Digital Ship CIC Presentation - action-engineering.com • TeamCenter /NX developer and maintainer...

-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.


Current Assessment 3


• 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


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


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


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


Pilot Process 12

A Ten Step Solution


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


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


Digital Ship CIC Presentation - action-engineering.com • TeamCenter /NX developer and maintainer...

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