Integrated Shipbuilding Environment Enabling Shipbuilding Interoperability ISE-6 Project

Integrated Shipbuilding Environment Enabling Shipbuilding Interoperability ISE-6 Project Exchange of Product Models for Life Cycle Support ISE Overview Presentation (to be used as basis for Overview at Final Demo) As Presented on: February 3, 2009 in Port Hueneme, CA Presented by: 3 February 2009 Dr. Burton Gischner Electric Boat Corporation 1

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 3 February 2009 2

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 industrywide initiatives with aggressive technology transfer to, and buy-in by, multiple U. S. Shipyards 3 February 2009 3

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 3 February 2009 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 e. Business for Enterprise Integration – across construction, repair, logistics activities and suppliers Benefit: cuts labor and cycle time of daily processes by 60% 3 February 2009 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 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 & functions Benefit: Reduces costs & acquisition cycle time, improves 1 st time quality, enables outsourcing Joint Lean Learning Curve - Accelerate adoption of productivity Improvement Benefit: Systematic, repeatable boosts in productivity from shop-level to design, engineering and supply chains 5

Product Data Initiatives Alignment LEAPS Navy ERP SPARS ISE Total Ship Shock Trial 3 February 2009 CPC Navy Initiative NSRP Initiative 6

Product Information Modeling 3 February 2009 7

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 3 February 2009 8

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 3 February 2009 9

ISE Interoperability Solution • 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 • Drive development of shipbuilding product data standards (e. g. STEP, PLIB) – Construct a single Shipbuilding Information Model – Demonstrate and educate U. S. shipbuilding community • Develop and demonstrate tools that are low cost – Can be selectively used by shipyards to support interoperability – Capitalize on XML and related Internet technologies 3 February 2009 10

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 3 February 2009 11

XML + STEP • Data is independent of IT infrastructure, but standards are required to reflect system needs for exchange Transactions of Data Packaged in Standards Virtual XML = Industry Standard Ship Container for Data part(s) Company STEP = ISO Standard A B Language for Data XSLT - map data to another XML schema XML : • Accepted format/schema method • Standards for data expression • Web-enabling 3 February 2009 STEP : • Standards for geometric exchange 12

ISE Architecture ISE architecture represents an innovative, practical solution to the information interoperability challenge • 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 3 February 2009 13

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 – Automated test frameworks for conformance testing 3 February 2009 14

Information Interoperability Roadmap Ship Product Model Data Ship Structural Envelope Distribution Systems Ship Arrangement HVAC ISO AP 216: 2003 Miscellaneous ISO AP 227: 2005 Systems Engineering Product Config / Geometry ISO AP 233 ISO AP 203/214: 1994 Reference Data Libraries ISO AP 227: 2005 Ship Moulded Forms Life Cycle Maintenance Common Parts Catalog (CPC) Piping ISO AP 215: 2004 Equipment / Subsystems Product Life Cycle Support ISO AP 239: 2004 ISO 15926 Finite Element Analysis ISO AP 209: 2001 Ship Structures Cable Trays Outfit & Furnishings ISO AP 218: 2004 ISO AP 227: 2005 NSRP 0428: 1992 Manufacturing Support Mechanical Systems ISO AP 227: 2005 ISO APs 224, 238, 240 ISO AP 212: 2001 3 February 2009 Standard Approved ISO AP 232: 2002 Computational Fluid Dynamics Electrical Standard In Work Logistics / Spares ISO AP 237 Information Model Prototype Translators Testing Framework Deployment, Integration, Testing 15

ISE Information Model Methodology ISO STEP NSRP ISE Testing Information Prototype Model Translators Framework Deployment, Integration, Testing Ship Program 3 February 2009 Requirements Definition Information Interoperability Specification Business Decisions Contractual Specification NAVSEA Phases: Technology Standard in In Work Approved Production Deployment 16

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 t por S up ycle P ro duc t Lif e. C cal hni t ec ctro E le 2009 2007 ISE-6 2008 p. A S t e rra n g E ng i n e e l P ro e me n e ri n ts c g A essin g n Ele alysis ct r i cal S hi ISE-5 ISE-4 2006 2004 2003 2002 ISE-3 2005 H e rf V A C ac es I nt CP 3 February 2009 2001 ISE-2 2000 ISE-1 1999 C Str Re qu i re me uc tu P i p re s ing nt s • NSRP funded program focused on interoperability using international standards – ISO STEP, PLCS, S 1000 D, W 3 C 17

Interoperability: Current Related Efforts • ISE-6 (Enabling Shipbuilding Interoperability) – 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 enterprisewide 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 under the ISE Project under NSRP over the past nine years – It will be a separate document from the IPDE Specification to be 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 wilt Product Life Cycle Support and will be based on the results of the ISE-6 Project 18 3 February 2009

ISE Team Participants 3 February 2009 19

ISE Test Ship – TWR 841 This ship is used to locate and retrieve torpedoes and missile drones. It has a maximum payload capacity of 42 long tons which includes the deck cargo plus full liquids, full complement, and normal stores. 3 February 2009 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. 20

ISE-2 Demonstration (April 2003) AP 216: Ship Moulded Forms AP 218: Ship Structure AP 227: Piping 3 February 2009 21

ISE-3 Demonstration (October 2004) 3 February 2009 AP 227: HVAC 22

Washington DC 3 February 2009 • Integrated Shipbuilding Environment HVAC Demonstration • 23

ISE-4 Demonstration (April 2006) ISE-4: • Ship Arrangements • Engineering Analysis • Electrical Design • Steel Processing TWR 3 D Product Model Geometry Engine Room 3 February 2009 24

Systems Involved in the ISE-4 Interoperability Demo Initial Design Detail Design Concept & Preliminary Design Engineering FEA Analysis Electrical KSS/KM Preliminary Arrangement AP 212 P 28 A Atlantec ADAPT AP 212 P 21 Modify Arrangement Sener TRIBON B EBC AP 209 P 21 C AP 218 P 28 FORAN Partnership Yard Manufacturing Lifecycle Support Steel Processing Feed Mfg from ISDP AP 218 P 28 GDEB NGSS Intergraph ISDP AP 215 P 28 Repair Shipyard INTELLISHIP AP 215 P 28 B AP 215 P 21 Suggest Design Changes Submit Design LEAPS Navy Analysis Programs AP 215 P 21 Approval Submit Design For Approval LEAPS Arrangements Navy Response Center Detail Design Engineering Analysis Key: 3 February 2009 = Mediators Required Final Product Model Delivered to Navy = Demonstrated = Not Demonstrated 25

TWR Compartment Overview Compartment Name Air Handling Room Ballast Tank #1 Ballast Tank #2 Ballast Tank #3 Ballast Tank #4 Bosuns Stores Bow Thruster Chain Locker CO State Room CPO State Room Crews Berthing Deck Gear Electrical Room Engine Room Exhaust Trunk Engine Room Supply Trunk Forepeak Fuel Oil Tank #1 Fuel Oil Tank #2 Fuel Oil Tank #3 Fuel Oil Tank #4 Fuel Oil Tank #5 Galley and Mess Area Hold Head Hold Passageway Lazarette Passageway Linen Locker Lube Oil Tank Main Deck Head Main Deck Passageway Observers Berthing Pilot House Passageway Potable Water Tank #1 Potable Water Tank #2 Provisions Storeroom Pump Room Passageway Pump Room Supply Trunk Void Waste Oil Tank 3 February 2009 Compt # 1 -8 -3 -Q 2 -6 -1 -V 1 -6 -2 -V 2 -23 -6 -V 1 -23 -0 -F 2 -2 -0 -A 2 -5 -0 -Q 2 -2 -0 -Q 1 -5 -2 -L 1 -5 -1 -L 2 -6 -0 -L 1 -14 -3 -A 1 -7 -1 -Q 2 -16 -0 -E 2 -15 -1 -Q 2 -15 -2 -Q 2 -0 -0 -V 2 -9 -1 -F 1 -9 -2 -F 2 -16 -0 -F 2 -23 -2 -F 2 -9 -1 -F 1 -9 -0 -L 2 -10 -2 -L 2 -8 -0 -L 2 -25 -0 -Q 2 -23 -0 -Q 2 -9 -1 -A 2 -23 -4 -F 1 -7 -2 -L 1 -7 -0 -L 2 -10 -1 -L 01 -6 -0 -C 1 -9 -1 -L 2 -13 -1 -W 2 -13 -2 -W 2 -11 -0 -A 2 -12 -0 -Q 2 -14 -1 -Q 1 -14 -1 -Q 2 -2 -0 -V 2 -15 -0 -F Volume (m^3) 9. 344559387 5. 621280313 5. 621280378 10. 94196403 11. 45422363 31. 1542512 29. 65740748 2. 128270093 15. 19818335 15. 19818517 65. 55600522 5. 256314651 4. 672279696 164. 4171673 2. 803369266 1. 897890198 9. 703230573 7. 47810508 7. 47810645 11. 87955578 4. 791415503 4. 572601083 59. 46537759 20. 57645565 18. 1679584 45. 19140913 6. 423977119 2. 786579543 0. 987812699 7. 00841954 6. 371290497 17. 82688618 45. 87356833 4. 014929551 9. 928594336 7. 495108964 112. 0118041 3. 82277429 0. 424752699 3. 395942412 0. 976931207 26

ISE-5 Demonstration (February 2007) DXF or IGES (2 D CAD) AP 214 (3 D CAD) AP 227 (3 D Cableways) 3 February 2009 27

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 3 February 2009 28

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 3 February 2009 29

Issues Arising for Data Transfers Throughout Life Cycle • 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 3 February 2009 30

ISE-6 Project • Two year project, funded by National Shipbuilding Research Program (NSRP) • Coordinate the use of the PLCS (STEP AP 239), S 1000 D, 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 S 1000 D capabilities with PLCS and ISE information models Manage change by linking S 1000 D modules to design structure Demonstration details are currently being defined Demo will probably take place in late April 2009 3 February 2009 31

Standards for Life Cycle Support Standards for Design, Engineering, Production (STEP AP 212, 215, 216, 218, 227 ed 2 ) (ISE information models) Standard for Logistics & Life Cycle Support (PLCS) (STEP AP 239) ISE-6 Phase 1 International ISO Standards Focus of ISE Projects since 1999 International ISO Standard Driven by Aerospace and Defense ISE-6 is Prototyping Use for Shipbuilding International Standard for Technical Publications (S 1000 D) ISE-6 Phase 2 3 February 2009 Driven by Aerospace, Defense Emerging Do. D IETM Standard 32

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 3 February 2009 33