1. 30 April 2009 1 Enabling Shipbuilding Interoperability ISE-6 Project Exchange of Product Models for Life Cycle Support ISE-6 Final Demonstration Overview Presentation Presented on: April 30, 2009 Presented by: Dr. Burton Gischner Electric Boat Corporation Integrated Shipbuilding Environment

2. 30 April 2009 2 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. 30 April 2009 3 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 industry- wide initiatives with aggressive technology transfer to, and buy-in by, multiple U.S. Shipyards

4. 30 April 2009 4 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

5. 30 April 2009 5 NSRP = Industry-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 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 Joint Lean Learning Curve - Accelerate adoption of productivity improvement Benefit: Systematic, repeatable boosts in productivity from shop-level to design, engineering and supply chains eBusiness for Enterprise Integration – across construction, repair, logistics activities and suppliers Benefit: Cuts labor and cycle time of daily processes by 60% 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

6. 30 April 2009 6 Product Data Initiatives Alignment Full Ship Modeling & Simulation CPC Navy Initiative NSRP Initiative NPDI MAINTAIN Planning Yard Product Data Manager SPARS ISE LEAPS Navy ERP

7. 30 April 2009 7 NSRP Project – Improved Methods for the Generation of Full-Ship Simulation/Analysis Models 2 NSRP Project – Improved Methods for the Generation of Full-Ship Simulation/Analysis Models 2 The NSRP Modeling and Simulation Workshop The NSRP Modeling and Simulation Project will hold a one day workshop in association with the DoD CREATE Project covering Ship Modeling and Simulation efforts. June 10, 2009

8. 30 April 2009 8 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

9. 30 April 2009 9 Current Process for Updating Technical Data Radar Navy Legacy Systems Navy Tech Manuals & Deliverables Embedded Tech Data Training Radar Tech Data Radar System is designed and produced Contractor and Navy agree on LRU breakdown Logistics Organization builds Tech Manual ­ Primary inputs are Drawings and Parts List ­ Maintenance Engineering defines maintenance data and procedures Documents delivered to Navy Navy Logistics Organization ­ Builds Navy Tech Manual ­ Generates data for other Navy Logistics systems from documents Goal is to Reduce Life Cycle Costs through Standards-Based Integration

10. 30 April 2009 10 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

11. 30 April 2009 11 ISE Interoperability Solution Drive development of shipbuilding product data standards (e.g. STEP, PLIB) –Construct a single Shipbuilding Information Model –Demonstrate and educate U.S. shipbuilding community 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 Develop and demonstrate tools that are low cost –Can be used selectively by shipyards to support interoperability –Capitalize on XML and related Internet technologies

12. 30 April 2009 12 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

13. 30 April 2009 13 XML + STEP XML = Industry Standard Container for Data STEP = ISO Standard Language for Data Data Company A Standards Virtual Ship part(s) Company B Transactions of Data Packaged in Standards XSLT - map data to another XML schema XML : Accepted format/schema method Web-enabling STEP : Standards for data expression Standards for geometric exchange Data is independent of IT infrastructure, but standards are required to reflect system needs for exchange

14. 30 April 2009 14 ISE Architecture 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 ISE architecture represents an innovative, practical solution to the information interoperability challenge

15. 30 April 2009 15 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 –Mediators (i.e. between STEP Part 21 and STEP Part 28) –Automated test frameworks for conformance testing

16. 30 April 2009 16 Information Interoperability Roadmap ISO AP 239:2004

17. 30 April 2009 17 ISO STEP NAVSEA Ship Program Standard Approved Standard In Work NSRP ISE Prototype Translators Testing Framework Information Model Phases:Requirements Definition Information Interoperability Specification Production Deployment ISE Information Model Methodology Contractual Specification Deployment, Integration, Testing Technology Business Decisions Standard in Work

18. 30 April 2009 18 Requiring the Use of STEP Air Force incorporates PLCS into acquisition and sustainment policy –ACQUISITION AND SUSTAINMENT LIFE CYCLE MANAGEMENTAIR FORCE INSTRUCTION 63-101 SECRETARY OF THE AIR FORCE 17 APRIL 2009 –The PM shall ensure development and acquisition of engineering data sufficient for the acquisition, modification, maintenance, spares, repair, and demilitarization of the weapon system –The PM shall require the use of International Standards Organization (ISO) 10303, Standard for Exchange of Product (STEP) Model Data, AP239, Product Life Cycle Support, for engineering data –Air Force Instruction is available on the Web at: http://www.e-publishing.af.mil/shared/media/epubs/AFI63-101.pdf Army is currently implementing use of AP239 for Product Life Cycle Support NAVSEA Instruction 9040.3 Recommends the use of STEP for product model exchange, but the Navy has yet to require its implementation on major ship programs

19. 30 April 2009 19 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 NSRP funded program focused on interoperability using international standards – ISO STEP, PLCS, S1000D, W3C 19992000200120022003200420052006200720082009 ISE-6ISE-5 ISE-4 ISE-3ISE-2ISE-1 Ship Arrangements Steel Processing Engineering Analysis Electrical Electrotechnical Product Life Cycle Support Requirements HVAC CPC Interfaces Structures Piping

20. 30 April 2009 20 Interoperability: Current Related Efforts ISE-6(Integrated Shipbuilding Environment) –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 enterprise- wide 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 and prototyped by the ISE Project under NSRP over the past nine years –It will be a separate document from the IPDE Specification being 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 with Product Life Cycle Support and will be based on the results of the ISE-6 Project

21. 30 April 2009 21 ISE Team Participants

22. 30 April 2009 22 ISE Test Ship – TWR841 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. 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.

23. 30 April 2009 23 Previous ISE Demos ISE-2 Demonstration (April 2003)ISE-3 Demonstration (October 2004) Engine Room ISE-4: Ship Arrangements Engineering Analysis Electrical Design Steel Processing TWR 3D Product Model Geometry ISE-4 Demonstration (April 2006) Design Agent 1 SVG XML AP212 (ET Data) AP212 (ET Data) DXF or IGES (2D CAD) Design Agent 2 Design Agent 3 DXF or IGES (2D CAD) AP214 (3D CAD) AP227 (Cableways) Concept & Preliminary Design Production Design Refit & Upgrade Design Electrotechnical Data and Document Interoperability ISE-5 Demonstration (February 2007)

24. 30 April 2009 24 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

25. 30 April 2009 25 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

26. 30 April 2009 26 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 Issues Arising for Data Transfers Throughout Life Cycle

27. 30 April 2009 27 STEP for Archiving and Sustainability of Data Long Term Retention of Product Model Data is a Problem –Shipbuilding Products in general have life spans that far exceed the span of the CAD, CAE, or PDM systems that create the Product Models –Accurate Product Model Data is needed throughout the Life Cycle of the Product for Repairs, Overhauls, In-Service Modifications, etc. –Data must be retained for the life of the product which can be up to 50 years –On the other hand, the life of a CAD, CAE, or PDM system used to design the product is often less than 10 years How will you read your product model data in 5 years? 10? 15?

28. 30 April 2009 28 Data Archiving: STEP Standard Formats Preserve Data for Future Use Regardless of changes to Hardware, OS or CAD System STEP is a Potential Solution 10 20 30 40 Years Convert X to STEP Convert A to STEP Convert B to STEP Convert C to STEP System X System A System B System C System N Convert to long-term archiving format (STEP) once 50 40 10 20 30 40 Years Convert X to A Convert A to B Convert B to C Convert C to N System X System A System B System C System N Preserving data for future use without standardsrequires you to convert all your data each time you modify Hardware, OS or CAD system

29. 30 April 2009 29 ISE-6 Project Two year project, funded by National Shipbuilding Research Program (NSRP) Coordinate the use of the PLCS (STEP AP239), S1000D, 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 S1000D capabilities with PLCS and ISE information models –Manage change by linking S1000D modules to design structure –Final Demonstration on April 30, 2009

30. 30 April 2009 30 ISE-6 Project Participants Electric Boat Northrop Grumman Shipbuilding – Gulf Coast Atlantec-es Industrial Planning Technology Intergraph Knowledge Systems Solutions NSWC-CD NSWC-PHD Northrop Grumman Information Systems Product Data Services Corporation ShipConstructor Software USA

31. 30 April 2009 31 ISE-6 Phase 1: Functional Scenario 31 Design (3D CAD Data) Shipyard A IDE (Design & Logistics) Shipyard B IDE (Design, Logistics, & CAD ) Navy IDE (Design & Analysis) Navy Depot (Design, Logistics, Support) Data Prep & QA (Design, Logistics, & CAD)

32. 30 April 2009 32 AIM/SIR LPD 17 IPDE Software Teamcenter DDG 1000 IDE Software episTree Knowledge Management Software LEAPS Navy Design & Analysis Repository CATIA (V4 AEC) ShipConstructor 2006 ShipConstructor 2008 AP 227 AP 239 AP 214 Design Navy IDE Shipyard A-IDE Shipyard B-IDE 3D Design Design & Logistics AP 214 AP 239 Design & Logistics, including 3D Design AP 239 AP239/PLCS (ISE-6) Phase 1 Scenario Demo: April 2, 2008 in Washington, DC

33. 30 April 2009 33 Standards for Life Cycle Support Standards for Design, Engineering, Production (STEP AP 212, 215, 216, 218, 227ed2 ) (ISE information models) International ISO Standards Focus of ISE Projects since 1999 Standard for Technical Publications (S1000D) ISE-6 Phase 2 International Standard Driven by Aerospace, Defense Emerging DoD IETM Standard Standard for Logistics & Life Cycle Support (PLCS) (STEP AP 239) ISE-6 Phase 1 International ISO Standard Driven by Aerospace and Defense ISE-6 has Prototyped Use for Shipbuilding Use of these standards is the focus of today’s demonstration

34. 30 April 2009 34 Phase 2 of the ISE-6 Project runs from April 2008 through June 2009 S1000D is an international specification for the procurement and production of technical publications It is an SGML/XML standard for preparing, managing, and using equipment maintenance and operations information The Navy has been working toward a new-generation of interactive technical manuals for deployment on-board ship There has been pressure to move to the topic-based approach embodied in the S1000D standard but, to date, this migration has been only partially accomplished This phase of ISE-6 has developed use cases for shipboard interactive technical documents that take advantage of the new capabilities of the S1000D standard ISE-6 Phase 2

35. 30 April 2009 35 Product Life Cycle Support (PLCS) 35 Project to Develop AP239 as an ISO Standard for PLCS Copyright Eurostep Group AB

36. 30 April 2009 36 The Key Business Problem Copyright Eurostep Group AB Feedback Copyright Eurostep Group AB

37. 30 April 2009 37 Business Drivers Reduced Cost of Ownership Users of products are seeking improved availability, reliability, maintainability, and lower cost of ownership Exploit Investment in Product Data Users of information systems want more open platforms to reduce IT costs and ensure longevity in use of information Digital Product Data has become a valuable business asset For shipyards, the investment in Product Data has not yet been leveraged for life cycle support Copyright Eurostep Group AB

38. 30 April 2009 38 ISO 10303-239 Product Life Cycle Support (PLCS) Change Management Product Structure Requirements Management Schedule Activities Organizations Property Classification Approvals, Security, Status Maintenance Support Tasks APSI Support History Messaging PLCS PLCS provides an integrated data model with a scope that is a holistic view encompassing the entire product life cycle ISE-6 Lifecycle community needs to access information defined during acquisition ● Acquisition community can also benefit from the use of PLCS to exchange integrated design and logistics information

39. 30 April 2009 39 Copyright Eurostep Group AB Typical complex systems environment – point to point integration

40. 30 April 2009 40 Product Life Cycle Support (PLCS) 40 Copyright Eurostep Group AB

41. 30 April 2009 41 PLCS Vision 10/20/ 2008Intergraph Proprietary and Confidential Ship Acquisition Programs Ship Life Cycle Support Design Data Ship Design Parts Manufacturing Ship Configuration Logistics Data Program Data Documents Change Mgmt Ship Program A Integrated Data Environment (IDE) Ship Design Parts Manufacturing Ship Configuration Logistics Data Program Data DocumentsDesign Data Change Mgmt Ship Program B Integrated Data Environment (IDE) Shipyard Legacy Logistics & Support Systems Navy Legacy Logistics & Support Systems Regional Maintenance Centers Change Management Product Structure Requirements Management ScheduleActivities Organizations Property Classification Approvals, Security, Status Maintenance Support Tasks APSI Support History Messaging PLCS Marine Corps Legacy Logistics & Support Systems NATO Legacy Logistics & Support Systems

42. 30 April 2009 42 Integrating Lifecycle Processes Across the Navy Virtual Enterprise - Demonstrating an integrated approach for SCD Changes between ISEA and Shipyard - Automated identification of logistics documentation change impacts - Standards based exchange of integrated design, logistics, and technical publication data using PLCS and S1000D Planning Yard / NAVSSES ISEA NCSDB NDE-FMPNAVICP WSFCDMD-OATDMISTDKM PLCS + S1000D HM&E Design Combat Systems Design & Logistics Ship Configuration Design & Logistics LEAPS Engineering Analysis IDE S1000D IETM Data Other Navy Systems Future Applicability Demonstration

43. 30 April 2009 43 PLCS/S1000D is the right choice for the U.S. Navy and Shipbuilding Industry PLCS (ISO10303-239) and S1000D Standards have been used successfully by: –Norwegian Frigate Program –Air Force Joint Strike Fighter (JSF) –Army TACOM ISE-6 Project is prototyping these tools and standards for current Navy systems The right solution for today’s IPDE environments in the Navy and the Shipyards

44. 30 April 2009 44 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