“capability creates the unexpected” · 2019. 3. 12. · 13 but we’re not there yet •...

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“Capability creates the unexpected”

© Unpublished Work, Lockheed Martin Corporation 2017. All Rights Reserved.

This presentation has been publicly released

Gen Jon M. Davis, USMC, AHS Forum 73 keynote

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Never wait for a spare part again

Customize capability in the field



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Embracing Complexity,

Enabling the Unexpected: (Next Generation Agile Manufacturing to Enable “Point of Use” Customization for Complex Vehicles)

Bill Harris

with Jonathan Hartman



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Art of the Possible Concepts

Move to “add on” instead of “built in”

Move to “point of use” instead of “fixed factory”

Move to qualification during manufacture



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“Add on” instead of “build in”

Capability with

limits Easily added

flexibility



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Move the factory to “point of use”

Driven by functionality

and customer need Driven by economics and

technical expertise

Coast Guard Air Station

Kodiak



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Qualification as part of manufacture

Process data = physical characteristics = performance

When in doubt, add a gauge, within

reason



https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjcx4bHuvDOAhUFXB4KHdDmDD8QjRwIBw&url=https://www.3dhubs.com/3d-printers/fortus-400mc&psig=AFQjCNFp4REqRMGxQPIg3bODLKw-F2s4nQ&ust=1472897937932013

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Additive manufacturing

A Comprehensive “Digital Twin”

Remote presence, real time cooperation

Catalysts



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Additive Manufacturing

Complexity and variety are advantages

Little or no assembly required

Near zero lead time

Unlimited design space

Less waste

Customizable replication

But,

Limited build volumes and material selection

Limited material property knowledge

Limited in situ process monitoring/ability to replicate



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A Comprehensive “Digital Twin”

Real Time, Tail Number

Specific Data

Historical Model Test

Data

Assess, anticipate, and adapt the aircraft and its parts with

low risk using real time and historical data

Adaptive, Evolving,

Unique Digital Twin



http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiS-76S-pLUAhVC34MKHeYTC1MQjRwIBw&url=http://www.dmitryshulgin.com/category/air-force/page/22/&psig=AFQjCNFRMBR2MxcQnhthTxciF_sxlaVd5A&ust=1496073449832991

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Remote presence, real time cooperation

Secure, interactive, collaborative data exchange between

humans and automated quality processes

Aircraft Data

Manufacturing Capability

Modeling Tools

Manufacturing Instructions

Manufacturing Visualization

Problem Solving

Crew Chiefs

&

Maintainers

Technical

Experts



http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiCmbyZ5pzUAhUE6yYKHUMfAw0QjRwIBw&url=http://www.nbcconnecticut.com/news/local/Sikorsky-Deal-Requires-Approval-from-General-Assmebly-Union-394350961.html&psig=AFQjCNEYfdlZGfg4t9shXUvRO80Aajo24Q&ust=1496411651507951

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwinzKjj_J7UAhXJ24MKHQWwCcoQjRwIBw&url=https://www.eventscribe.com/2017/AMUG/ajaxcalls/PresenterInfo.asp?efp%3DQ1dYR1JBS0czNTAx%26PresenterID%3D277604%26rnd%3D0.4596408&psig=AFQjCNGqykaIwXcWY4Juz6Q2fc7m9KMiSQ&ust=1496486468971099

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Rapidly maturing enablers

Statistically capable

processes

High pedigree material

and its performance data

Secure, high powered

computational resources



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But We’re Not There Yet

• Machines and Materials

• Fluid configuration management of

vehicle and manufacturing capability

• Warranty, liability and business model

• Data security

• Ability to deal with uncertainty and

noise

• Moving Technical Experts to ‘On’

Instead of ‘In’ the Loop

• Certification and Quality Standards



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Evidence it can work

Version 1

September 1939 Version 4

December 1941

2 models

4 versions

6 modifications

Local design team

Onsite manufacturing

Full certification authority



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The Story of Sikorsky and Working

Towards the Future

Use the greatest caution when combining the

words Impossible and Aviation



“capability creates the unexpected” · 2019. 3. 12. · 13 but we’re not there yet •...

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