffener Forming Capacity

• Automated Linear Stringer Machines

• Automated Radial Frame Machines

• Engine Case Wrap Capacity

• CNC Milling Machine Capacity

• Large Diameter Autoclave Capacity

• NDI Systems - Automated Ultrasonic Inspection

(AUIS)

• Water Jet and Machining Capacity

• Hot Drape Forming

MANUFACTURING AREA

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About ATK – Our Place

MANUFACTURING AREA Freeport Composite Center

Located in Clearfield, Utah

Anchor Programs: Boeing 787 and

Lockheed Martin F-35

• Floor Space: 403,000 sq ft

• Clean Rooms

• Fiber Placement Machines

• Case Wrappers

• Ovens

• CNC Milling Machines

• Lathes

• Autoclaves

• Automated Ultrasonic Inspection

Systems (AUIS)

• ASFM Machines

• Pattern Cutter

• Leica Measurement Systems

• Laser/Radar Measurement Systems

• Virtek Projection Systems

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In the Beginning…

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Concept Stage - Shop Floor and MFG Systems

Solumina Shop Floor PC

Barcode Scanner

Engineering Desk PC

Oracle 10g

Solumina / Impresa

Data

Oracle 10g

ePIC Data

EWI &

MRP

PLM

1. Keep current MES’ish

Systems

Goals

Shop Floor Machine

Control PC

2. Talk to Shop Floor

machines

3. No sneaker-net

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Concept Stage - PLM , EWI, Control PC

Engineering Desk PC

Part Program - Name - Revision - Location

ePIC Solumina

Work Order - Part Program - Name - Revision

Control PC

Machine Designation Part Programs Output Data Files Output Reports

700+ Part

Numbers

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Prototype Stage

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Prototype Stage – Take One

Shop Floor Machine

Control PC

Solumina Shop Floor

PC

Barcode Scanner

Oracle 10g

Solumina / Impresa

Data

Engineering Desk PC

Part Files

MS Win MFG File Server

ATK network MFG subnet

Oracle 10g

ePIC Data

• Machine controls say

take a hike

• Use EWI for interface

12

Prototype Stage – Take Two

Shop Floor Machine

Control PC

Solumina Shop Floor

PC

Barcode Scanner

Oracle 10g

Solumina / Impresa

Data

Engineering Desk PC

Part Files

MS Win MFG File Server

ATK network MFG subnet

Oracle 10g

ePIC Data

• Bug machine

controls until they

give in

MS SQL Express

Machine Specific

Data

• Use Local DB for

interface

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Prototype Stage – Let’s Go into Production

Solumina / Impresa

Data

Engineering Desk PC

Machine G

Machine Specific

Data

Machine C

Machine Specific

Data

Machine B

Machine Specific

Data

Machine E

Machine Specific

Data

Machine F

Machine Specific

Data

Machine D

Machine Specific

Data

Machine A

Machine Specific

Data

Take Three

• IT states we’re nuts

• Starting to panic

• Go with it anyhow

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Release Stage

“Release the Kraken”

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Release Stage – First Big Tweak

Shop Floor Machine

Control PC

Solumina Shop Floor

PC

Barcode Scanner

Oracle 11g

Solumina / Impresa

Data

Engineering Desk PC

Part Files

MS Win MFG File Server

ATK network MFG subnet

Oracle 11g

ePIC Data

MS SQL Server

Machine Data

• Single SQL Server for

multiple machines

• Process Specific HMIs

- UI/Interface Wrapper - SQL Calls

HMI

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Release Stage - HMIs

Tool Prep HMI

Vacuum Bag

HMI

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Release Stage - HMIs

Vacuum Timer

Open WO

Material Usage

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Continuous Improvement

There was an engineer, manager and programmer driving down a steep mountain

road.

The brakes failed and the car careened down the road out of control.

Half way down the driver managed to stop the car by running it against the

embankment barely avoiding going over a cliff.

They all got out, shaken by their narrow escape from death, but otherwise

unharmed.

The manager said "To fix this problem we need to organize a committee, have

meetings, and through a process of continuous improvement, develop a solution."

The programmer said "I think you're both wrong! I think we should all push the car

back up the hill and see if it happens again."

The engineer said "No that would take too long, and besides that method never

worked before. I have my trusty pen knife here and will take apart the brake system,

isolate the problem and correct it."

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Continuous Improvement – Cool Integration

Solumina / Impresa

Data Oracle 10g

Engineering Desk PC

Part Files

MS Win MFG File Server

Shop Floor

Machine

Web Services

Web Server

Control PC

Oracle 10g

ePIC Data

MS SQL Server

InfinityQS (SPC) Data

- UI/Interface Wrapper - Web Services

HMI

MS SQL Server

Machine Data

Barcode or RFID Scanner

Manual Station

or

OAT RFID Data

SQL Server

• Add one heaping

batch of Web

Services

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Continuous Improvement – Sustainable HMIs

Control PC

- UI/Interface Wrapper

HMI

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Continuous Improvement – Off the Shelf

ArchestrA System Platform

ePicSolumina

Visual

Action BoardInfinityQSEMS

TC Mapping

SOA Platform (Apache Tomcat, Microsoft IIS Webservers)

MPM-01

HMI

CART LOAD

HMI

CART

UNLOAD

HMI

DIM-03

HMI

COV-01

HMI

AUIS-7

HMI

MC-11

HMI

CAC-01

HMI

ASFM-L04

HMI

ASFM-R02

HMI

TOOL PREP

HMI

BAG

HMI

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Continuous Improvement – OMP

ArchestrA System Platform

ePicSoluminaVisual

Action BoardInfinityQSEMSTC Mapping

OMP Manufacturing Information Bus

MPM-01

HMI

CART LOAD

HMI

CART

UNLOAD

HMI

DIM-03

HMI

COV-01

HMI

AUIS-7

HMI

MC-11

HMI

CAC-01

HMI

ASFM-L04

HMI

ASFM-R02

HMI

TOOL PREP

HMI

BAG

HMI

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Now for the good stuff…

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Tangible Benefits – Failures w/o HMI

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Tangible Benefits – Failures w/ HMI

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Tangible Benefits – Failures Detail

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Tangible Benefits – Cycle Time Improvements

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Tangible Benefits – Cycle Time Details

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HMI Review

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HMIs – Process Flow

1- Tools Arrive

Start Tool Prep

Process

Conveyors

3- Vacuum Bagging

Process

2- Part

Forming

Machine

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HMIs – System Interfaces

HMI

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Tool Prep HMI - Start Operation

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Tool Prep HMI – Scan Tool to Retrieve WO

Applicable

work orders

Scanned tool

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Tool Prep HMI – Perform Work

Material

location on tool

Required

Materials

Required Software

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Tool Prep HMI – Material Usage

Consumed

Materials

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Vacuum Bag HMI - Start Operation

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Vacuum Bag HMI – Scan Tool

Scanned tool

Applicable work

orders

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Vacuum Bag HMI – Open WO & Perform Work

Graphical

Representation

of part

Required Caul Software Detail

39

Vacuum Bag HMI – Scan Cauls

Cauls

Scanned

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Vacuum Bag HMI – Vacuum Test Timer

Vacuum Timer

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Vacuum Bag HMI – Complete Operations

All Operations

Completed

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Q & A

Please be gentle