Advanced Steel Production Facility Industrial Modeling and Simulation

1. Chris Ligetti Penn State Applied Research Laboratory Advanced Steel Production Facility Industrial Modeling and Simulation Mike Cunneen Newport News Shipbuilding March 12-14, 2019 Charleston, SC Mindy West Newport News Shipbuilding Approved for Distribution A

2. Agenda • Background • Penn State Applied Research Laboratory / iMAST • Newport News Shipbuilding • Issue / Objectives • Approach • Benefits • Current Analysis Activities • Summary

3. Penn State Applied Research Laboratory • Established in 1945 at the request of the U.S. Navy • Originally focused on undersea weapons technology development, ARL now includes a broad research portfolio addressing the needs of various sponsors • Undersea Systems • Communications and Navigation • Fluid Dynamics and Acoustics • Materials and Manufacturing • Department of Defense (DoD) designated University Affiliated Research Center (UARC, 1996) • Conducts essential research, development, and systems engineering in support of our nation's priorities free from conflict of interest or competition with industry • “…maintains a special long-term strategic relationship with DoD.” • ARL is wholly reliant on sponsored research programs

4. Institute for Manufacturing and Sustainment Technologies • Sponsored under NAVSEA contract by the United States Navy, Office of Naval Research Manufacturing Technology (ManTech) program • Formally established in February of 1995 and is one of seven U.S. Navy ManTech Centers of Excellence • Investments are focused on manufacturing technologies to assist key acquisition program offices in achieving their respective affordability goals • Thrust areas include:

5. Newport News Shipbuilding • Builder of the most complex ships in the world for more than 132 years • Sole supplier of U.S. Navy Aircraft Carriers and Aircraft Carrier Inactivation • One of two builders constructing Virginia- Class nuclear submarines • Exclusive provider of refueling services for nuclear-powered aircraft carriers • Largest non-governmental provider of fleet maintenance services to the Navy • Provide design and support for Columbia-Class submarines • Largest industrial employer in Virginia – approximately 23,000 employees

6. Newport News Shipbuilding – Navy Programs Gerald R. Ford (CVN 78) Carrier New Construction Post-Shakedown Availability Ship Arrival Third Quarter 2018 John F. Kennedy (CVN 79) Detailed Design and Construction Delivery 2022 USS George Washington (CVN 73) RCOH Delivery August 2021 USS John C. Stennis (CVN 74) RCOH Pre- Advanced Planning Ship Arrival January 2021 Virginia Class (VCS) Submarine Construction 10 Boats Under Construction Fleet Support Worldwide Working NIMITZ Class CVNs, USS Gerald R. Ford (CVN 78) & all Submarines Classes Columbia Class Design and Construction, Leveraging VCS Successes Ex-USS Enterprise (CVN 65) Newport News Inactivation Complete, Transitioning to Storage period though September 2021 Workload Snapshot • 19 Ships Being Worked Offsite • NNS Resources Working Offsite ≈ 800 Shipbuilders • 23 Ships Being Constructed / Overhauled or Planned • Supporting EB with Columbia-Class Design

7. Issue Description • NNS panel lines originally built and installed to fabricate panels for non-military vessels • Limitations based on weight, access (robotics), plate thickness • Equipment replacement necessary due to age and obsolescence • NNS is developing an Advanced Steel Production Facility (ASPF) concept: • Optimizes equipment size/capabilities based on current and future product mixes • Allows high cost offline, manually intensive work typically completed at static build sites to be processed on the panel line • Latest in advanced cleaning/joining processes, robotics, material handling and controls • Effort needed to minimize the risk through early identification of the technology gaps to be bridged for implementation of the ASPF and SOB-A concepts • Alternative factory configurations and new technology insertion can be modeled to provide justification to proposed facility upgrades

8. Issue Description

9. ONR ManTech Project Objectives • Develop a validated stochastic discrete event simulation (DES) Model capable of assessing proposed ASPF configurations • Model must be reusable, configurable, and modifiable to conduct future ASPF Analysis of Alternatives • Model will be used to identify technology needs/gaps for additional R&D to support the ASPF • Provide data-driven, statistically accurate facility upgrade and design decision support to shipyard stakeholders • The simulations will form the baseline and justification for future ManTech R&D proposals and NNS SPF refurbishment acquisition efforts

10. Discrete Event Simulation – What is it? • Purpose • To analyze and improve complex systems that can be broken down into discrete time events • Application • Manufacturing system and logistics analysis • Facility (re)design / Machine selection • Throughput analysis / bottlenecks • Logistics analyses • DES will NOT automatically optimize the system

11. Benefits • Successful modeling projects help decision makers... • Understand/justify facility requirements • Understand resource requirements (labor, cranes, trucks, etc.) • Analyze the impact of inherent process and inspection variability • Common questions / expected results • What is the shop capacity? • How are our assets utilized (labor, machines, etc.)? • Where do bottlenecks exist and what is the impact of correcting them? • Nearly impossible to evaluate system performance with highly variable processes “on paper” • You can’t experiment with machines or facilities that do not yet exist • It’s costly to experiment with existing systems due to “shut down” effect • Proposed changes may, in fact, worsen system performance

12. Approach – Data Collection • High Level: • Fabricate Panel • Mid Level: • Fit/Tack • Seam Welding • Cleaning/Marking/Burning • Fit Structure • Weld Structure • Low Level: • Load Panel • Blast Panel • Mark Panel • Burn Panel • Remove Scrap • Inspect • Repair • Greatest risk for failure in any modeling project • Process Flows • Level of detail • “Goes into’s – Goes out of’s” • Process steps • Station Attributes • Cycle times • Frequencies/probabilities (e.g., % inspection failure) • Resource Requirements • Lifting and handling • Labor (by trade)

13. Approach – Develop Models • DES software review and selection • Three COTS tools recommended – Flexsim selected for development • Demand generation • Recursive generation of “products” based on probabilistic ship unit “starts” • Station sub models • Efficient troubleshooting • Integration into System model • Development of metrics

14. Approach – Develop Models Custom Station Logic Recursive Demand Generation Logic Individual Product Stats NNS Steel Production Facility (Panel Lines)

15. Approach – Develop Models NNS Profile Fab Shop Model

16. Approach – Verification and Validation • Verification – model logic is correct • Starts at concept model (process flows, etc.) and continues through integrated DES model • Input data and statistical distributions are accurate representations of actual system • Validation – model results make sense • Final validation of the model will be accomplished by performing appropriate statistical tests on real and simulated metrics of interest (e.g., throughput, utilization) • Involve everyone! • Iterative process

17. Approach – Experimentation and Analysis Sample results • Simulation models configurable • On / Off switch for various potential technologies • Global attributes (demand, shifts, failure rates, etc.) • FlexsimExperimenter • Define Scenarios • Define Performance Measures (i.e., from metrics) • Define run length / replications

18. Current Analysis Activities • NNS Panel Lines • Increased robotics • Induction heating for preheat • Increased NC marking and burning • Multi-plate milling • Paint removal (laser ablation; weld-through primer) • Profile Fab Shop • Comparison of alternative robotic lines • Throughput sensitivity analyses • Manning requirements for manual processing area

19. Summary • Simulation is an effective means to test system changes before implementing change • Success is contingent on participation from industrial engineers, manufacturing engineers, shop supervision, and manufacturing trades • Involve early and often • ASPF scenarios result from: • Machine upgrades due to obsolescence • Current research of new technologies • ASPF modeling and simulation project resulting in recommendations slated for implementation

20. Acknowledgements