30 april 2009 1 enabling shipbuilding interoperability ise-6 project exchange of product models for...
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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