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NSRP Contribution in Advancing Information Technology in the Shipbuilding Enterprise

NSRP Contribution in Advancing Information Technology in the Shipbuilding Enterprise. Presented by : Ron Wood Date: November 16, 2007. 1. Authors. Dr. B. Gischner Electric Boat Corporation J. Fowler NAVSEA L. Karns ATI R. Wood Northrop Grumman Ship Systems. Agenda.

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NSRP Contribution in Advancing Information Technology in the Shipbuilding Enterprise

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  1. NSRP Contribution in Advancing Information Technology in the Shipbuilding Enterprise Presented by : Ron Wood Date: November 16, 2007 1

  2. Authors • Dr. B. Gischner • Electric Boat Corporation • J. Fowler • NAVSEA • L. Karns • ATI • R. Wood • Northrop Grumman Ship Systems

  3. Agenda • Product Information Modeling • Business Process Technologies • Common Parts Catalog • Automatic Generation of Control Program for Robotic Welding • Shipyard Design Tool Enhancement • Capture As-Built Models for 3D CAD Systems • Shipyard Equipment Wireless Monitoring and Control • Open Architecture Standards • Other Shipyard Computer Applications

  4. NSRP = Enterprise-wide Collaboration Effecting Large Scale Change with Industry-wide Solutions Accuracy control – metrology, processes and tools Benefit: Reduces rework labor, materials, cost and cycle time; enables automation IT Interoperability– Integrating shipyard IT systems (CAD, CAM, Parts …) across firms & functions Benefit: Reduces costs & acquisition cycle time, improves 1st time quality, enables outsourcing Steel Processing – Laser cutting, precision forming, and tab & slot technology Benefit: 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 Common Parts Catalog – Enterprise standard, shared parts database Benefit: facilitates standardization & IPDE initiatives; fewer parts to procure, inspect, certify, track, warehouse … eBusiness for Enterprise Integration – across construction, repair, logistics activities and suppliers Benefit: cuts labor and cycle time of daily processes by 60%

  5. Common Parts Catalog Enterprise Integration Projects SIMSMART SIMSMART SIMSMART SIMSMART V1 V1 V1 PDM PDM PDM PDM CAD CAD P1 P1 P1 V1 V1 PipeStress PipeStress PipeStress PipeStress Simulation Simulation P1 P1 V1 V1 Piping Detail Piping Detail Catalog / Library Catalog / Library Catalog / Library Catalog / Library P&ID P&ID P1 P1 V1 V1 V1 V1 V1 P1 P1 P1 P1 P1 Parts Parts Diagrams Diagrams AutoCAD Extension Tier 1 & 2 Yards Commercial/T-ship parts and standard interim parts Material Identification & Procurement System Integrated Shipbuilding Environment Tier 1 Tier 2 + Navy ISO Standards for Ship Construction & Repair Integrated Steel Processing Environment

  6. Interoperability Problem • Communication between diverse computer systems is a big challenge in today’s environment: • As CAD/CAE/CAM systems have expanded 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 • These problems are exacerbated 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 • Requirements for life cycle support of the ship will far exceed the life span of current computer systems

  7. Product Information Modeling

  8. Product Data Initiatives Alignment Navy ERP LEAPS SPARS CPC ISE Total Ship Shock Trial

  9. Information Interoperability Roadmap

  10. Information interoperability lifecycle Roles Well-Defined Solution Path –- much progress -- $17M to complete Standard Development Standard Approved ISO Technology Information Model Prototype Translators Testing Framework NSRP Contractual Specification NAVSEA Business Decisions Deployment, integration, testing NAVAL PROGRAM Information interoperability specification Requirements definition Production deployment Phases:

  11. Program Offices

  12. ISE Team Participants

  13. Ship Arrangement Loading conditions • Compartments • types • properties • (shape, • coatings, • adjacency, • access….) • Zone Boundaries • Controlling Access • Design Authority • Cargo Stowage • Machinery Compartments • Crew Occupancy • Common Purpose Spaces • Stability • intact • damaged • Cargoes • assignment to compartments • weight, • centre of gravity General Subdivision of a Ship into Spatially Bounded Regions

  14. Ship Moulded Forms Surface, wireframe and offset point representations Design, Production and Operations lifecycles General characteristics Main dimensions Hullform geometry Major internal surfaces Hydrostatics Intact Stability tables

  15. Hull Cross Section • Geometric Representations • Wireframe • Complex Wireframe • Surfaces • Solids Ship Structures • Configuration Management • Class Approval • Approval Relationship • Change Administration • Promotion Status Production Design Data Product Engineering Data • Product Structure • Generic Product Structure • System • Space • Connectivity • Assembly Technical Description Weight Description • Structural Parts • Feature • Plate • Edge Content • Opening • Profile • Profile Endcut

  16. Piping & HVAC • Connectivity • assembly • penetrations • ports Configuration Management of Product Structure Versioning and Change Tracking Bill of Materials • 2-D and 3_-D Shape Representation • Diagrammatic Presentation • Solid Model Presentation • Interference Analysis Pipe/Duct Flow Analysis and Sizing

  17. Electrical Design and Installation • Data Supporting • Terminals and Interfaces • Functional Decomposition of Product • 3D Cabling and Harnesses • Cable Tracks and Mounting Instructions • Electrotechnical Systems • Buildings • Plants • Transportation Systems • Electrotechnical Plant • Plant, e.g., Automobile • Unit, e.g., Engine Control System • Subunit, e.g., Ignition System • Equipment Coverage • Power-transmission • Power-distribution • Power-generation • Electric Machinery • Electric Light and Heat • Control Systems

  18. Finite Element Analysis & Related Design

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

  20. ISE Summary • ISE has successfully demonstrated the potential of standards based data exchange to LEAN design and construction processes for HVAC, moulded forms, structures and piping, Electrical, Ship Arrangements, Steel Processing, Analysis • Web site: http://www.isetools.org/ • Two major challenges lie ahead of us: • Commercialization of this technology • Continuing to prototype standards based data exchange in other application areas such as product life cycle

  21. Multidisciplinary Modeling & Simulation Environment (MM&SE)

  22. Full-Ship Live-Fire Shock Testing can be Prohibitively Expensive!

  23. But Its Not Just Shock! Hydrodynamics The Design of Naval Vessels Involves Various High-End Computational Mechanics and Simulation Needs. Acoustics

  24. Commercial Ships Also Have Full-Ship Analysis Requirements Critical Areas in Ultra-Large Container Carriers

  25. Related Modeling & Simulation Efforts We Have Needs for Multi-Disciplinary Modeling & Simulation (M&S) Environments Which Support Varied Requirements Stress Analysis CAD 3D Design Shock Analysis Analysis Context De-Feature, Heal, Mid-Surface Analysis Context Common Abstract Analysis Model Acoustic Analysis Analysis Context

  26. Multidisciplinary Modeling & Simulation Environment • To reduce the cycle time required to develop large scale full ship analysis models for strength, stress, shock, and acoustic simulation and assessment.

  27. CREATEComputational Research and Engineering Acquisition Tools and Environments

  28. Business Process Technologies eBusiness for Enterprise Integration – across construction, repair, logistics activities and suppliers Benefit: cuts labor and cycle time of daily processes by 60%

  29. Shipbuilding Partners and Suppliers (SPARS)

  30. Industry Consensus eBusiness Model Integrated Shipbuilding Environment for the Networked Functional Capability across the Enterprise Workflow CAD GD Yard PDM CAM Navy Logistics Naval Yards Suppliers Suppliers Suppliers MRP / ERP Part Catalog Interfaces and Tools to exchange data among key IT systems and across the enterprise’s organizations - Engineering Data (ISE) - Inter-organization Transaction Data (SPARS) - Parts Data (Common Parts Catalog, Mat’l Stds) - Manufacturing data (ISPE) Common Parts Catalog Common Parts Catalog Part Catalog MRP / ERP CAM Customers Navy Fleet Ship NG Yard Private Sector Repair Yard PDM CAD Workflow

  31. Shipbuilding Partners and Suppliers Virtual Enterprise that simplifies and speeds business interactions $2M in cost reductions per process implementation at each shipyard

  32. SPARS Current Processes

  33. SPARS 2007 – 2008 Processes

  34. SPARS Virtual Enterprise Server “How It All Integrates” Supplier Web Browser Interface VSRS VREQ / VTPR VBID / VEST Business Intelligence (Data Mining) WEBINAR TRAINING VES:Shipyard Interface Program VPBMT VFI / GFI VQUOTE Contract Administration Mgt Tool Set Applications VNCR . VXPD VIR VPA VIPP (System Integration) Supplier/Shipyard User Administration Services LDAP Authentication Service Email Service Workflow MQ Series (Messaging) WebSphere Web Server DB-2 Database “Patterned Oriented Architecture”

  35. W link (MQ) VQuote / iMars POSS BAS Reference (shared key?) SCMILSEngineeringQAPlanning Manually Create VFI Override SCM Approval for Award VFI Coord VBIDTemplates ReviewersCOGs Email “TPR is ready” to Requisition Group Suppliers TPR Templates Buyers Reviewers PO#PO dateRevisedTPRAdditionalData Suppliers PDM TPR’s Archive VFI Data Apply Templates Auto-Create VFI VTPR VBID POAWARD VFI • Select Applicable TPRs* Assign Name*Assign TPR Start & Complete Dates*Revise TPR prior to VBID (add’l data)*Revise TPR prior to award Revision per Reconciliation (subject to review) – Should be minimum of SCA included in upfront review and approval of TPR Email to Engineers for reconciliation TPR List - - - - - VBIDData VFIData Payment Notification Suppliers VPA Invoice Amount Reviewers/ Approvers Note: Original driver is Master Equipment List (MEL) and Schedule driver is Integrated Master Schedule (IMS) Reviewers/ Approvers Suppliers Buyers Reconcile: Is change within/outside scope of contract VIR Archive VIR Data TPR Under Change Management Changes After This Point Require Revisions Supplier Requested Future State Buyers Customer Requested ECN ECN Process

  36. Common Parts Catalog Common Parts Catalog – Enterprise standard, shared parts database Benefit: facilitates standardization & IPDE initiatives; fewer parts to procure, inspect, certify, track, warehouse …

  37. CPC is Used by the Shipbuiding Enterprise at Different Levels

  38. EB, BIW and NGSS have Implemented a Common Parts Catalog

  39. Document to Part X-Ref User Friendly Search Common Parts Catalog is: • shipyard parts catalog • part search and retrieve repository • shipyard, supply chain, Navy collaborator • future business facilitator Shipyard Part to NSN X-Ref Inter-shipyard Part Equivalency

  40. 65% of the Navy’s Surface Ship, Submarine, and Amphibious Procured Material is Now Standardized and Configuration Managed in CPC

  41. Automatic Generation of Control Program for Robotic Welding(AUTOGEN) Automate the generation of robotic control programs directly from CAD data, weld process tables and production planning information

  42. AUTOGEN • completed in 2003 • efforts have continued under different funding streams. • Current effort focuses: • industrially hardening the developmental code and populating the necessary data infrastructure toward production use • The team is also adding an Operator Graphical User Interface (GUI) and documenting the individual use cases in support of intended commercial release of the software.

  43. Ship Check Data Capture • Purpose • data collection of as-built ship conditions in digital format using currently available (COTS) 3D laser scanners and digital cameras • Benefits • provides measurements of as-built conditions, readily available, at any time as needed • provides means to get accurate measurements of components, piping, etc. from ship’s lines • provides cost savings compared to traditional ship checks • eliminates return visits to ship for missed measurements • minimizes measurement errors • minimizes rework at construction • Uses • take measurements of as-built space elements directly from raw scans • validate 3D CAD models to as-built data • create solid 3D electronic models of the as-built space • Archive the data captured for future use

  44. Ship Check Data CaptureHardware 3Dguru 3D Laser Scanner Z+F Imager 5003 3D Laser Scanner

  45. Ship Check Data Capture Data Processing / Data Analysis • Post processing and modeling of the data collected use various software applications, including: • BitWyse LASERGen • LeicaGeosystems Cyclone • InnovMetric PolyWorks • Raindrop Geomagic Studio • INUS Technology RapidForm • UGS NX Imageware • Dassault Systèmes SolidWorks • Vexcel FotoG • Intergraph SmartPlantReview • Models were analyzed in various CAD systems • CATIA • AutoCAD • Intergraph’s Integrated Ship Design and Production (ISDP)

  46. Ship Check at Bender Shipyard • 280 ft. Candies Inspection, Maintenance and Repair (IMR) Vessel under construction at Bender was used for ship check (May 02 -05, 2006) • Ship checks were also conducted onboard the TWR841 and SSGN729 during the FY05 and FY06 NSRP Ship Check Projects Candies IMR under construction at Bender

  47. Ship Check Data Capture • Candies IMR • Spaces Ship Checked: • Bow Thrusters • Engine Room • Moon Pool • Moon Pool Door • Z-Drive Cavity • Underside Stern • Z-Drives

  48. Ship Check Data CaptureIMR Valve Station Ship Check: As-scanned Data to As-built 3D Model

  49. Ship Check Metrics (Cost/Time Savings) • Ship check data capture/post processing of Candies IMR Engine Room Bulkhead select components: • Realized Cost Savings = $3,079/$8,327 = 37% • Realized Time Savings = 46/118 = 39% • Cost savings is above the project goal of 30% • Time savings is above the project goal of 35% • Savings shown are only for first ship check and do not include elimination of future ship checks for the same ship space • Ship checks with the data capture technologies provides additional cost/time savings by • Eliminating the need to go back to the ship for missed measurements • Providing complete and accurate as-built space information (more than the traditional ship check with tape measure), which in turn reduces construction costs and scrap, and saves refit time

  50. Ship CheckConclusions • Take measurements from scan data • Not intuitive, requires experience • Advocated by scanning software vendors • Validate 3D CAD models to as-built data • Overlay as-design CAD model onto point cloud to check placement of components • Overlay new design model onto point cloud to check interferences • Create 3D as-built arrangements from the scan data • Use library parts to place on location in the scan • Cost effective • Create surface models for visualization and analysis • Cost effective • Create 3D as-built models of the entire space from the scan data • Create primitives (cylinders, cubes, etc.) from point cloud • Not cost effective at present • Manual effort (software vendors need to automate the process) • Reduced ship check costs: fewer days, fewer personnel • Elimination of return visits to the ship for missed measurements • Obtaining measurements which are difficult or unsafe for human reach

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