A Journey in Culture Change: From Engineered Drawings to ......qMobile craftsman qSWiMS: dashboard...
Transcript of 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
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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
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q The 1st major transition
q CV6launchesOct.3,1936
q Oneofthe1st NNSAllWeldConstruction
q CVN6decommissioningFeb.17,1947
USS Enterprise (CV 6)
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q The 2nd major transition
q CVN65launchesSept.24,1960
q BeginsNNSnuclearera
q CVN65decommissioningFeb.3,2017
USS Enterprise (CVN 65)
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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
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Digital Shipbuilding has evolved:
qMobilecraftsman
q SWiMS:dashboardforwork
q Drawingless,model-basedenterprise
q IntegratedSmartShipyard
q VisualWorkInstructions
q VisualBuildManagement
q Andmore…
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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
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Challenges
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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
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• 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
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Other
Legacy Programs
Many Customers and Multiple Older Programs
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OpportunityFor
Change
Brownfield toGreenfield
Infrastructure
Biggest Asset
Tools
Process
People
What do we have to start from?
Our Business Trinity
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• 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
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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
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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
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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
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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
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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
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Process Flow
Discrete Work Location Grouping of Parts
Processes: Lego Block Context
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Visual Work Instructions
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“How to” Videos
Augmented Reality
VWI can take many forms
Laser Scanning / Reality Capture
Digitized Drawings
Siemens NX Product Model
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Visual Planning
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Visual Work Instruction Example
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Many Customers and Multiple Older Programs
Other
Legacy Programs
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3 Views to 3D through Point Cloud
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• 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
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Visual Work Instruction Experiences
1000+VWI’s
created
200+Mobile
Devices
0Requests
toReturnto
Drawings
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