nsrp national shipbuilding research...

National Shipbuilding Research Program NSRP

2015 All Panel Meeting March 10-12, 2015

Charleston, SC

Richard McCreary Executive Control Board Chair

John Carney Affordability Initiatives Division and Navy ManTech Program

Navy ManTech Program Impacting Key Platform Affordability

John Carney Director, Affordability Initiatives and Navy ManTech (ONR 03T)

10 March 2015

Distribution Statement A: Approved for public release

• ONR ManTech Organization • Navy Manufacturing Portfolio (6.1-7.8) • Navy ManTech Investment Strategy • New CH-53K Affordability Initiative • Centers of Excellence – Execution Agents • Affordability Initiatives

• Focus on Transition / Implementation • Affordability Assessments • Planning

• Affordability Initiative Highlights • VIRGINIA Class Submarine (VCS) • Joint Strike Fighter (JSF)

Overview

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Program Director ManTech Portfolio Manager: - PEO (Carriers) - PEO (Ships) - PEO (LCS) - PEO (Subs) JDMTP Principal

John Carney ONR 03T

Director, Affordability Initiatives and Navy ManTech

Greg Woods Program Officer

Program Officer / COR: - iMAST - NMC JDMTP Metals Subpanel

Rich Henson Program Officer

Neil Graf Program Officer

Program Officer / COR: - CMTC - NSAM ManTech Portfolio Manager: - PEO (JSF) - JSF - PEO (A) - CH-53K JDMTP Composites Subpanel

Paul Huang Program Officer

Coordination with S&T AME Subject Matter Expert JDMTP AME Subpanel

Program Officer / COR: - EMPF - EOC JDMTP Electronics Subpanel

Angela Gray (On-site) ADS (SA)

Financial / Budgetary Support

ONR Detailee Contractor

Legend

Dr. Richard Fonda NRL

6.1 ManScience Program

Sarah Mitchell Bill Palko Lorie Lee (Off-site)

ADS / ADS Consultant

ManTech Contractor Support

ONR ManTech Organization

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Vision: Integrated approach from S&T basic research through industrial base preparedness (6.1 through 7.8) to address manufacturing and affordability in manufacturing for DoN systems

Navy Manufacturing Portfolio

6.1 – Manufacturing Science Novel manufacturing technologies and control methods to produce critical new and replacement parts on-demand

– Cyber-Enabled Manufacturing Systems for Direct Digital Manufacturing (CeMS-DDM)

6.2 – Mfg Applied Research Scale-up and development of emerging manufacturing process innovations for product-related S&T programs (FNCs) to reduce cost of fielding new capabilities

– Azimuth and Inertial MEMS Disk Resonator Gyros

– Fuel Cell Producibility

6.3 - Mfg Technology S&T Acceleration of manufacturing technologies to reduce total ownership costs for DoN systems (higher risk than ManTech)

– Integrated Manufacturing of Submarine Composites

– Distortion Reduction for Additively Manufactured Electronic Chassis (SEWIP)

7.8 - Manufacturing Technology (ManTech) Affordability (acquisition and life-cycle) for 5 key naval acquisition platforms

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Transitioning to 6.3 in FY16


• Mission: – Development of novel manufacturing technologies and

control methods to produce critical new and replacement parts on-demand

• Funding: Approx. $1.0M/year

• Execution: BAA / Grant

• Current Focus: – Cyber-Enabled Manufacturing Systems for Direct Digital Manufacturing (CeMS-DDM)

• BAA Closed – Mar 2014 / Awards – Summer 2014 • Goal – development of the fundamental principles for CEMS-DDM to closely couple

computation and manufacturing – Enable prediction and control over manufacturing processes – Anticipate defect formation and initiate corrective actions in real-time

• POC: Dick Fonda

h f

Physical Model (dynamics)

Measurement Model

Observation Vector

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+ +

Z-1

Control Vector

Process Noise Vector Measurement Noise Vector

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uk

Xk+1

yk+1

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CeMS and Welding

6.1 – Manufacturing Science (ManSci)

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• Mission: – Scale up and development of emerging manufacturing process innovations for both future

platform affordability and to address manufacturing challenges inherent in product-related S&T programs to reduce cost of fielding new capabilities.


• Execution: ManTech COEs

• Current Projects: – Fuel Cell Producibility

• Goal – Address producibility requirements for system/components of UTC Aerospace Systems Fuel Cell

• Payoff – Significant cost avoidance as technology transitions into acquisition program in FY18-19 – Mfg Process Optimization of Azimuth and Inertial MEMs (AIM) Disk Resonator Gyros

• Goal – Optimize wafer processing / production of low cost high quality sensors for the Digital Magnetic Compass Silicon Disc Resonator Gyroscope (SiDRG)

• Payoff – Reduced component cost of a low SWaPC replacement

• POC: Paul Huang

6.2 – Manufacturing Applied Research (S&T)

Analysis of Fuel Cell Producibility for Long Endurance Undersea Vehicle Propulsion

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• Mission: – Acceleration of recently discovered manufacturing technologies to reduce acquisition and

ownership costs for DoN weapon systems (higher risk than ManTech)


• Execution: ManTech COEs

• Current Projects: 1. SiC High-Efficiency Power Switches Wafer Process Improvement (DDG-51 Flight III)

• Goal - Improve epi-layer growth and device manufacturing technology to increase yield • Payoff – Reduced cost and increased power density resulting in ship power increase

2. Fire Safe Resins (VCS/ORP) • Goal - Robust FST-safe material system/properties database for design of internal sub components • Payoff – Improved manufacturing efficiency and reduced cost for composite shipboard parts

3. Enabling Technologies for Integrated Mfg of Submarine Composites (VCS/ORP) • Goal - Repeatable manufacturing approaches and associated cost/weight impacts • Payoff – Acquisition/life-cycle cost reduction; applicable to surface ships/other defense systems

4. Distortion Mitigation for Additively Manufactured Electronic Chassis (SEWIP) • Goal - Rapid manufacture of reconfigurable, complex, monolithic aluminum electronics chassis • Payoff: Procurement cost, lead time, and part count reduction

• POCs: ONR Program Officers / COEs

6.3 – Manufacturing Technology Science and Technology (MS&T)

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• Mission: Industrial Preparedness – Development of enabling manufacturing technology -- new processes and equipment --

for implementation on DoD weapon system production lines

– DoD 4200.15 states investments should: • Transition emerging S&T results to acquisition programs • Improve industrial capabilities in production, maintenance, repair and industrial base

responsiveness • Advance manufacturing technology to reduce cost, improve performance, and

responsiveness

• Funding: Approximately $55M

• Execution: – Seven (7) Centers of Excellence (COEs)

• 6 Contracted, 1 Government

• POCs: ONR Program Officers / COEs

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7.8 – Manufacturing Technology (ManTech)

Transitioning to 6.3 (PE 0603680N) in FY16


• Addressing affordability (acquisition and life-cycle)

• Investment Strategy focused on largest DoN acquisition programs as determined by: Total acquisition funding Stage in acquisition cycle (remaining years of acquisition) Platform cost reduction goals Cost reduction potential for manufacturing

• Recent Changes Addition of CH-53K

PEO (LCS) LCS

ManTech - making a significant impact on affordability, highlighted by recent implementations and cost savings

ManTech Investment Strategy

PEO (Subs) VIRGINIA ORP

PEO (Carriers) CVN 78 Class

PEO (JSF) F-35

PEO (A) CH-53K

Affordability Initiatives

PEO (Ships) DDG 51 Class

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• Marine expeditionary heavy-lift assault transport of armored vehicles, equipment and personnel

- Triples external load carrying capacity of predecessor

- Fully shipboard compatible and operable from austere/remote forward bases

• Rationale for ManTech Investment:

- Production: 200 aircraft - Manufacturing lessons learned with desired improvements identified - Timing right to impact early manufacturing phase and FRP

• Status: - Working closely with PMA-261 and Sikorsky/subs to identify critical

manufacturing issues - Some late FY15 project starts likely

New CH-53K Affordability Initiative

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Centers of Excellence • Executed through Centers of Excellence (COEs)

– Execute projects; manage project teams – Collaborate with acquisition program offices / industry to identify and resolve mfg issues – Develop and demo mfg technology solutions for identified Navy requirements – Facilitate transfer of developed technologies

• CNST NSAM Center – Recompeted Summer 2014 with expanded mission; now includes aircraft assembly

and fabrication

Electronics Manufacturing Productivity Facility (EMPF) Operated by American Competitiveness Institute (ACI) Philadelphia, PA

Institute for Manufacturing and Sustainment Technologies (IMAST) Penn State University State College, PA

Navy Metalworking Center (NMC) Operated by Concurrent Technologies Corporation (CTC) Johnstown, PA

Electro-Optics Center (EOC) Operated by Penn State Univ Kittanning, PA

Composites Manufacturing Technology Center (CMTC) Operated by South Carolina Research Institute (SCRA) Anderson, SC

COE Legend Contracted Government

Naval Shipbuilding and Advanced Manufacturing (NSAM) Center Operated by South Carolina Research Institute (SCRA) Charleston, SC

Energetics Manufacturing Technology Center (EMTC) Naval Surface Warfare Center – Indian Head (NSWC-IH) Indian Head, MD

(Recent Award)

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• Composites (CMTC) – – Automated Fiber Placement – Out of Autoclave Composites – Thick-Walled Composites – Vacuum Assisted Resin Transfer Molding – Controlled Volume Molding for High Temp

Composites – Manufacturing Automation for Polymer Composites – Composites for Very Large Format Radomes

• Shipbuilding / Advanced Mfg (NSAM Center) – – Shipbuilding Technology – Process / Fabrication Optimization – Digital Work Instructions – Modeling – Spatial Scheduling – Inspection Technology

• Metalworking (NMC) – – Simulation & Modeling – Materials Processing and Fabrication – Near Net Shape Fabrication (including DDM) – Surface Treatment

• Institute of Mfg & Sustainment Tech (iMAST / REPTECH) –

– Laser Processing – Materials and Composites Processing – Manufacturing Systems – Systems and Operations Automation – Sustainment / Repair Technologies

• Energetics (EMTC) – – Propellants – Munitions

• Electronics (EMPF) – – Automated Packaging – RF Technology – Wide Band Gap Technology – Environmental

• Electro-Optics (EOC) – – Focal Plane Array & Sensor Technology – Fiber Optics & Photonics – Carbon Based Electronics – Window and Dome Technology – Lasers and Laser Weapon Systems

Greg Woods – Prog Officer

Neil Graf – Prog Officer

Rich Henson – Prog Officer

Chuck Painter NSWC – Indian Head

Centers of Excellence – Core Compentencies

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Affordability Initiatives Focus on Transition / Implementation

• Navy ManTech definitions – Transition - - Denotes point at which … the technology meets customer (Program Office /

industry) criteria / goals for implementation, and the technology is transitioned to industry partner

– Implementation -- Denotes the actual use on the factory floor of ManTech results • Realization that ManTech, alone, cannot ensure implementation

• Technology Transition Plans (TTPs) for each project – Upfront agreement by all parties as to required actions / responsibilities from technology development

through implementation (includes required resources for implementation) – Signed by Navy ManTech, COE Director, Industrial Facility Management, Program Office, and, if

appropriate, Technical Warrant Holder

• Implementation Risk Assessment / Management Process – Recognize risks to implementation upfront and assess / manage through project execution – Risks discussed during Program Reviews to ensure ManTech on same page as acquisition / industry

stakeholders

• IPT for each Affordability Initiative – Reps from Navy ManTech, the platform Program Office, and industry – Conduct Program Reviews to coordinate and review portfolio: progress of projects and continued

likelihood of transition / implementation • Joint Program Review (all platforms) held once annually (Jun timeframe) for cross-pollination

ManTech goal is implementation, not just transition 13


Affordability Initiatives Affordability Assessments

• Affordability Assessments – Have acquisition Program Office-approved process / metrics for assessing cost

savings of current ManTech portfolio – Assess both acquisition and life-cycle savings semi-annually – Aug 2014 update (shown) / Feb 2015 update in progress

Acquisition Cost Reduction - Aug 2014 Affordability Assessment

Platform

Navy Investment

($M)

EROM Cost Reduction

per Hull or Aircraft ($M)

Probable EROM Cost Reduction

per Hull or Aircraft ($M)

CVN 78 Class Carriers $32.0 $51.1 $15.6DDG Family (1) $86.6 $53.6 $25.8VIRGINIA Class Submarine (VCS) $69.4 $47.8 $36.5Littoral Combat Ship (LCS) $50.4 $7.0 $3.4Joint Strike Fighter (JSF) $18.2 $0.7 $0.3NOTE: (1) Includes DDG 51 and DDG 1000 Classes

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1 ManTech Investment Strategy Guidance Jul 20142 Industry/COE Discussions & Idea Generation Aug–Dec 20143 ManTech Program Office Approval Mtg Dec 20144 Program Office Prioritization and Approval Jan–Feb 20155 Approved Prioritized Plan per Platform Mar–Apr 20156 Project Proposal Phase Apr–Jul 20157 Proposal Review / Approval Jul–Aug 20158 Project Initiation Oct 2015

FY16 Planning Cycle

• Annual Planning Cycle – as shown

• Top level questions for candidate projects - – Does it support one of 5 Affordability

Initiatives? – Is it ManTech? – Is it a process change or a design change

project (much riskier)? – Overall cost savings/hull (or cost

savings/aircraft) – ROI

• At ManTech P.O. Approval Meeting

(in December), use ManTech’s Implementation Risk Assessment and Management Process to rank candidate projects

1 Technical Risk2 Design Change Required?3 PO/TWH Approval Required?4 Major Milestone or Go/No Go Decisions5 Certification Required?6 Capital Equipment Funding Required?7 Outside Implementation Funding Required?8 Business Case (Cost Savings and ROI)9 Insertion Schedule (Compatibility)?10 Technology / Product Maturity11 Commercialization Partner Required?12 Industry / Prog Office / Navy Resistance to Change?13 Industry Partner Commitment / Implementation History

Implementation Risk Assessment / Management - Planning

Affordability Initiatives Planning

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VIRGINIA Class Submarine (VCS) and

Joint Strike Fighter (JSF) Affordability Initiatives

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VIRGINIA Class Submarine Affordability Initiative

On track to save nearly $500M with current portfolio of approx. $69M • Projected acquisition savings: $36.5M/hull

– Cost savings to date: $32.4M/hull – 36 implemented projects per Electric Boat (8/2014)

• Projected class maintenance/repair cost savings: $100+M

Won 2013 DOD Value Engineering Achievement Award • Letter of appreciation from HON Frank Kendall, USD (AT&L) – Jun 2014 • Presented to ONR ManTech, VCS Production Cost Reduction Team

(PMS 450), and Electric Boat – Oct 2014

Annual Navy ManTech Budget returned with yearly VCS cost savings of >$60M

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$/Hull • Product Centric - Digital Data System Implementation $0.54M • Product Centric - One-Stop $0.25M • Reduced Cost Impeller $0.27M • Low Cost Composite Sail Cusp $0.05M • Laser Image Projection $0.53M • Composite Manufacturing Technology for Marine Impeller $0.40M • Composite MBT Flood Grates $0.40M • VCS Material Management $5.40M • DfP Process Improvement $3.60M • Arc-Cladding Workcell for Submarine Mfg $0.23M • Small Weldment Optimized Cell $0.40M • Metrology Tools for Automated Hull Layout $0.48M • Outfitting Process Improvements $5.00M • Installation of Composite Bow Access Covers $0.01M • Sheet Metal Processes Affordability Improvements $0.09M • Large Diameter Pipe Process Improvement $0.33M • Steel Casting Optimization $0.22M • Structural Fabrication Welding Improvement $0.10M • Pipe Shop Reengineering $1.20M • Material Risk Management Process $0.05M • Efficient Environmental Controls for Painting Environments $0.41M • Pipe Preparation Methods $0.58M • Web Based Welding $0.98M • Outfit Processing Sequencing and Scheduling $0.75M • Improved Production Engineering Management Tools $0.68M • VCS Supply Chain Improvements $2.05M • Composite LWWAA Support Plates $0.22M • Automated Fiber Optics Link Test and Evaluation $0.06M • VCS Shipyard Material Flow Processes and Technology $1.55M • Lead Installation Process Improvement $0.33M • Alternate Damping Material Application $0.72M • Optimized Blasting $0.29M • SHT Bond Detector $0.35M • Pipe Assembly Installation Improvement Methods $0.60M • VCS Outfitting Tooling and Processing $0.74M • Improved Welder Productivity $2.50M TOTAL: $32.36M/hull

36 projects implemented Total cost savings > $32M/hull

(GD Electric Boat Spreadsheet - Aug 2014)

VCS Implementations Recognized Cost Savings/Hull to Date

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VCS Project Highlight VCS Robotic Interim Products

Goal: • Reduce welding costs for part family and interim

product and major product assemblies by increasing the number of joints that can be welded using robotics

• Targeting 30% reduction in weld hours

Warfighter Impact / Payoff: • Total Cost Savings: $500K/hull

Implementation: • Electric Boat – Quonset Point – implementation targeted for Fall 2015

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NAVY

Goal: • Develop composites technology for doubly-curved steel VCS sail sections to

reduce acquisition and maintenance costs - Current sections difficult to fabricate and corrode frequently in harsh underwater

environment.

Warfighter Impact / Payoff: • Total Cost Savings: $3.5M/hull total

- $1.8M/hull acquisition / $1.7M/hull maintenance

Implementation: • Implemented VCS 2014 / anticipated implementation on ORP

VCS Project Highlight Composites for VCS Submarine Sail

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Joint Strike Fighter Affordability Initiative

• Navy impact – projected $700M savings for DoD aircraft on $27M Navy investment

• Joint Navy, Air Force and OSD ManTech collaboration

Canopy Thermoforming Automation • $75-125M DoD savings on $1.4M investment

Automated Fiber Placement of BMI Materials • $100M+ DoD savings on $3M investment

Controlled Volume Molding (CVM) – • $20M+ DoD savings on <$200K investment

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The partnership between the F-35 Program Office and the Navy ManTech Office is producing real benefits that will improve affordability of near-term production units. We look forward to increasing our collaboration for continued improvements in acquisition and life-cycle affordability.

Amanda Gentry, F-35 Blueprint for Affordability and Science and Technology Lead, Oct 2014


• http://www.onr.navy.mil/en/Science-Technology/Directorates/Transition/Manufacturing-ManTech.aspx - Project Book (snapshot of all projects active during past FY) - Points of Contact Directory

• Navigation – www.onr.navy.mil; click on “03T Transition” under Directorates heading; and click on “Manufacturing Technology”

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Navy ManTech Web Site

http://www.onr.navy.mil/en/Science-Technology/Directorates/Transition/Manufacturing-ManTech.aspx

http://www.onr.navy.mil/en/Science-Technology/Directorates/Transition/Manufacturing-ManTech.aspx

http://www.onr.navy.mil/

RDML Thomas Kearney NAVSEA 06

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10 MARCH 2015 RDML TOM KEARNEY, NAVSEA 06,

ACQUISITION and COMMONALITY DIRECTORATE

NSRP ALL PANEL Meeting

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Structure that Supports Innovation

Value of NSRP Operations to Navy and Industry

• Decreased time to market for R&D project new technology

• Research projects are aimed at specific customer needs

• Open opportunities for not-for-profits, small business and universities identify innovations not previously captured

Benefits • Sharing of risk and cost for short and longer term research

• Solutions are mutually beneficial to shipbuilders and Navy.

NSRP continues to evolve and improve synergy between the Navy and the Shipbuilding Industry

$15 M

$30M annually

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Attacking Shipbuilding Challenges Program Specific to Industry-Wide

• Platform Specific Issues and Cost Drivers

• Manufacturing Innovation • Planning and Process

Improvement • Flexible Infrastructure • Commonality

• Excess Variation

NSRP mission is in direct alignment with the challenges shipbuilders and Navy program offices are facing today and specifically with NAVSEA Strategic Goals to

build an affordable Fleet.

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• A/C Plants: 36 Major Variants • Centrifugal Pumps (Surface

Ships): Fresh Water – 273 models with 56 Different

Suppliers Sea Water – 316 models with 35 Different Suppliers • Steering Control Systems (Surf) 25 Major Variants

Commonality TOC

Industry-Wide Cost Driver Variation in the Fleet

• Boat Davits (7M & 11M RHIBs): 22 Configurations (8 OEMs) (Just to handle RHIBs!) • Major C4I Systems (DDG): 42 Configurations of 8 Major Systems

• Machinery Control Systems (Surface Ships):

94 Unique VME Cards 24 Unique Workstations 18 Different UPS

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Circle of Acquisition: Government, Small Business

and Large Business

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Circus of Acquisition: Large Business

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Circus of Acquisition: Small Business

Approved for public release - distribution unlimited

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=&url=http://depositphotos.com/vector-images/unicycle.html&ei=0C3BVIWFN4mmNsnIgYgH&bvm=bv.83829542,d.eXY&psig=AFQjCNHzSwuE4KwlqmeujRyOe4apprO1Kw&ust=1422032721375393

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Circus of Acquisition: Government Requirements

Approved for public release - distribution unlimited

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.worldpolicy.org/journal/summer2013/snared-bureaucracy&ei=Xy_BVO_SIsHDggTo9oKwBA&bvm=bv.83829542,d.eXY&psig=AFQjCNGz6d_hv6uA1VUtx-c9Kuz8TLx_ZQ&ust=1422033090199129

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Improving Small Business Engagement

SEA 06 Applied Innovation for Affordability

Strong

Ties

Problem Weak Ties Between

Small Business And Government

Opportunity Ensure Government

Leadership knows that Open engagement with

Small Business is: -Allowed-

-Encouraged- -Valuable-

False sense of

legalistic rules prevents full engagement between Government and Small Business

Key to getting the most value from Small Business is to Increase Communications

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Take-Away

Continue to generate and renew interest in the NSRP mission • Industry

– Bring more projects in to compete for annual funding – Maximize project sponsorship by multiple shipbuilders – Follow through on implementation activities, including refinement of

ROI expectations – Revisit promising technologies not implemented from previous

projects

• Navy – Identify cost drivers at the program level that NSRP can attack – Follow through on implementation – Identify and attack “customer factors” that are cost drivers – Revisit promising technologies not implemented from previous

projects

National Shipbuilding Research Program NSRP

State of the Panels 2015 All Panel Meeting

March 10, 2015 Charleston, SC

Business Processes Virgel Smith

Ingalls Shipbuilding

Mission Statement To provide a collaborative industry forum that develops methods that will simplify and optimize business processes required to execute each phase of the ship lifecycle while improving sustainable, repeatable processes that will result in cost reductions and improved service to the customer.

Current Focus Areas • Evaluate tools, technologies, and

processes that focus on improving business practices throughout the industry.

• Target solutions that integrate innovative and efficient approaches for rapid implementation.

• Panel Projects • 0 awarded in FY2014 • 5 submitted to BP Panel for Voting for FY2015 • 4 submitted for ECB Funding Consideration for FY2015 • 2 awarded by ECB in FY2015

• Leveraging Detail Design Data in Weight Engineering Phase II – DRS (Project Kicked off in December 2014)

• Shared Manufacturing Drawing Qualifications Requirements – HII NN (Project in SCRA Contract Negotiations)

Current Panel Activities

• 2015 Business Process Panel Project • Leveraging Detail Design Data in Weight Engineering

Phase II – Lead by DRS Technologies, Inc. • Project Team – NAVSEA05, Austal USA, Marinette

Marine (MMC), VT Halter Marine (VTHM), General Dyamics NASSCO, Gibbs & Cox, Inc., BAS Engineering (BAS), and ShipConstructor Software USA, Inc.

• Project Technology Transfer Brief – BP Breakout Session – Thursday, 9:15 AM in Opal One


• 2015 Business Process Related RA Projects • Dynamic Change Awareness (DCA) – Lead by HII -

Ingalls Shipbuilding • Project Team – Austal USA, Bollinger Shipyards,

ShipConstructor Software USA, Inc. • Project Summary - Business Process Documentation

with System Architecture Development. • Project Technology Transfer Brief – BP Breakout Session

– Thursday, 10:30 AM in Opal One


• 2015 Spring Meeting – NSRP ALL Panel Meeting (Opal One) • BP Panel Whitepaper Project Proposal Topics for 2016

• Discussion @ 1:00 PM • Topics;

– Big Data Analytics – Business Integration Technologies – Navy’s 3D Virtual Environment

• 2015 Fall Meeting – Planning • Looking for co-located meeting with other panels

• West Coast - San Diego, CA (GD NASSCO) • East Coast – Newport New, VA (HII – NN) • In 2014, 2 Panel Meetings on Gulf Coast

Future Panel Activities

Questions?

Electrical Technologies Jason Farmer Ingalls Shipbuilding

Mission Statement Reduce the cost associated with the installation and operation of electrical systems in ship construction, maintenance, and modernization. Facilitate communications among Navy programs, electrical system integrators, ship designers, shipbuilders and other NSRP panels.

Current Focus Areas • Promote commonality (processes, products,

components, methods) across ship programs. • Evaluate electrical system technologies,

installation processes, and electrical system specifications. The panel's mission is to identify and implement technologies and processes that improve: • Total Ownership Cost • Energy Efficiency • Electrical System Performance • Safety of Workforce and Ship's Crew

Current Panel Activities • The Electrical Technologies Panel typically meets three

times per year • Panel meetings include:

• Review of active and recently completed projects • Discussion and brainstorming • Facility tours where available • New technologies applicable to the ETP focus area are

presented and discussed • Industry & Tech Transfer

• NSRP Day @ NAVSEA • SNAME/SPS

2014 Summary • Panel Meetings

• Spring Meeting (Philadelphia, PA) • DDG 1000 Test Site tour • L3/SPD Technologies tour

• Summer Meeting (Washington, DC) • Joint meeting with SWSI Panel

• Winter Meeting (New Orleans, LA) • International Workboat Show • Joint meeting with BP Panel • Tour of Bollinger

• Technology Transition Activities • NSRP Day @ NAVSEA • 2014 SNAME Maritime Convention

Bollinger Shipyard Tour

Panel Projects • Projects Recently Completed

• Low Voltage Quick Connector Evaluation

• Materials & Components for Exterior Electrical Connections

• Fiber Optics Installation and Acceptance Criteria

Low Voltage Quick Connector Evaluation Lead: Greg Stevens - BIW

Materials & Components for Exterior Electrical Connections Lead: Maurissa D’Angelo – D5T

• Next Panel Meeting will be Thursday at 9:00 (Emerald One) • Project Updates • Electrical Safety

• Summer meeting tentatively planned for June • Fiber Optics • Presentation of New Panel Project Topics

• Industry & Tech Transfer • NSRP All Panel Meeting Expo • NSRP Day @ NAVSEA • SNAME/SPS


Questions?

Environmental Pat Killeen

Signal International

Mission Statement Research, develop, and sustain current and emerging environmental technologies that will both enhance and assist the national shipbuilding and ship repair industry with the reduction of ship construction and repair costs to the U.S. Navy and other national security customers while ensuring compliance to federal, state, and local environmental regulatory requirements.

Current Focus Areas • Evaluate best practices to prevent

pollution and improve the overall environmental proficiency of the U.S. shipbuilding and ship repair industry.

• Provide a collaborative framework to improve shipbuilding-related technical and business processes in the environmental field.

Current Panel Activities • Develop a Data Management Application (Emissions

Tracker) to reduce Labor and Increase Accuracy in the Regulatory Reporting of Environmental Emissions

• Control Technology Comparison for Heavy Metals Removal from Shipyard Storm Water Runoff Both projects are now complete. The emissions tracker project is nearing a field/facility implementation and the field test of several types media, abating heavy metals contained within storm water, has delivered successful products

Future Panel Activities • Develop via panel brainstorming, opportunities for

‘environmental profitability’, i.e., how can a facility meet or exceed the regulatory requirements yet minimize or eliminate cost associated with the compliance with those requirements

• Ensure compliance with environmental laws and regulations

• Explore opportunities to reduce the logistic burdens and costs associated with shore-side offload and disposal of ship wastes

• Explore technological tooling for environmental emergency response

Questions?

Information Technologies Denny Moore

Electric Boat

Mission Statement The Information Technologies Panel addresses the collection, use, storage and exchange of data related to all aspects of the shipbuilding enterprise, including all business processes required to acquire and transform raw materials into a quality, optimal-cost product. The Information Technologies Panel provides a public forum for Research & Development teams to share ideas with their peers and support emerging technologies, and allows technologies to be easily transferred and implemented across the industry.

Current Focus Areas • Data Exchange / Interoperability / Intra-

Operability • Standards-Based Open Architecture • Shipyard Integration & Collaboration • Shipyard-NAVSEA Collaboration • Data Delivery • Electronic Work Packaging • Improving Shipyard Tools, Approaches,

and Processes with Information Technologies

• Two Joint Panel meetings with SDMT panel • San Antonio, April 2014-Highlights

• Introduction & Big Data • Augmented Reality • Independent NAVSEA review of 3D Product Model Technical Data • Navy 3D Virtual Environment Presentation • Product Model Driven Weld Management

• Mystic, October 2014- Highlights • Model Based Machining and Assembly • Ship Design in the Model Based Environment • Y-12 National Security Facility’s Knowledge Preservation & Management (KPM)

• IT Panel Chair participated in Bottom Up Review & participation at NSRP Day and SNAME SPS

• 1 RA completed, 4 Active; 1 PP completed, 0 active


• IT Panel Breakout 3/15- Highlights • CTC’s Innovation Pipeline • Enterprise Data Management using Semantic Technologies • Model Based Engineering • Workflow Tracking

• Panel Reorganization • Discussions started with Business Process Panel and other interested

parties


Questions?

Planning, Production Processes & Facilities

Ken Fast Electric Boat

Mission Statement

Discover and disseminate best practices related to the principal manufacturing processes, equipment, planning, and facilities required to support the fabrication, assembly, and testing phases of ship production.

Current Focus Areas • Improve the efficiency and quality of

constructing a ship, including: • Researching and evaluating advanced technologies,

tools and materials used during the ship production phase.

• Examining methods to optimize build strategies and improvements to facilities.

• Maximizing collaborative efforts with the Ship Design & Materials Panel to fully realize new technologies, tools and processes developed by both panels.

• Researching new and emerging technologies to reduce service and support costs.

• Seeking collaborative opportunities in welding, coatings and electrical technologies.

Current Panel Activities • Two very successful panel meetings in 2014

• Joint meeting in Mobile, AL • Business Processes, Workforce Development • Tour of Austal

• Solo meeting in San Diego, CA • Tour of SDSU, live padeye destructive testing

Current Panel Activities • Two Panel Projects in work during 2014

• Padeye Attachments • Validation of Analysis Methods for Padeye Attachment

Under Dynamic Loading Through Destructive Testing • Scaffolding Design

• Modular Scaffolding for Block Outfitting

Future Panel Activities • Two Panel Projects in work for 2015

• Mobile Welding Robot • Mobile Robotics to Increase Welder Productivity and

Weld Quality “Virtual Reality Control (VRC) Mobile Robot”

• Shoot Through Stud Templates • Use of Shoot Through Templates for Shot Studs in

Mounting Electrical Equipment

Future Panel Activities • Planning for two Panel Meetings in 2015

• Late summer • TBD

• November • Meet in conjunction with FabTech in Chicago, IL

Future Panel Activities • Strategic Objectives

• Continued emphasis on Facilities (PPP&F) • Motivation for Facilities R&D

• Overhead, non-value-added expense • Mostly non-competitive between shipyards • Aging infrastructure, limited footprint • New technologies offer new opportunities

– Energy efficiency, BIM, automation

Questions?

Risk Management Thresa Nelson

Newport News Shipbuilding

Mission Statement Provide open, interactive forum to explore/share best practices in accident prevention and workers’ compensation cost reduction. Promote technology transfer and broad industry interaction in support of the NSRP Mission.

Current Focus Areas • Promote research to develop or refine

processes, tools and programs to address safety, health and risk avoidance issues.

• Monitor and evaluate the impact of new regulations on the shipbuilding industry.

• Strive to reduce work-related injuries/illnesses and their associated costs.

Current Panel Activities • Regulatory Interfaces

• MACOSH Meeting, Feb 24-25 • OSHA-Maritime Alliance Implementation Meeting, Feb

10 • Panel Projects Completed

• Noise Control for Portable Vent Blowers • Analysis of Metals in Paint with XRF Technology

Future Panel Activities • Panel Projects

• NAVSEA 8010 Manual (Fire Prevention and Response) Impact Analysis and Best Practices

• Panel Meetings • June 24-25, New Orleans

• Panel Project Implementation • Best Practices Round Table • Work Hardening

• OSHA-Maritime Alliance – scheduled to be updated by May 2015 for a 5-year period.

Questions?

Ship Design & Materials Technologies

Alicia D’Aurora Newport News Shipbuilding

Mission Statement Major focus areas that map to the Ship Design and Material Technologies (SDMT) Panel are: • Promotion of Modular Construction • Reduction of Re-work • Improving Production Engineering • Improving Specifications and Standards • Improving Integration of Shipboard Warfare

Systems • Reduction of Total Ownership Costs

Current Focus Areas • In addition to the NSRP major focus areas, the SDMT

Panel will focus more specifically in the following areas: • Improving technologies in early ship design. • Improving integration of all shipboard systems and

undefined mission systems during design. • Improvement of design technologies, including design

and analysis tools, to reduce costs in production engineering and construction.

• Investigate material technologies to improve material performance, standardization, and overall material processes while reducing part count and total ownership costs during all phases of ship design and construction.

Current Focus Areas (cont.) • Reduction of re-work in all areas of ship design

and construction. • Improving specifications and standards and

investigating new technologies that can be incorporated into Rules or technical requirements documents for both commercial and naval shipbuilding programs.

• Collaborate and partner with other NSRP panels on topics and initiatives that encompass the other panel focus areas.

• 3 New Panel Projects Selected in September: • Implement Residual Mass DDAM • Development of an Alternative Low Cost False Deck • 3D Modeling Standard for OEM Suppliers of GFE

• 3 New Research & Development Projects: • Flexible Infrastructure Qualification • Swage Panel SVR Rule Development • Development & Application of Standard Hull,

Mechanical & Electrical (HM&E) Modules to Increase Flexibility in Ship Design Using DFA Principles


• Panel Meeting – July 2015 • Marinette, WI

• Panel Meeting – Nov/Dec 2015 • San Diego, CA


Questions?

Ship Warfare Systems Integration

Perry Haymon Ingalls Shipbuilding

Mission Statement Reduce the costs of integration and test for warfare systems in ship construction and maintenance/ modernization. Facilitate communications among Navy programs, warfare system integrators, ship designers, shipbuilders and other NSRP panels.

Current Focus Areas

• Promote standardization of physical interfaces between IWS GFE/CFE and shipboard spaces.

• Promote ship mission system infrastructure flexibility, modularity and scalability.

Current Panel Activities • Completed Projects

• Flexible Infrastructure Panel Project- Completed Aug. 2014

• Ongoing Panel Projects • Standardized Foundation- Expected completion Apr. 2015

• The objective of this project was to develop a database of pre-qualified foundations on Navy Ships.

• Ship Warfare Systems Interface Descriptions- Expected completion by April 2015

• The overall objective of this research was to develop an integrated shipbuilding database of interfaces and connectors so that a reduced set of common connectors can be established and provided to designers of shipboard systems.

Current Panel Activities • New Panel Projects awarded 2014

• Ship Specification Review to Identify Technical Gaps between FI and Requirements (NNS)

• This project will conduct a Ship Specification(s) review and identify where there are disconnects between the Flexible Infrastructure technology and the specifications for all Navy platforms that are being considered for FI.

• Optimization of Design/Manufacturing of Flexible Interface Adapters (NNS)

• This project will investigate the feasibility of designing Interface Adapters that can be used on multiple Navy platforms that employ the Flexible Infrastructure Deck Track system.

• Standardizing Warfare System Interfaces to Reduce Integration Costs (SFI)

• Identify and establish common physical, electrical and data interface definitions for current and projected combat system components and between those components and the ship HM&E and other infrastructure.

Future Panel Activities • Continue to focus on commonality • Identify opportunities to support the “Flexible Warship”

concept • Focus on increasing involvement from Combat System

Houses on the Panel • Determine if the results of SWSI Panel and RA projects are

beneficial • Increase collaboration with other panels

Questions?

Surface Preparation & Coatings

Arcino Quiero Jr. Newport News Shipbuilding

Mission Statement Research, evaluate, develop, and sustain current and emerging technologies that will reduce cost and maintain or enhance quality for coatings and corrosion control of new construction shipbuilding and repair of U. S. Navy and commercial ships.

Engage the suppliers, applicators, and specifiers of preservation systems to improve processes, reduce costs, and streamline production to deliver ship’s that satisfy customer life-cycle requirements.

Facilitate panels meetings to encourage broad participation by including; meetings collocated with member facilities; meetings coincident with other conferences/seminars attended by members; and provide video teleconferencing.

Current Focus Areas • Reduce preservation process cost while maintaining or

enhancing quality. • Maintain a teaming relationship with NAVSEA 05 (Tech

Warrant Holder) & NAVSEA 04 (Public Shipyards, Regional Maintenance Centers and local Supervisors of Shipbuilding).

• Focus on ship preservation: surface preparation, coatings and corrosion control technologies

• Focus on processes, work-practices, and “people” to streamline preservation work.

• Partner with the Work Force Development Panel on whitepaper projects so that a successful implementation strategy is always one of the deliverables.

• Create an alliance to establish continuous process improvement in the IMO PSPC with our global coating community partners.

Current Panel Activities • Current Projects

• Robust Functional Paperless Paint- Phase II • Reducing Inspection Costs Using the Latest Digital

Inspection Tools • Cost Savings Comparison in Application of Polysiloxane vs.

Silicone Alkyd Topcoats • Other Activities

• The Society of Protective Coatings (SSPC) • Mega Rust • Society of Naval Architects and Marine Engineers (SNAME)

Future Panel Activities • 2015 Projects:

• Universal Primer and Surface Preparation Process • Partial Blast of Ultra High Solids Coated Tanks • Alternative Corrosion Methods for Inaccessible Void

Spaces

Keys to Success • Technical Warrant Holder (TWH) Active and Consistent

Involvement • Echoed in the Bottom Up Review

• Engaged Coatings Community • Suppliers • Applicators • Specifiers

• Challenge and Effect Requirements NAVSEA SI 009-32 Review Process

• Industry rate of acceptance equivalent to the Government

Questions?

Welding Technology Lee Kvidahl

Ingalls Shipbuilding

Mission Statement The NSRP Welding Technology panel scope is: • Welding and other material joining

technologies. • Inspection methods that may be used to

determine the acceptance of a weld. • Pre/post welding process technologies (i.e.

PWHT and other processes).

Current Focus Areas • Investigate technology to improve welding productivity. • Investigate technology to improve welding quality. • Research in reducing distortion and residual stress. • Technology for weld processes. • Technology for welding procedures. • Technology for welding equipment, power sources, end effectors,

and delivery mechanisms. • Technology for welding inspection. • Development of welding filler materials and gases. • Research for base material developments for welding efficiency,

plate, pipe, castings, forgings). • Software for weld data collection, weld

processes, weld procedures.

Current Focus Areas (cont.) • Tools and fixtures for both material preparation, fitting and welding. • Research in design details for adequate ship performance and weld

producibility. • Support new technology for ship hull construction and pipe systems. • Robotic applications for ship construction. • Support all welding technology that might eventually lead to a future

development even though there is no immediate application. • Guidance for welding engineering development. • Guidance for welder training for production. • Research methods to reduce rework. • Investigate process limitations and capabilities.

Current Panel Activities • Welding Technology Panel meets twice each year • Excellent technical agendas including welding,

inspection, materials, processes • Each meeting includes a industry tour • Several panel projects completed during past year • Notably the Training Program for Thin Steel

• Addresses a need not previously available • Showing returns following implementation at Ingalls

Shipbuilding

Future Panel Activities • Continue two meeting each year • Developing technologies to enhance shipyard welding

programs • Several new projects now underway including

development of filler materials, welding of challenging materials and avoidance of cracking in castings

• Facilitate shipyard implementation of technologies with open communication to assist each other in identification and removing obstacles

Questions?

Workforce Development Anna Bourdais Ingalls Shipbuilding

Mission Statement Reduce the cost of shipbuilding through effective projects centered on training and development, human resources, change management and technology transfer. Ensure that all NSRP panel projects reflect a consideration of issues regarding project implementation, especially around human interactions.

Current Focus Areas

• Workforce of the future.

• Collaboration with other NSRP panels and other organizations.

• Facilitating technology transfer.

Current Panel Activities • 2014 Panel Projects Submitted:

• Development of Project-based Shipbuilding Curriculum using Siemens PLM Software

• Workforce Assessment of Aging Workforce Workers • Workforce Assessment of Aging Workforce Supervisors • Identify Effective and Efficient Structured, Formalized

Mentorship Guidelines

Future Panel Activities • Workforce of the future. • Collaboration with other NSRP panels and other

organizations. • Facilitating technology transfer.

Questions?

• Lunch will be right outside

Thank You!

Adjourn General Session Lunch & Project Expo

nsrp national shipbuilding research...

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