a journey in culture change: from engineered drawings to ......qmobile craftsman qswims: dashboard...

HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I

A Journey in Culture Change: From Engineered Drawings to Digital User-Centered Visual Instructions at Newport News Shipbuilding3Views to 3D3D CIC Conference 2017 Jim Dorwart


2

Newport News Shipbuilding• 131 year old company

• Virginia’s largest Industrial Employer (20,000+)

• 2.5 miles of waterfront (550 acres)

• 20+ different Shops (valve sheet metal, foundry, etc.)

• Primarily Navy Work

• Complex Design

• Construction

• Overhaul

• Maintenance/Modernization

• Logistics


3

q The 1st major transition

q CV6launchesOct.3,1936

q Oneofthe1st NNSAllWeldConstruction

q CVN6decommissioningFeb.17,1947

USS Enterprise (CV 6)


4

q The 2nd major transition

q CVN65launchesSept.24,1960

q BeginsNNSnuclearera

q CVN65decommissioningFeb.3,2017

USS Enterprise (CVN 65)


5

q The latest major transition

q CVN80drawingless packagescurrentlybeingworked

q CVN80firstcutofsteelceremonyin2017

q BeginsNNSdigitalera

USS Enterprise (CVN 80)

NNS Launches the Digital Shipyard

Search for “Newport News Shipbuilding launches the digital shipyard” on YouTube https://www.youtube.com/watch?v=93za-vO_ffs


6

Digital Shipbuilding has evolved:

qMobilecraftsman

q SWiMS:dashboardforwork

q Drawingless,model-basedenterprise

q IntegratedSmartShipyard

q VisualWorkInstructions

q VisualBuildManagement

q Andmore…


7

Job-to-be-Done

PartorAssembly

ProductionCapabilitiesWhatdoIhavetodothejob?

NNSsemanticallydefinedcapabilitydata

BuildStrategy

ü Do shops & work center’s have the capacity to support the work?

ü Do we have the resource capacity to support the work?

ü Do suppliers have the capacity to meet the demand?

ü Can we store it? Security?

ü How long will material/ parts be in inventory??

CapacityAnalysis&Tradeoff’s

FabricateA

InstallB

X

XX

O

Routing

KeyDates&

Milestones(IMS)

Alltheinformation

neededtoexecutethe

processatthechosen

workcenter

SemanticTechnologies

Sequence&

Schedule

ProductSpecs (MBD)

AutomaticallyGenerateProduction&Routing

Options

WorkCenterwithProcessOption1of5

Process Architecture

Ontology

Product Ontology

Facilities /Asset

Ontology

Production Rules

Prioritizedbycostofresources

consumed(man-hoursandasset

usage)

Execution

Executionprovidesdataforanalysis

toaidinreal-time,adaptiveplanningand futureproductdesign&planning Dataisalsousedtodiscoverandgauge process

improvements.

MBE

01011

0 10101

01110

1100100110

00110 10100

101

010

MBE/IA

MBDBehindMBDisasemanticdatamodelthatisableto

conveydesignintent

SmartManufacturingArchitecturebasedon

Standards

ProductSpecs (MBD)

MBD

ProductSpecs (MBD)

Add

detailed

PMI

Onceanoptionis

selected,addhigh-

levelPMIandPA

blocks

MBE

Vision of the Digital Shipyard

AutoVWIGeneration&Dispatch


8

Challenges


9

THEPROCESS

Our Craftsmen Build the Most Complex Ships in the WorldTHIS NEEDED TO BE MORE EFFICIENT

THEHUNT

THECONFUSION

Our World is built on Complex Paper Processes


10

• Multiple large mounds of disparate, disconnected, duplicated data in multiple formats

• No consistent cross system language. (Enterprise wide tower of Babel)

– No Enterprise Ontology or Data Dictionary

– No Enterprise wide Semantic Data Model/Web

• Most of our documented processes are not repeatable at a Semantic Data Level

– Process vs. Practice

No Common Digital Foundation

Semantic Data uses context to allow machines to understand the meaning of discrete data elements.

I love you I U Semantically the same: Syntax is Different


11

Other

Legacy Programs

Many Customers and Multiple Older Programs


12

OpportunityFor

Change

Brownfield toGreenfield

Infrastructure

Biggest Asset

Tools

Process

People

What do we have to start from?

Our Business Trinity


13

• Start with the end user

• Develop ‘Low-Res’ Prototypes

• Follow Through on Delivering

• Make our Brown Field Work for Us/ Plan for a Greenfield

Real time info

Real time comprehensive support status

Think and Feel

SeeHea

r

Say and Do

Safety and Quality very important

Mistrust in the system

FrustratedOverwhelmed

Computer limitations to get info

Time off Deck Plate

Lack of useful info

Pride in their WorkExhausted

Flying by the seat of their pants

Get job done on-time/on-budget

Too Much to Track

Pressure

Works too many hours

This Job is hot Material

is missing

Go faster for less budgetJust fix it

Why are you late?

Your people are lazy

You work too many hours

Need an ECD for …

You already have everything you need

That is not your job

The Drawing is messed up

I need …

Works many hours

Sign off partiesEmpowers people

MentorsMakes Challenging Decisions

Get out of my way

Must do everything themselvesGo-go-go attitude

vsScrew it No Support

MetricsShare status and Problems Verbally

Works the phones to coordinate work

None of this info helps me

There is a better way to do this

Stacks of paper work

Frustrated Employees

Metrics that don’t apply to the work

Too many meetingsIndustrial Dangerous environment

Only on Ship for few hoursMany people working hard with little progress

Useless info (dwgs, mat’l, plan, etc.)

Others in the way of workCrowded messy ship

Small cramped offices

People sitting around waiting for work

Pain

Gain

SAP GUIConstantly changing prioritiesEvery Job is hot

No access to schedule

Too much useless informationCritics No real time actionable

infoToo many hours at work

Multiple Queues for support from value streamSlow to no response from the value stream

Unskilled crew members

Others behind schedule

Who should I call for what

Distance between Physical Work and info

Just on time is never on timeLittle time on deck plate

Rework A voice in the system

Time with employeesReal Time

Material StatusClear priorities across jobs

Clear Instructions (useless design info removed)

Clear Instructions (useless design info removed)

Mobile access to all informationIntuitive interface

Real time status of work

Electronic OQESense of accomplishmentAutomated Info

CaptureLess time to accomplish more work More time at

homeOpen communications to focus on real problems

All feedback adjudicated and incorporated as appropriate

Design Thinking

People: End User Centered Product


14

Catia V4 AC – Shell Glob Models

2015Teamcenter 9.0.x

NX 8.5 with 4GD

2000Dassault PLM

19984.0 execution

2015UniCode Compliant

i. Lots of custom drawing only code

ii. All CAD Data was developed as Design Only

usage

iii. All Design authored in 4GD not BVR

iv. NO MPP, NO EWI

i. Work Packages

ii. Operations

iii. Material

iv. SAP VE (Right Hemisphere) embedded in our BOM

process

Reports, Metrics, Business Management, ERP, MRP, MESPLM, CAD

14

Mobile Infrastructure

2018HANA S4 (Ad Manf)

i. Minimize Custom Code

ii. Work Packages /Work Orders

iii. Eliminate custom transactions

iv. MES

2017Teamcenter 11.x

NX 11.X with 4GD and NGP i. Minimize Custom Code

ii. OOTB NGP w/ XML ingestion

iii. Model, Drawing, Point Cloud, etc.

Tools: Brown Field and Green Field


15

1. People Focused Only2. Author Master Data Once3. Digital String (Config and Change Man)4. Common (Processes, Tools, etc.)5. Reuse (Hull, Across Hull, Across Platforms)

6. Allow People to Fail Fast 7. Allow People to Test to break the

systems (find the Limits)

Rules: Driving Philosophies for Data Provisioning and Processes

https://github.com/bahmutov/talks/blob/master/agile-software-quality.md"Desired paths" by Jan-Dirk van der Burg http://www.olifantenpaadjes.nl/

Processes: New Philosophy for Development


16

Design

&

Engine

ering

Plan

ning

Ope

ratio

ns

ReleaseWorkPackage

DevelopSupplementalInformation

Prepare forWork

ManufactureParts

AssembleInstall Parts

CloseoutWork

DevelopWorkBreakdownStructure

TranslateWorkInstruction CloseouttoAs-Built Disclosure

Release Model& Disclosure

Processes: Commonality = Money

Program Integration

Point

Savings


17

Focus: Show how a Semantic Model Foundation would work for Process Architecture

• Discrete Repeatable Processes

• Context

– Process Flow

– Discrete Work Center

– Grouping of Parts

PA

How

Where

What

Work Location

Processes: Digital Process functions like Lego Blocks


18

Process Flow

Discrete Work Location Grouping of Parts

Processes: Lego Block Context


19

Visual Work Instructions


20

“How to” Videos

Augmented Reality

VWI can take many forms

Laser Scanning / Reality Capture

Digitized Drawings

Siemens NX Product Model


21

21

Visual Planning


22

22

Visual Work Instruction Example


23

Many Customers and Multiple Older Programs

Other

Legacy Programs


24

3 Views to 3D through Point Cloud


25

• Part Id Numbers • Drawing views • Field joints• Weld information• Details • Compartment numbers• Structural THKNS/MTL• Hull Applicability• Test Boundaries

Manufacturing Model/Sketch

Design Products Manufacturing Information• Dimensions • Flow arrows • Frames and Reference lines • Label Plates, Damage Control

plates • Method • Tolerances • Surface Finishes • Consumable company stock

material

Visual Work Instruction

Visual representation of the technical instructions and product manufacturing information

VWI in a Nut Shell


26

Visual Work Instruction Experiences

1000+VWI’s

created

200+Mobile

Devices

0Requests

toReturnto

Drawings


27

“Individual elements of this presentation may not be copied or distributed without the express written permission of Huntington Ingalls Industries.”

a journey in culture change: from engineered drawings to ......qmobile craftsman qswims: dashboard...

Documents