30 April 2009 1

Enabling Shipbuilding InteroperabilityISE-6 Project

Exchange of Product Models for Life Cycle Support

ISE-6 Final DemonstrationOverview Presentation

Presented on: April 30, 2009

Presented by: Dr. Burton Gischner Electric Boat Corporation

Integrated Shipbuilding Environment

30 April 2009 2

Agenda

Integrated Shipbuilding Environment (ISE)-6:

A National Shipbuilding Research Program (NSRP) Project to Enable Interoperability for Product Life Cycle Support (PLCS)

– Overview of NSRP

– Interoperability Problem and Solution

– ISE Architecture, Information Model Methodology, and Roadmap

– Current Focus on Life Cycle Support

– Summary

30 April 2009 3

National Shipbuilding Research Program (NSRP)Advanced Shipbuilding Enterprise (ASE)

• NSRP ASE is a collaboration of 12 major U.S. Shipyards focused on industry-wide implementation of solutions to reduce the cost of building and maintaining U.S. Navy warships

• The collaboration was created in 1998 by industry in response to the Navy’s request for a cost-effective, cross-program vehicle for rapid and effective implementation of cost-reduction processes and technologies to address common cost drivers

• The program targets solutions to consensus priority issues that exhibit a compelling business case – solutions that include both leverage of best commercial practices and creation of industry-wide initiatives with aggressive technology transfer to, and buy-in by, multiple U.S. Shipyards

30 April 2009 4

NSRP Major Initiative Areas

• NSRP is structured into six Major Initiatives that tie the strategic vision to proposed industry research through collaborative R&D and other mechanisms

• Each Major Initiative constitutes a strategic technology focus area that is managed and budgeted by the NSRP ASE Program

• The Major Initiatives include:– Shipyard Production Process Technologies– Systems Technology– Business Process Technologies– Facilities, Tooling, and Risk Management– Product Design and Material Technologies– Crosscut Initiatives

• ISE is a major effort under the Systems Technology initiative

30 April 2009 5

NSRP = Industry-wide CollaborationEffecting Large Scale Change with Industry-wide Solutions

Accuracy control – metrology, processes and toolsBenefit: Reduces rework labor, materials, cost and cycle time; enables automation

Steel Processing – Laser cutting, precision forming, and tab & slot technologyBenefit: 30% reduction in steel cutting costs; 8% reduction in steel plate usage in first production use

Joint Lean Learning Curve - Accelerate adoption of productivity improvement

Benefit: Systematic, repeatable boosts in productivity from shop-level to design, engineering and supply chains

Todd

NASSCO

Bath Iron Works

Northrop Grumman Ship Systems

Newport News

Suppliers

Electric Boat

NationwideeBusiness Networkfor Shipbuilding &

Ship Repair

eBusiness for Enterprise Integration – across construction, repair, logistics activities and suppliersBenefit: Cuts labor and cycle time of daily processes by 60%

Common Parts Catalog – Enterprise standard, shared parts database

Benefit: facilitates standardization & IPDE initiatives; fewer parts to procure, inspect, certify, track, warehouse …

IT Interoperability – Integrating shipyard IT systems (CAD, CAM, Parts …) across firms & functionsBenefit: Reduces costs & acquisition cycle time, improves 1st time quality, enables outsourcing

30 April 2009 6

Computer AidedEngineering

Visualization

Simulation

ANALYZE

ComputerAided

Design

DEFINE

Planning/ERP

PLAN

Parts Order/Parts Catalog

SOURCE

ComputerAided

Manufacturing

MANUFACTURE

Product Data ManagerProduct Data Manager

Requirement Management

System

REQUIREMENTS

Computer AidedEngineering

Visualization

Simulation

ANALYZE

ComputerAided

Design

DEFINE

Planning/ERP

PLAN

Parts Order/Parts Catalog

SOURCE

ComputerAided

Manufacturing

MANUFACTURE

Product Data ManagerProduct Data Manager

Requirement Management

System

REQUIREMENTS

Product Data Initiatives Alignment

Full Ship Modeling & Simulation

CPC

Navy Initiative

NSRP Initiative

NPDI

MAINTAIN

Planning Yard

Product Data Manager

SPARS

ISE

LEAPS Navy ERP

30 April 2009 7

NSRP Project –

Improved Methods

for the Generation of

Full-Ship

Simulation/Analysis

Models 2

NSRP Project –

Improved Methods

for the Generation of

Full-Ship

Simulation/Analysis

Models 2

The NSRP Modeling and Simulation WorkshopThe NSRP Modeling and Simulation Project will hold a one day workshop in association with the DoD CREATE Project covering Ship Modeling and Simulation efforts.

June 10, 2009

30 April 2009 8

Interoperability Problem

• Communication between diverse computer systems is a big challenge in today’s environment:– As CAD/CAE/CAM systems have proliferated in the U.S. shipyards,

interoperability among these systems has become a major issue

– Interoperability is an issue within a shipyard as well as between partnering yards and with the Customer

• This situation is further aggravated because:– Most recent and future ship design and build contracts involve multiple

shipyards

– Length of time to design and build a ship often exceeds the life span of current computer systems, driving the need to move existing data to new computer systems

– Requirements for life cycle support of the ship will far exceed the life span of current computer systems, again driving the need to move existing data to new computer systems

30 April 2009 9

Current Process for Updating Technical Data

Radar

Navy Legacy Systems

Navy

Tech Manuals & Deliverables

Embedded Tech Data

Training

RadarTech Data

• Radar System is designed and produced• Contractor and Navy agree on LRU breakdown• Logistics Organization builds Tech Manual

­ Primary inputs are Drawings and Parts List­ Maintenance Engineering defines maintenance data and procedures

• Documents delivered to Navy • Navy Logistics Organization

­ Builds Navy Tech Manual­ Generates data for other Navy Logistics systems from documents

Goal is to Reduce Life Cycle Costs through Standards-Based Integration

30 April 2009 10

ISE Interoperability Solution

• The Integrated Shipbuilding Environment Consortium (ISEC) is attacking the interoperability problem on a broad front involving numerous standards, tools, and organizations including:– XML (Extensible Markup Language)

– STEP (Standard for Exchange of Product Model Data)

– isetools.org Website

• Demonstrate that improved interoperability will achieve cost reductions in Navy and commercial shipbuilding processes across shipyards and across the design/build/support life cycle

• Leverage past work by deploying information technology systems that meet the shipbuilder’s interoperability requirements

• Support other NSRP initiatives for better integration among shipbuilding enterprise functions

30 April 2009 11

ISE Interoperability Solution

• Drive development of shipbuilding product data standards (e.g. STEP, PLIB)– Construct a single Shipbuilding Information Model – Demonstrate and educate U.S. shipbuilding community

• Flexibility is critical– Allow shipyards to transform their data to/from common

information model– Enable each enterprise to use its own tool set rather than all

move to the same tools

• Develop and demonstrate tools that are low cost – Can be used selectively by shipyards to support

interoperability

– Capitalize on XML and related Internet technologies

30 April 2009 12

ISE Interoperability Solution

• The ISE Projects have helped develop standards, defined the approach, and implemented a solution to ensure information interoperability

• The goal of current and future efforts is to make these techniques and tools available in production to all U.S. shipyards– STEP Shipbuilding Translators– XML Tools– Common Parts Catalog Interfaces

30 April 2009 13

XML + STEP

XML­=­Industry­StandardContainer­for­Data

STEP­=­ISO­StandardLanguage­for­Data

Data

CompanyA

StandardsVirtualShippart(s)

CompanyB

Transactions of Data Packaged in Standards

XSLT­-­map­data­to­another­XML­schema

XML :

• Accepted format/schema method

• Web-enabling

STEP :

• Standards for data expression

• Standards for geometric exchange

•­Data is independent of IT infrastructure, but standards are required to reflect system needs for exchange

30 April 2009 14

ISE Architecture

• Accessible to large and small shipyards– Only system dependency is Web infrastructure

– Utilizes open standards

• Innovative integration of STEP and XML technologies– Supports sharing of geometry & geometric product models

• Permissive (mediation) architecture– Lets each enterprise choose its own tool set

• Amenable with CAD platforms used by U.S. shipbuilders

ISE architecture represents an innovative, practical solution to the information interoperability challenge

30 April 2009 15

ISE Tools• Tools developed by the ISE Project are made available

on the Web at: www.isetools.org• These include:

– Formal information requirements published• Ship Piping

• Ship Structures

• Ship HVAC

• CPC Interfaces

• Electrical

– Translator generators for custom representations

– XML schema generators• ISO 10303-28 ed 2

– Mediators (i.e. between STEP Part 21 and STEP Part 28)

– Automated test frameworks for conformance testing

30 April 2009 16

HVACISO AP 227:2005

PipingISO AP 227:2005

Ship ArrangementISO AP 215:2004

Ship Moulded FormsISO AP 216:2003

Ship StructuresISO AP 218:2004

Reference Data LibrariesISO 15926

Common Parts Catalog (CPC)

ElectricalISO AP 212:2001

Mechanical SystemsISO AP 227:2005

Cable TraysISO AP 227:2005

Finite Element Analysis

ISO AP 209:2001

Product Config / Geometry

ISO AP 203/214:1994

Product Life Cycle Support

Systems EngineeringISO AP 233

Computational Fluid DynamicsISO AP 237

Logistics / SparesISO AP 232:2002

Outfit & FurnishingsNSRP 0428:1992

Manufacturing Support

ISO APs 224, 238, 240

Standard­Approved

Information­Model

Prototype­Translators

Testing­Framework

Deployment,­Integration,Testing

Standard­In­Work

Ship Product Model Data

Ship StructuralEnvelope

DistributionSystems

Equipment /Subsystems

Life CycleMaintenance

Miscellaneous

Information Interoperability Roadmap

ISO AP 239:2004

30 April 2009 17

ISO STEP

NAVSEA

Ship Program

Standard Approved

Standard In Work

NSRP ISE Prototype Translators

Testing Framework

Information Model

Phases: RequirementsDefinition

Information Interoperability Specification

ProductionDeployment

ISE Information Model Methodology

ContractualSpecification

Deployment,Integration,

Testing

Technolo

gyB

usiness Decisions

Standardin Work

30 April 2009 18

Requiring the Use of STEP• Air­Force­incorporates­PLCS­into­acquisition­and­sustainment­policy

– ACQUISITION­AND­SUSTAINMENT­LIFE­CYCLE­MANAGEMENTAIR­FORCE­INSTRUCTION­63-101­• SECRETARY­OF­THE­AIR­FORCE­17­APRIL­2009

– The­PM­shall­ensure­development­and­acquisition­of­engineering­data­sufficient­for­the­acquisition,­modification,­maintenance,­spares,­repair,­and­demilitarization­of­the­weapon­system

– The­PM­shall­require­the­use­of­International­Standards­Organization­(ISO)­10303,­Standard­for­Exchange­of­Product­(STEP)­Model­Data,­AP239,­Product­Life­Cycle­Support,­for­engineering­data

– Air­Force­Instruction­is­available­on­the­Web­at:• http://www.e-publishing.af.mil/shared/media/epubs/AFI63-101.pdf

• Army­is­currently­implementing­use­of­AP239­for­Product­Life­Cycle­Support

• NAVSEA­Instruction­9040.3­Recommends­the­use­of­STEP­for­product­model­exchange,­but­the­Navy­has­yet­to­require­its­implementation­on­major­ship­programs

30 April 2009 19

ISE Interoperability Focus Areas• The Integrated Shipbuilding Environment Consortium

(ISEC) is led by U.S. shipbuilders along with commercial software vendors, and information technologists

• This team has been together for nine years and has developed much of the infrastructure and architecture necessary for shipbuilding information interoperability

• NSRP funded program focused on interoperability using international standards – ISO STEP, PLCS, S1000D, W3C

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

ISE-6ISE-5ISE-4ISE-3ISE-2ISE-1

Ship

Arr

ange

men

ts

Stee

l Pro

cess

ing

Engi

neer

ing

Ana

lysi

sEl

ectr

ical

Elec

trot

echn

ical

Prod

uct

Life

Cyc

le S

uppor

t

Requ

irem

ents HVAC

CPC

Inte

rfac

es

Stru

ctur

esPi

ping

30 April 2009 20

Interoperability: Current Related Efforts• ISE-6 (Integrated Shipbuilding Environment)

– Deploy information technology systems that meet the shipbuilder’s interoperability requirements in the area of life cycle support and post-delivery operations

• NPDI (Navy Product Data Initiative)– To specify the requirements for and drive the implementation of product data

systems based on an open architecture having suitable functionality and enterprise-wide interoperability to support affordable Navy ship design, construction and service life support

– Initial version of the IPDE Specification has been written and delivered to the Navy for review and comment

• SCIM (Ship Common Information Model)– SCIM will codify the models developed and prototyped by the ISE Project under

NSRP over the past nine years

– It will be a separate document from the IPDE Specification being produced by the NPDI Project, but it will be referenced by that IPDE Specification

– Initial version of the SCIM has not yet been completed• Six of fifteen proposed chapters have been developed

• One of the remaining chapters deals with Product Life Cycle Support and will be based on the results of the ISE-6 Project

30 April 2009 21

ISE Team Participants

­

30 April 2009 22

ISE Test Ship – TWR841

This­ship­is­used­to­locate­and­retrieve­torpedoes­and­missile­drones.­It­has­a­maximum­payload­capacity­of­42­long­tons­which­includes­the­deck­cargo­plus­full­liquids,­full­complement,­and­normal­stores.

This ship was selected because it is in-service, has a complete set of drawings available for distribution, and is:

Approved for Public Release: Distribution Unlimited.

30 April 2009 23

Previous ISE DemosISE-2 Demonstration (April 2003) ISE-3 Demonstration (October 2004)

Engine Room

ISE-4:

•Ship Arrangements

•Engineering Analysis

•Electrical Design

•Steel Processing

TWR 3D Product Model

Geometry

ISE-4 Demonstration (April 2006)

Design Agent 1

SVGXML

AP212(ET Data)

AP212(ET Data)

DXF or IGES(2D CAD)

Design Agent 2

Design Agent 3

DXF or IGES(2D CAD)

AP214(3D CAD)

AP227(Cableways)

Concept & Preliminary

Design

ProductionDesign

Refit & Upgrade Design

Electrotechnical Data and Document Interoperability

ISE-5 Demonstration (February 2007)

30 April 2009 24

ISE Interoperability Progression

• Interoperability solutions must apply to the entire life cycle

• Initial efforts focused on Design issues– Transfer between multiple Design Agents

– Exchange between Design and Construction Agents

– Transfer of Product Models from Design Agent to Customer

• Later stages focused on Manufacturing– ISE efforts addressed unique Manufacturing issues involved

in transfer of Models for Steel Processing, HVAC, and Piping

• Focus has now shifted to Life Cycle processes (such as Maintenance and Repair) – Involves different issues and requires different information

30 April 2009 25

Issues Arising for Data Transfers Throughout Life Cycle

• The information exchanged to support Maintenance and Repair is different from Design and Construction– As-built conditions of the ship needed– Changes made during ship’s service must be reflected in the

product model– Updates to Catalogs for replacement parts must be available

• Ships have long life span (up to 50 years)– Ship will likely outlive CAD systems used during Design– Even computer hardware and storage media will not survive

for life of ship

• Change management is a major cost driver throughout the life of the ship and should be addressed by any interoperability solution

30 April 2009 26

• Majority of the total cost of ownership of a Navy ship accrues after the ship has been delivered

• Life cycle support; repair, maintenance and overhaul; ships’ operations; testing and training are all information intensive processes

• The Navy has steadily moved toward more modern systems and technologies to cope with the burgeoning information needs, but technology has evolved faster than the deployed solutions

Issues Arising for Data Transfers Throughout Life Cycle

30 April 2009 27

STEP for Archiving and Sustainability of Data

• Long Term Retention of Product Model Data is a Problem– Shipbuilding Products in general have life spans that far exceed the span of

the CAD, CAE, or PDM systems that create the Product Models

– Accurate Product Model Data is needed throughout the Life Cycle of the Product for Repairs, Overhauls, In-Service Modifications, etc.

– Data must be retained for the life of the product which can be up to 50 years

– On the other hand, the life of a CAD, CAE, or PDM system used to design the product is often less than 10 years

STEP

OR?

How will you read your product model data in 5 years? 10? 15?

30 April 2009 28

Data Archiving: STEP Standard Formats Preserve Datafor Future Use Regardless of changes to Hardware, OS or CAD System

STEP is a Potential Solution

10 20 30 40Years

Convert­X­to­STEP

Convert­A­to­STEP

Convert­B­to­STEP

Convert­C­to­STEP

System­X

System­A

System­B

System­C

System­N

Convert to long-termarchiving format (STEP)

once

50 504010 20 30 40Years

Convert X to A Convert

A to BConvert

B to C

Convert C to N

System­X

System­A

System­B

System­C

System­N

Preserving data for future use without standardsrequires you to convert all your data each time you modify Hardware, OS or CAD

system

30 April 2009 29

ISE-6 Project

• Two year project, funded by National Shipbuilding Research Program (NSRP)

• Coordinate the use of the PLCS (STEP AP239), S1000D, and ISE standards to enable these standards to integrate more closely with the shipyard’s product model to enable product life cycle interoperability

• Phase 1 - April 2007 through March 2008– Integrated PLCS with ISE information models– Mapped core Navy ship configuration and logistics data to PLCS– Demonstrated an exchange to reuse configuration and logistics data across

Integrated Data Environments (IDE)

• Phase 2 - April 2008 through June 2009– Integrate S1000D capabilities with PLCS and ISE information models– Manage change by linking S1000D modules to design structure– Final Demonstration on April 30, 2009

30 April 2009 30

ISE-6 Project Participants

• Electric Boat• Northrop Grumman Shipbuilding – Gulf Coast• Atlantec-es• Industrial Planning Technology • Intergraph • Knowledge Systems Solutions• NSWC-CD• NSWC-PHD• Northrop Grumman Information Systems• Product Data Services Corporation• ShipConstructor Software USA

30 April 2009 31

ISE-6 Phase 1: Functional Scenario

31

Design(3D­CAD­Data)

Shipyard­A­IDE(Design­&­Logistics)

Shipyard­B­IDE(Design,­Logistics,­&­CAD)

Navy­IDE(Design­&­Analysis)

Navy­Depot(Design,­Logistics,­Support)

Data­Prep­&­QA(Design,­Logistics,­&­CAD)

30 April 2009 3232

AIM/SIRLPD 17 IPDE Software

TeamcenterDDG 1000 IDE Software

episTreeKnowledge Management

Software

LEAPSNavy Design & Analysis

Repository

CATIA(V4 AEC)

ShipConstructor2006

ShipConstructor2008

AP 227

AP 227

AP 239

AP 214

Design Navy IDE

Shipyard A - IDE Shipyard B - IDE

3D Design

Design & Logistics

Design & Logistics

AP 214

AP 239

Design & Logistics,including 3D Design

AP 239

AP239/PLCS (ISE-6) Phase 1 ScenarioDemo: April 2, 2008 in Washington, DC

30 April 2009 33

Standards for Life Cycle Support

Standards for Design, Engineering, Production(STEP AP 212, 215, 216, 218, 227ed2 )

(ISE information models)

International ISO Standards

Focus of ISE Projects since 1999

Standard for Technical Publications (S1000D)

ISE-6 Phase 2

International Standard

Driven by Aerospace, DefenseEmerging DoD IETM Standard

Standard for Logistics & Life Cycle Support (PLCS)

(STEP AP 239)ISE-6 Phase 1

International ISO Standard

Driven by Aerospace and DefenseISE-6 has Prototyped Use for Shipbuilding

Use of these standards is the focus of today’s demonstration

30 April 2009 34

• Phase 2 of the ISE-6 Project runs from April 2008 through June 2009

• S1000D is an international specification for the procurement and production of technical publications

It is an SGML/XML standard for preparing, managing, and using equipment maintenance and operations information

• The Navy has been working toward a new-generation of interactive technical manuals for deployment on-board ship

There has been pressure to move to the topic-based approach embodied in the S1000D standard but, to date, this migration has been only partially accomplished

• This phase of ISE-6 has developed use cases for shipboard interactive technical documents that take advantage of the new

capabilities of the S1000D standard

ISE-6 Phase 2

30 April 2009 35

Product Life Cycle Support (PLCS)

35

Project to Develop AP239 as an ISO Standard for PLCS

Copyright Eurostep Group AB

30 April 2009 36

The Key Business Problem

Copyright Eurostep Group AB

ProductProductIn FocusIn Focus

Feedback

Copyright Eurostep Group AB

30 April 2009 37

Business DriversReduced Cost of Ownership

• Users of products are seeking improved availability, reliability, maintainability, and lower cost of ownership

Exploit Investment in Product Data• Users of information systems

want more open platforms to reduce IT costs and ensure longevity in use of information

• Digital Product Data has become a valuable business asset

For shipyards, the investment in Product Data has not yet been leveraged for life cycle support

Copyright Eurostep Group AB

30 April 2009 3838

ISO 10303-239Product Life Cycle Support (PLCS)

Change Management

Product Structure

Requirements Management

ScheduleActivities

Organizations

Property

Classification

Approvals, Security, Status

Maintenance

Support Tasks

APSI

Support History

Messaging

PLCS

• PLCS provides an integrated data model with a scope that is a holistic view encompassing the entire product life cycle

ISE-6

• Lifecycle community needs to access information defined during acquisition

● Acquisition community can also benefit from the use of PLCS to exchange integrated design and logistics information

30 April 2009 3939Copyright Eurostep Group AB

Typical complex systems environment – point to point integration

30 April 2009 40

Product Life Cycle Support (PLCS)

40Copyright Eurostep Group AB

30 April 2009 41

PLCS Vision

10/20/ 2008 Intergraph­Proprietary­and­Confidential

Ship Acquisition Programs

Ship Life Cycle Support

Design Data

Ship Program AIntegrated Data

Environment (IDE)

Ship Design

Parts

Manufacturing

Ship Configuration

Logistics Data

Program Data

DocumentsDesign Data

Change Mgmt

Ship Program BIntegrated Data

Environment (IDE)

Shipyard Legacy Logistics &Support Systems

Navy Legacy Logistics &Support Systems

Regional Maintenance Centers

Change Management

Product Structure

Requirements Management

ScheduleActivities

Organizations

Property

Classification

Approvals, Security, Status

Maintenance

Support Tasks

APSI

Support History

Messaging

PLCS

Marine Corps Legacy Logistics &Support Systems

NATO Legacy Logistics &Support Systems

30 April 2009 42

Integrating Lifecycle Processes Across the Navy Virtual Enterprise

- Demonstrating an integrated approach for SCD Changes between ISEA and Shipyard - Automated identification of logistics documentation change impacts - Standards based exchange of integrated design, logistics, and technical publication data

using PLCS and S1000D

Planning Yard

/ NAVSSESISEA NCSDB

NDE-FMP NAVICP WSF CDMD-OA TDMIS TDKM

PLCS + S1000D

HM&EDesign

Combat SystemsDesign & Logistics

Ship ConfigurationDesign & Logistics

LEAPS

EngineeringAnalysis

IDE

S1000D IETM Data

OtherNavy

SystemsFuture Applicability

Demonstration

30 April 2009 43

PLCS/S1000D is the right choice for the U.S. Navy and Shipbuilding Industry

• PLCS (ISO10303-239) and S1000D Standards have been used successfully by:– Norwegian Frigate Program

– Air Force Joint Strike Fighter (JSF)

– Army TACOM

• ISE-6 Project is prototyping these tools and standards for current Navy systems

The right solution for today’s IPDE environments in the Navy and the Shipyards

30 April 2009 44

Summary

• Computer system interoperability in U.S. shipyards is a major issue facing shipbuilders and the Navy

• Enabling interoperability throughout the ship’s life cycle is a major challenge in achieving the goals of NSRP– ISE Project is addressing these goals by developing

and prototyping the tools necessary to enable interoperability

• ISE-6 tasks support the development of future integrated technical data scenarios