Objective Model Based Control Systems to Reduce TOC

1. Objective Model BasedControl Systemsto Reduce TOC Joe Famme Michel Masse Chang-min Lee Ted Raitch May 26, 2011 r4

2. Elevator Summary • Design and Operate Systems with the Goals in Mind • Objective Models: Achieve Purposes of User • Reduce Manning • Human Systems Integration • Systems Assurance before Production • Reduce TOC, or, Increase Return on Investment (ROI) • Object Models used to Create Objective Models • Physics based models of each component of the ship’s hull, mechanical, electrical and DC systems as “objects” modeled in physics equations • Object is: pump, pipe, valve, generator, SB, motor, wire, diesel engine, GT Engine, tank, control element …

3. “Objective” Modeling: The Adaptive Lenses1994 - 2011 • “Objective” Model Designs to support of Navy Priorities • 1994: Human Risk Mitigation • Reduce Manning [USS Stark, Roberts, Princeton, Tripoli] • 2003: Human Systems Integration • Single objective model from design to training / operational decision aids • 2009: Performance Validation for Affordability • Dynamic V&V of design before release to production • 2011: Reduce Total Ownership Costs • Use Cost and ROI as object attributes

4. ASNE ISS 1994

5. ASNE ISS 1994 ASNE ISS May 2011

6. ASNE ISS 1994 ASNE ISS May 2011

7. Simultaneous Design & Control CAD ………………..“Does it Fit”? Physics ……………“Does it Work”? Run-Time Data Trend Automation Analysis

8. ~85% Standard Navy HME Items Adjust properties www.ITEinc.US

9. Example Total Ship Model Drill into Firemain by Deck & Section for compartment model, get Integrated Product Data Environment (IPDE www.ITEinc.US

10. Firemain System by Compartment (Deck and Section) Click on Pump “Motor” link and Open the Associated Electrical Model, then get www.ITEinc.US

11. Associated Electrical System See Associated Motor (to right) then To switchboard (left) www.ITEinc.US

12. Content • To Invigorate Discussion on TOC • An Affordable Navy • Early Design Decisions Control Cost • Commercial vs. Naval Control Systems • Example: Mining Enterprise • OMB Design & Control Reduce TOC • Concurrent Design /Control Systems / TOC reduction • Commercial Enterprise (Mine): Objective = $ ROI • Example Navy TOC Savings • Conclusions

13. Ms. Stiller (DASN): TOC Reduction ASNE Event, March 15, 2011 • “Design for Affordability” - challenge requirements • Contract for Affordability - competition • Build Affordably - Navy and Industry work together • Maintenance and Operational Affordability - explore to reduce TOC • Affordability Tools - decision tools focus on overall affordability. • Affordable Innovation - tell / show decision makers the return on investment (ROI ) • Affordable Planning - Strategic planning beyond the FYDP allow industry to make stable investments Note: This DASN guidance for cost reduction is a continuation of NAVSEA shipbuilding cost reduction conferences conducted 2007 – 2009, summarized in ASNE Technical Paper, “Performance Based Design for Fleet Affordability,” ASNE Day 2009 – Published in Naval Engineers Journal, 2009 | Vol. 221 No. 4, p.117, copy at www.ITEinc.US, Tab Technical Papers.

14. Early Design Decisions Drive Cost Cost (and Performance) “Locked-in” Cost Incurred Detail Design and Construction NAVSEA Ship Design Panel (SD-8) JHU-APL March 2011 Feasibility Studies Contract Design ASNE ISS May 2011

15. Objective Models • Objective Model refers to the objective purpose of the model • Objective Purpose include: • Operate the plant • Operate safely • Control costs • Make a profit • ROI • environmental compliance • Attributes of Supporting Physics Object Models: • Physical Attributes: Size, Weight, Position • Performance Attributes: Physics Volume, Velocity, Thermal, Watts … • Control Attributes: Analog / Digital • TOC Attributes: Cost$, LCC$, MTBF to support ROI Analysis

16. Object Models • “Object” model in physics of each component of the plant or ship’s hull, mechanical, and DC systems as an “object” modeled in physics equations such as a pump, pipe, valve, motor, wire, diesel engine, tank • Object Model Equation Variables / Attributes include: Physical Attributes: Integrated CAD – Physics Size, Weight, Position … Performance Attributes: Physics Models Volume, Velocity, Thermal, Watts … Control Attributes TOC Attributes Available, but not used: Cost$, LCC$, MTBF(T) to support ROI Analysis

17. Commercial Enterprise: Mine ASNE ISS May 2011

18. Cost – Benefit Analysis to Objective ASNE ISS May 2011

19. Mine Strata Green = Bore levels for ore mapping ASNE ISS May 2011

20. A CVN is a LARGE Design Model ASNE ISS May 2011

21. Size of Nimitz CVN Compared to a Nickel Mine 333 m CVM = 333 m long Mine = 2,100 m deep, 40 Levels Mine is 105 years old 2,100 meters ASNE ISS May 2011

22. Mine Cross Section ASNE ISS May 2011

23. Mine by Level ASNE ISS May 2011

24. Mining ASNE ISS May 2011

25. ASNE ISS May 2011

26. Air Flow Control by Level / by Section ASNE ISS May 2011

27. Control Network:Know a Ship – Know a Mine Redundant Computing for Life Safety ASNE ISS May 2011

28. Process / 5 Level Economic Control Model ASNE ISS May 2011

29. Mass Balance Calculations & Economic - Environment ASNE ISS May 2011

30. Economic Model – Real Time ASNE ISS May 2011

31. Mine Control HMI: Bottom Line = $$vs. Variable Speed Computed Variable Ops Standard Ops ASNE ISS May 2011

32. Challenges: Culture – Miners are Human Too ! ASNE ISS May 2011

33. OBM Lifecycle Savings – Table 3 ASNE ISS May 2011

34. ROI estimate for DDG Model • The cost of OMB object and objective design modeling for a class of ships as described in this paper might be in the range of $25M. • The Navy return on investment is in the range of $242 for every $1 of model cost. To be conservative, the estimated cost of building the total ship object model was doubled

35. Double Equipment Life Reduce TOC 19% • Doubling Equipment “Life” can Reduce TOC 19% • A NAVSEA ROI model for the doubling of the life of “parts” showed a 19% reduction on TOC for the ship program (Strickland, J. at NAVSEA SD-8 Panel, JHU-APL March 2011) • The submarine community seems to have already adopted this strategy to reduce TOC with the Virginia Class.

36. Thank You! Fair Winds and Following Seas!

37. Figure 2. OMBC Mining System Mine Control System ASNE ISS May 2011

38. Achieving CNO Sea Enterprise Objectives Transformational Ship Design Process – Improve Design, Reduce Costs ITE Inc. 1507A N Colonial Terrace, Arlington,. VA 22209 jfamme@ITEinc.US Integrate Ship Design Tools www.NSRP.org (Maritech) Integrated Shipbuilding Environment Use the Design Tools For HSI Validate Ship Systems & Model • The Ship • Real-time • Validated • PBD • Model • of theShip • CADDrawings • Update allconfigurationpartnumbersto theERP – TDKMIPDEPrograms Deliver To the Navy Re-use the PBD Model for HSI Objectives of: • Shore & Afloat Dynamic Eng/DC & Total • Ship Training • Real-timeReadinessAssessmentof ship& systems • Engineering & • DC OperationalDecisionAids • DistanceSupport • Future Ship • Modernization Tests & Trials • Spiral • Design • Process • Conceptual • Preliminary • Contract • DetailAchieve HSIobjectives: • Automation • Reduced Crew • Survivability • Safety • Delivera Full ShipPBD Modelto supportTests &Trials • T&Tusing the • PBD model • “Virtual • Ship” • Before • Dock • & Sea • Trials: • All • Systems, • Separately • & • Together • Electrical • Fluid • Gas • HVAC • Controls • T&Tof the • “Actual • Ship” • During • Dock • & Sea • Trials: • All • Systems, • Separately • & • Together • Electrical • Fluid • Gas • HVAC • Controls Common Parts Catalog CAD = Design “FITS” PBD = Design “WORKS” S3D ONR Smart Ship System Design Environment Seamless Data Exchange With all IPDE Programs Reduce RISK & COST Physics Based Design (PBD) is a foundation for Navy Sea Enterprise Metrics: verifies systems performance (temp., pres., amps …) and timing. Will ENSURE that ALL ship systems “work” together and meet ship mission requirements before dock & sea trials.

39. Integrated Object Design and Control • Operational, Threat & Damage Adaptive • Autonomic (M&S Based) Reconfiguration • Intelligent Agents • Autonomic Response • Integrated & Distributed Command Capabilities • Combat & Engineering Systems • Personal On-Move PDA Communications & Control • Electronic Navigation / M&S Based Decision Aids • Integrated Design • Doctrine • Ship Design • Automation Design • Simulation Based Total Ship-Crew Model • Validate Automation - Reduced Manning • Security • Access Points • Remote Monitoring • Mission Readiness • Local & Network within ship & across Battle Force platforms • Combat Systems • Engineering Systems • Damage Control • Distant Support • EHM & CBM • Electronic Manuals • 3D Visualization • Crew Location / Monitoring • Embedded M&S Based Training / Decision Aids • Networked BG to Shore • Individual to Total Crew Core Model & Simulation • Damage Control • Autonomic • Intelligent Agent SW • M&S Based Reconfiguration • Personal On-The Move Displays • Combat Systems • Engineering Systems • Damage Control • Electronic Manuals • 3D Visualization • Simulation Based Acquisition & Operation • Integrated CAD-Physics Smart Product Model through all design phases, with dock & sea trial model validation, reuse of the validated model that will run in parallel during operations, supporting decision aids, ship wide performance monitoring to support all functions on this slide and future Alts & modernization