dennis%jarabak,%hii qnns !digital(shipbuilding!

-Digital Shipbuilding-NSRP Advanced Shipbuilding Enterprise Research Announcement, NSRP letter dated March 13, 2014

Submitted by: Huntington Ingalls Industries ,Newport News Shipbuilding

Huntington Ingalls Industries, Newport News Shipbuilding

General Dynamics Electric Boat

SIEMENS Product Lifecycle Management (PLM) Software

A Collaborative Project on behalf of:

Presentation for:

“3D Collaboration & Interoperability Congress (CIC)”Presenter: Dennis Jarabak, HII-NNS

(Copyright 2015 Huntington Ingalls Industries, Inc. All Rights Reserved.)

“Digital Shipbuilding” is a NSRP Research Funded ProjectOpportunity

Ø Drawings are expensive, labor intensive to develop, maintain and distribute.

Ø In digital environment, drawings are unnecessary.

Ø Most other industries have gone digital;; shipbuilding has been slow to transition.

Ø Other opportunities include data driven machine tool automation, less rework.

ØWhat’s holding us back?– Full understanding of data that needs to migrate from drawings to a model environment.

– Mature definition of the work instruction delivery to the deck plate that will replace today’s drawings.

– Deck plate readiness for this change.

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Goal: Accelerate Industry Transition to a Digital, Drawingless Environment


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Digital Shipbuilding Project Synopsis

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/reference 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.


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Focus Area Benefits(NEW) Increased application of digital technologies

ü

ü

• Innovative application of collected/stored data to shipyard business processes• Increased paperlessworkflow• Increased real-‐time digital communication and configuration management • Increased application of modern communications and information technologies

ImprovingProductionEngineering

ü

• Span Time Reduction from Engineering to Manufacturing• Optimized Sequencing of Work• Definition of Interim Products• Cellular Manufacturing/Process Lanes• Development and Implementation of Best Practices related to Process Technologies, Build

Strategy and Design for Affordability• Configuration management of hull effectivity and part commonality in design and

manufacturing execution systemsImproving Production Planning

ü

• Optimized Work Instructions• Work Instruction Development Tools• Capacity Planning Analysis• Optimized Sequencing of Work

Improving Manufacturing Processes

ü

• Outfit Installation Process Improvements• Pull up-‐ to-‐ date manufacturing data electronically from its source product model• Provide a common work instruction format and content to the shop floor regardless of Ship

Program I.e. CVN’s, SSN’s, Overhauls

Improving Data Exchange

ü

• Integrating internal systems (ERP, estimating, planning, scheduling, procurement, 3D/2D design tool, process libraries, etc)

• Flexibility to create manufacturing data based on machine/process data feed requirements• Integrating the design and manufacturing views of the product model

Improving Specifications and Standards

ü• Eliminate unnecessary and/or redundant requirements• Identify PMI standards required for Shipbuilding manufacturing

Reducing Re-‐work ü• First Time Quality initiatives• Design work instructions with only required data

Total Ownership Cost ü• Design for Maintenance and Repair• Parts Commonality and re-‐use across platforms• Common Data Model to be used to support Maintenance and Production planning

ü

Digital Shipbuilding: Supports NSRP’s Strategic Investment Plan (SIP)

The Project provides benefits for Value Stream Customers across the Shipbuilding Data Environment(Copyright 2015 Huntington Ingalls Industries, Inc. All Rights Reserved.)

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1) Future State Requirements/Use Cases 2) System Configuration 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

Digital ShipbuildingProject Plan

Project Duration = 36 months

The Project will evaluate options for an effective Shipbuilding Data Environment,and then configure Pilot Environments for testing production impact.

Project Deliverables:•Requirements Documents•Process Use Cases•System Architecture Diagram•SIEMENS COTS software TC/NX•Pilot results / configuration•Shop Floor Transition plan•Implementation plans


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Digital Shipbuilding Architecture

The Project will Evaluate options for an Effective Shipbuilding Data Environment,and then configure Pilot Environments for testing production impact.

WORK Instructions

BOM/Material

Schedule

ERP/SAP

Intelligent Machines

Shop Foreman

“Digital Shipbuilding” Architecture (Current State)

Bi-‐Directional

Integration

3D Geometry

DESIGN EXECUTION

Access / Security Roles (Need to Know)

Electronic Data

Documents

2D Dwg’s

3D Model

PDM/TC

2D Environment 2D Drawings

PLANNING

Dispatcher

Partial Electronic Data Flow / 2D Drawings are Baseline

Replace

Replace

Direct Electronic Data Flow / 2D Drawing Elimination

NEW

NEW

Direct Interface


Technical Authority (TA)

Build Authority (BA)

As-‐Maintained(TA+TVD’s

+ Maintenance)

In-‐Service (LCM)(TA+TVD’s+Maintance

+Upgrades)

Ship Check/Scanning

CU, Part Information

Ship Design Planning

Hull Effectivity/Part Revision

“Hull #1”

As-‐Designed(TA)

As-‐Built(TA+TVD’s)

Models & BOM for temporary structure,

lifting pads,jigs & fixtures

Pull space, lifting & handling, eqpt removal

(Form,Fit,Function)

Technology Insertion

As-‐DesignedLinked Model

(BA)

ShopManufacturing(BA+ MFG)

ShipAssembly & Test(BA+ MFG+ PMI)

Build Sequence / BOM

In-‐Service (LCM)Linked Model

(BA)

ShopManufacturing(BA+ MFG)

ShipAssembly & Test(BA+ MFG+ PMI)

Build Authority (BA)

Planning (P)

Lifecycle Authority (LCM)

(Process Roles):(E) – Design Engineering(P) – Planning(M) – Manufacturing(A) – Assembly(T/I) – Test & Inspection

(E-‐P)

(E-‐P-‐M-‐A-‐T/I)

(E-‐P)

(E-‐P-‐M-‐A-‐T/I)

Technical Authority/ Build Authority/ Lifecycle Authority: Relationships in a (Model Based Enterprise)

Geometry, NC Data

Maintenance /Repair Part Details

Geometry, NC Data

Models & BOM for temporary structure,

lifting pads,jigs & fixtures

Build Sequence / BOM

Ship Design Planning

Planning (P)(Maintenance Availability)

Data Configuration Management - Roles

7(Copyright 2015 Huntington Ingalls Industries, Inc. All Rights Reserved.)

Digital ShipbuildingWork Content Phase 1 (Status Complete)

1. Document Requirements• Create a comprehensive Drawing Inventory (Use NSRP 2014 Panel Project results for “Requirements for a Drawingless environment”)

• Identify Drawing content for Key Piping and Structural Drawings • Identify design/ manufacturing view requirements• Develop As-is Use Cases for Drawing consumption within work instructions• Document Configuration Control for release and changes to the shipbuilding data environment (upstream and downstream)

• Document non-drawing data content required for a work instruction2. Match Requirements with Toolset capabilities

• Research Use of JT and PMI• Document Functional Requirements • Identify Interfaces and Data Exchanges• Identify Toolset gaps for future consideration

3. Document data flow architecture for Digital Shipbuilding4. Establish initial Development Environment5. Integrate Hardware/software


Unrestricted © Siemens AG 2015

Siemens PLM Software

Process Documentation Solution – Authoring and PublishOne Integrated Solution

3Create 3D

Product Views

5

Define Simulation

2Define Process

Plan

4

CreateAnimation

1EBOM\MBOM

View in EWI

86Author Textual Instructions

7Add Reference Documents

Publish to 3D PDF

9Integrate to

MES

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§ Author processes and sub-processes§ Author operation steps§ Assign consumed parts to operations§ Add resources (tools & fixtures)§ Define sequence of events

§ Build MBOM according to functions§ Add manufacturing specific parts (consumables)

§ Define configuration (effectivity)§ Modify structure according to manufacturing needs

§ Attach 2D images§ Create Product Views (3D snap shots) in MPP graphics viewer, add mark-up, show PMI, set view points, color

§ Auto create animations base on sequence and configuration settings

§ Perform change impact analysis

§ Create simulation for documentation when more complicated assemblies are used on the shop floor

§ Author text instructions in an embedded MS word environment

§ Write free text§ Reuse standard text fragments from library

§ Add symbols, collection data fields

§ Add documents attachments to the process plan operations, such as operation sheets

§ Add reference documents – safety plans

Electronic Work Instructions:§ Embedded 3D Visualization (JT)§ Report Issue§ Flexible layouts

§ Document solution to view Work Instructions on disconnected shop-floor and suppliers

§ Viewable in free viewer (Acrobat Reader)

§ Define templates in Adobe design environment

§ Generate documents in one click

Manufacturing Execution System:§ Teamcenter Manufacturing data is exported to MES and presented there to the shop-floor users

§ Integrated EWI

Digital Shipbuilding Work Content Phases 2-3

Phase 2. Development/Design Build

1. Develop functional specifications• Hardware and Software• Use cases for electronic work instruction

2. Set up environment• TC/NX, SAP, work instruction templates, etc..

3. Configure Siemens Toolset4. Develop Design / Manufacturing shipbuilding data environment5. Configure/develop interfaces

• SIEMENS/NNS developed systems

Phase 3. Pilot/Prototype 1. Develop use cases for fabrication and assembly processes2. Develop specific work instruction use cases3. Plan detailed Pilot activities4. Add necessary PMI information to shipbuilding data environment

• Load test data5. Extract CAD data to ERP manufacturing programs6. Extract ERP data to manufacturing systems7. Execute end-to-end process for electronic digital work instruction8. Analyze results9. Develop full scale implementation plan10. Develop training requirement


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ü Kick-Off meeting was held at NNS on 2/11/2015

ü Team members have been assigned from all organizations

ü Project plans are developed and being implemented

ü Documenting use-cases and requirements is complete

ü A 10 step data processing pilot has been accepted

ü A Pilot environment has been established at Siemens NN site

ü Conducted Internal Demo of EWI (electronic work instruction using TC MPP)

ü Stay engaged for future status reports & Technology Transfer opportunities

ü Digital Shipbuilding Phase 1 is complete & Phase 2 has started

Digital ShipbuildingSummary
