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Performance Based Design for Fleet Affordability. ASNE Day 2009 April 9, 2009 Session 7. Joe Famme ITE Chuck Gallagher NGS Ted Raitch ITE. Agenda. Affordability Imperative Performance Tools for Design & HSI The Road to Integrated CAD-Physics tools for Design & HSI

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performance based design for fleet affordability

Performance Based Design for Fleet Affordability

ASNE Day 2009

April 9, 2009

Session 7

Joe Famme ITE

Chuck Gallagher NGS

Ted Raitch ITE

agenda
Agenda
  • Affordability Imperative
  • Performance Tools for Design & HSI
  • The Road to Integrated CAD-Physics tools for Design & HSI
  • Examples in Design and HSI
  • Summary
omb gao cbo findings
OMB, GAO, CBO Findings

OMB disclosed in its 2004 Report on shipbuilding, the average over-cost of new ship classes is 30% and the major reason is release to production of premature designs. (Whitehouse 2004)

OMB

GAO : LPD-17 findings include … ship design incomplete before production causing cost over run & deficient systems (Report 05-183, 3/05) Also see INSURV MSG: PREINSURV Norfolk VA 181811Z July 05 LPD-17 Incomplete …

GAO

As Navy officials have stated, lead ships are often very difficult to build and typically have many problems in construction. The problems with the first littoral combat ships (for which costs doubled) and the lead ship of the LPD-17 class amphibious transport dock (for which costs increased by 80 percent and construction time more than doubled) illustrate the difficulties the Navy has encountered recently in constructing lead ships.16CBO March 2008

CBO

onr 2004 model should be the specification
ONR 2004: Model Should be the Specification

Guidance to reduce risk by ONR during the development of a Ship-Smart System Design (S3D) tool development project for IPS recommended that

“the model should become the specification.”

If a component cannot be modeled the shipyard should not buy it.

If a system cannot be modeled it is not understood sufficiently to release the design to production.

(Ericsen 2004)

affordability imperative panama city 10 08 sna symposium 1 09
Affordability ImperativePanama City 10/08 & SNA Symposium 1/09
  • Affordability = Biggest Challenge in Shipbuilding
  • Discussed Solutions:
    • Support steady-state production
    • Design for production
    • Requirements stability
    • Lifecycle tool to get full life from each hull
    • Reliability, maintainability, sustainability
    • Embedded Readiness Assessment and Training EOSS, OCC, EOCC
    • Need to know “age” of our ships
    • Design out excess margin
    • Commonality of Parts and Systems
    • Use the model as a specification
    • Produce a stable design in four dimensions
asne meeting navsea presentation december 2008 capt doerry opening thoughts
ASNE Meeting NAVSEA Presentation December 2008Capt Doerry Opening Thoughts
  • Decisions are made based on PREDICTED COST and PREDICTED PERFORMANCE …
  • PREDICTIONS HAVE UNCERTAINTY ….
  • RISK HAS A COST …
  • REQUIREMENT RISKS ARE REAL (AKA Market Risk)
    • Risk that the requirements you are designing / building to will change.
      • Not mitigating this risk can be expensive if the risk is realized late in design, in production, or in-service. (Extreme: retirement before design service life)
    • Preserving flexibility in design can reduce the cost of this risk.

Capt Doerry Approved for Public Release December 2008

navsea integrated design tools
NAVSEA: Integrated Design Tools

To this end, NAVSEA is developing a Ship Design Tools Roadmap and is collaborating with ONR and the Office of the Secretary of Defense OSD) High Performance Computing (HPC) Modernization Office on the Computational Research & Engineering for Acquisition & Tools Environment (CREATE) Ship Project.

There are a growing number of experienced ship design leaders who strongly believe that HPC is an enabling technology with significant benefits similar to those of 3-D CAD in the 1970's-80's: increased productivity of the knowledge workforce, reduced product development cycle times, and improved quality of the products. The vision of these experienced ship design leaders that is evolving is a highly integrated, physics-based analysis "design system“ where the technical specialist knowledge workforce concentrates on developing the physics-based analysis capabilities such that the design knowledge workforce can effectively execute the "design system" to develop more products that the customers want in shorter cycle times. As previously mentioned, we need to get the right people together with a vision of the future "design system", and get a shared vision and consensus on an approach to realizing the shared vision. The emphasis of the vision needs to be on the total ship and total ship design capability needs. (R. Keane, H. Fireman … “Ready to Design a Naval Ship? Prove It!”, SNAME, P19, 2008,

performance based design continuum has been developed over 14 years through navy funded programs
Performance Based Design Continuum has been developed over 14 years through Navy Funded Programs
  • Ship Design
    • Dynamic systems V&V in design phases to assure PERFORMANCE, REDUCE RISK, REDUCE COST AND SCHEDULE
    • Integrated CAD – PHYSICS TOOLS incorporating common parts and pre-validated systems to SAVE TIME, INCREASE ACCURACY and …
    • CAPTURE the INTELLECTUAL PROPERTY of the design for REUSE
  • Human Systems Integration
    • REUSES VALIDATED MODELS for:
    • Ship – Crew Model
    • V&V for Dock and Sea Trials & Live Fire Testing Models
    • Training Afloat Embedded and Ashore
    • Operational & Battle Decision Aids for Engineering & DC (DARPA PROA)
    • Distance Support
    • Modernization / ShipAlts
navsea use of physics based model design
NAVSEA Use of Physics-Based Model Design

In 1996 NAVSEA began using multi-discipline Physics Based Design (PBD) tools for HM&E process and control systems and to support ship design along with CAD as a core element of the Integrated Product Data Environment (IPDE):

  • The physics based design tool suites included:
    • Liquids
    • Gases
    • HVAC
    • AC/DC electrical generation and distribution
    • Logic and analog machinery control systems
    • Propulsion
  • CAD – Physics Integration:
    • 2001 – 2004 NAVSEA NSRP demo XML Integrated CAD - Physics
    • 2001 – 2009 DDG-1000 production API Integrated CAD - Physics
slide11

Overview of a Physics Based Model Design Tool

To create flow sheets just drag & drop the

desired equipment and control icons on

the screen from selected model libraries,

link them and enter their characteristics

slide12

NSRP 2001, 2002. 2003

SIMSMART™

Key Enabling Technology: XML

Electronic Data Integration CAD to Physics Modeling

SIMSMART™

Performance Metrics

Run-Time

Data Trend

...

slide13

Ship Firemain

Process Detail

A user may drill into any configured ship

process system to the smallest

level of detail for process engineering

Design and Training.

I/ITSEC Paper 1564 12/7/04

slide14

Ship Electric Plant

Process Detail

and then, navigate within the ancillary

process connections of the

multi-discipline SIMSMART™

environment.

I/ITSEC Paper 1564 12/7/04

slide15

Ship Compartments / Tanks

Ballast & Drain

Process Details

Ship compartments may be modeled forflooding and progressive flooding, fire and

smoke spread

The SIMSMART™ flooding model may be

linked to dynamic ship stability calculations

for draft, GM, etc...

I/ITSEC Paper 1564 12/7/04

slide16

Ship Design (New and Mod.) Using Dynamic Physics Models

to Validate & provide Metrics for Ship and Crew Performance

CAD

Total

Ship

Model

Integrated Product Data Environment (IPDE

slide17

The Domains of Single and Multi-Discipline Physics Based Design Tools

Domain of Multi-discipline Real-time Tools

Domain of Single Discipline Tools

  • Characteristics (Typical):
  • Models essentially custom built
  • Modeling SW does not come with Navy HM&E models
  • Usually non-real time
  • Usually single discipline: Electrical or Fluid or HVAC or Gas or …
  • Used for: sizing, transient / fault analysis, protective device settings …
  • Used for R&D, EDM development, Analysis
  • In general, do not interface to ship production CAD - CAM process (see notes)
  • Operating Doctrine / Human-in-Loop Performance Models
  • EOSS
  • EOCC
  • CSOSS
  • Human Task-Skill Actions: Time and Event based
  • HSI Support
  • Virtual Ship Model
  • Embedded Training
  • Manpower – Automation Analysis
  • Plant Performance Monitoring, Distance Support
  • Operational Decision Aids

Real-Time, Multi-discipline, Cascading Effects of HM&E operations & damage

Transition to

Smart Product Model /

Total Ship Model

when

Design Verified by

Engineering Analysis,

PE Certified

& Defined in CPC Format

Part Numbers

for Acquisition

Multi-Discipline

Total Ship Model

  • NAVSEA CPC Based Libraries & Multi-discipline for Total Ship Modeling:
  • Electrical
  • Fluid
  • Gas
  • HVAC
  • Controls

Smart

Product

Model

(CPC Based)

(PBD - CAD

By ship / class)

MATLAB™

SPICE™

EASY5™

Mentor Graphics™

RTDS™

VTB

CPC Compliant

Components

ROSE™

SIMSMART™ 2

ACSL™

Saber™

EASYPOWER™

EDSA™ 1

Ship Design / Production &

Lifecycle Support

PSCAD™

FLOWMASTER™

Ship / Class 2D/3D

CAD-Physics Dynamic V&V

1.EDSA is associated with CATIA for electrical design

2. SIMSMART supports systems engineering as well as total ship models using CPC parts with electronic data exchange with shipyard CAD-CAM systems.

Modeling Domains should be Complementary throughout the Design & Life Cycle Support Process

slide18

History and Applications

Performance Based Design for Fleet Affordability

Tools for

Dynamic Design

Program Mgmt

IV&V and HSI

Integrated Ship Design Tools

www.NSRP.org (Maritech)

Integrated Shipbuilding Environment

ONR Smart Ship System Design

Dynamic Validation

Ship

Systems & Model

  • The Ship
  • Real-time
  • Validated
  • Dynamic
  • Model
  • of theShip
  • CADDrawings
  • Update allconfigurationpartnumbersto theERP – TDKMIPDEPrograms

Deliver

To the

Navy

Lifecycle use

CAD - Physics

Model for HSI

Objectives of:

  • Shore & Afloat Dynamic Eng / DC & Total Ship
  • Training(BFTT)
  • Real-timeReadinessAssessmentship systems(ICAS)
  • Engineering &
  • DC OperationalDecisionAids
  • DistanceSupport
  • Future Ship
  • Modernization

Tests & Trials

  • Spiral
  • Design
  • Process IV&V
  • Conceptual
  • Preliminary
  • Contract
  • Program Control
  • Performance
  • Assessment
  • Automation
  • Reduced Crew
  • Survivability
  • Safety
  • DetailObjectives:
  • Delivera Full ShipPBD Modelto supportTests &Trials
  • T&Tusing the
  • PBD model
  • “Virtual
  • Ship”
  • Before &
  • During
  • Dock
  • Trials
  • All
  • Systems,
  • Separately
  • &
  • Together
  • Electrical
  • Fluid
  • Gas
  • HVAC
  • Controls
  • T&Tof the
  • “Actual
  • Ship”
  • Before &
  • During
  • Sea
  • Trials
  • All
  • Systems,
  • Separately
  • &
  • Together
  • Electrical
  • Fluid
  • Gas
  • HVAC
  • Controls

Common Parts Catalog

Integrated

CAD =

Design

“FITS”

PBD =

Design

‘WORKS”

  • XML or API Data Exchange
  • Create 4-D IPDE CAD-Physics
  • Smart Product Model

Assess Program METRICS & PERFORMANCE, Reduce RISK & COST

navsea leaps today
NAVSEA LEAPS Today

Physics Based Design Tools for Concurrent Dynamic V&V, Performance Model, Systems to Total Ship Level

CFX

RTS

IRENE

T

SDWE

FKS

T

VERES

ASSET 6 Surface/Sub

SMP

T

LEAPS Product Model

Version 4

LEAPS

Product Model

T

SVM/ASAP

T

CONTAM

GMULT/GCPL

T

CAD

T

STEP(214)

IGES

EMENG

RTC

T

  • Generic Class Structure
  • Product Model Schema
    • NAVSEA Ship Focus Object Model
  • Product Model Data

BAM

T

NCCM

T

SHIP AP’s

STEP(216)

STEP(215)

FORAN

M-OPT

T

TRIBON

OAR

T

Translator

T

SHCP

FASTSHIP

LEAPS

Editor

Presentation Manager

T

STEP/IGES

HLA Federate(s)

EXCEL

DOORS

Cogent

Existing

Beta Code

In Development

periodic dynamic performance collaboration

Total Ship Model

CAD & Physics by Deck

Periodic Dynamic Performance Collaboration

HM&E Component and Systems Designers – P&IDs …

LEAPS

TeamCenter

Environment

Periodic Dynamic V&V Performance Reviews System and Total Ship Every Phase / Step of Design

CAD: It Fits

Smart Product Model

Integrated CAD - Physics

Shipbuilder

Physics: It Works

NAVSEA Technical

CAD-Physics Combined Libraries

Will ship’s HM&E plant support ship & all missions / modules dynamically thru all scenarios?

PEO Ships

All Systems Work Together

slide21

NAVSEA SBIR 2000 – 2001 PMS430 – BFTT - Total Ship Training & Operational Decision Aids Architecture

Trainer

Trainer

Trainee

Trainee

BOPC

Scenario Generation

& Control

Debrief

Products

Performance

Monitoring,

Training &

Assessment

DATA COLLECTION LAN

STOW LAN

USN & Coalition Combat Systems Training

TPTS

Platform Simulation

IT21 SWAN & 2-Way Wireless LAN

IT21 LAN / SWAN

Two-way

Central Control Station (CCS), Damage Control Central (DCC),

Machinery Spaces, Repair Stations 2, 3, 5, 8, …

PERCIEVED TRUTH

MCS

GROUND TRUTH

Wearable Computers

DCAMS

Training Flags

Ground Truth

Perceived Truth

Perceived Truth

Ship Interior Communications

future shipboard training readiness assessment
Future Shipboard Training & Readiness Assessment

Navy DCAMS / DCTMS Wireless TSTS Demo Dec 2001

Army Embedded Sim-Center in a Box SBIR

6 to 12X PC, Signal, Mar. 2009

slide24

Application Across Training Continuum CNET 2007

(Revolution in Training and Task Force Excel Concept)

Performance and Debrief Products

- Can be printed out or downloaded to floppy

- Performance history, test scores, module completion status, etc. downloaded to floppy and imported into training database on arrival at ship

Total Ship Training System

  • LAN Based Training
  • Uses same models as CD-ROM and Total Ship Training System
  • Updates training database
  • Provides performance and debrief products

Enroute Training

Initial Qualification

Refresher Training

  • CD-ROM with Dynamic Engineering Models
  • Tailored to assigned ship
    • Actual system configurations
    • Actual EOSS, EOCC, EOP, CSOSS, etc.
  • Contains:
  • Computer Based Training Lessons
    • Cognitive Learning Principles Incorporated
  • Simulation Based Training Scenarios
    • Simulation Engine for interactive training

Accession Training

www.ITEinc.US

benefits of performance based design
Benefits of Performance Based Design
  • Anchor what you know
  • Share what you know
  • Standardize Systems in addition to parts
  • Let Systems “see” each other early in the design (electric – fluid …)
  • “Age” systems in different environments
  • Capture the design intellectual property electronically
likely savings from performance based design
Likely Savings from Performance Based Design

Table 3 PBDC Lifecycle Savings 30 Ship in Class

Table 2 PBDC Savings First Ship in Class

conclusions
Conclusions
  • … Navy and industry have not achieved a PERFORMANCE based ship design continuum because the focus is on the individual phases in design and lifecycle support and not the design and lifecycle phases of a ship as a holistic continuum.
  • … aggravated by different colors of money being used for shipbuilding, readiness and training.
  • … and lack of a top level policy that requires supporting operational systems and HSI metrics throughout the entire ship life cycle.
  • … will NAVSEA have the support necessary to bring ALL elements of the shipbuilding together including HSI / CNET training including the ship systems CAD & Performance (Physics) models into reusable repositories?
summary applications of performance based design
Summary: Applications of Performance Based Design
  • SECNAV – NAVSEA Shipbuilding Objectives:
      • Demonstrate dynamic “performance” during RDT&E and all design phases
        • System to total ship level
      • Demonstrate Mission and HSI Performance Requirements
      • Eliminate Risk
      • Reduce Costs
      • Model can be used as the specification
      • Model can be re-used for all HSI Lifecycle Support Applications
  • Mature tools: 20 year Performance Tools development to TLR-9
      • 14 years Support to NAVSEA, Shipbuilders and Marine Engineering Companies
        • Numerous ship design programs
      • API Integrated CAD – Performance V&V DDG 1000
      • XML Integration of CAD-Physics under NSRP - ASE Phase II:
        • CATIA, ShipConstructor, Intergraph, Simsmart
      • HSI Applications Demonstrated to the Total Ship Level:
        • NAVSEA SBIR Total Ship Model for Training (BFTT CS with HME&DC Model
  • Captures all physics models (basis of design) associated with CAD
      • Currently Builder delivers only drawings, none of the “performance”” (intellectual property)
  • ASNE-SNAME HSI Tech. Papers 2003-4: continuous IV&V / Ship-Crew Model
      • Recommended all designs use continuous IV&V
      • Resulting Validated Ship Model Supports the Full Ship Lifecycle
      • Training
      • Decision Aids
      • Modernization
      • Distance Support / SORTS
slide30

End

ASNE Day 2009

“Performance Based Design Continuum”

levels of definition for the design process reference model dprm

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Levels of Definition for the Design Process Reference Model (DPRM)

Distributive Systems Illustration

  • Gross level definition of system characteristics based on ship size or similar designs.

Parametric

  • System network layout and topology

The amount of data and detail increases as engineers work with smaller areas of the ship.

Schematic

Diagramatic

  • Schematic level information laid out in 3D ship space
  • 3D system layout and routing

Space Reservation

Distributive systems provide the utilities and infrastructure for the individual subsystems and equipment.

  • Maintenance Guides
  • Operational Manuals
  • Assembly drawings
  • Work packages

Assembly, Builders

Definition, Clearance

Full Component Breakdown, Maintenance Procedures

Capt Doerry Approved for Public Release December 2008

design process reference model
Design Process Reference Model

Based on Design Structure Matrix methods

Design Process Reference Model intended characteristics:

  • Model information development and flow during design
  • Model application of engineering labor during design
  • Granularity coarse enough for human comprehension (eg < 1000 elements) yet adequately fine to provide process insight

Design Process Reference Model intended use:

  • Capture current/historical process
  • Identify capability gaps
  • Use as design efforts planning aid for different future ship types
  • Estimate cost/benefit of design process improvement investments
  • Identify critical path for design development
  • Use as point of departure for alternate design strategies

Capt Doerry Approved for Public Release December 2008

asne meeting navsea presentation december 2008 capt doerry opening thoughts33
ASNE Meeting NAVSEA Presentation December 2008Capt Doerry Opening Thoughts
  • Decisions are made based on PREDICTED COST and PREDICTED PERFORMANCE
    • Ability to Predict is Important to making good decisions
    • Analysis is predicting performance of a design
    • If the cost model is not sensitive to an attribute, then making decisions on that attribute based on cost is not prudent.
  • PREDICTIONS HAVE UNCERTAINTY
    • Requirements, Acquisition Strategies, Systems Architectures and Design should account for this uncertainty
  • RISK HAS A COST
    • You can not generally reduce cost by “assuming” risk.
    • The cost of risk is what one would pay in insurance to cover the risk.
    • Risk Mitigation should have a Return on Investment (reduce cost of risk)
      • Cost of Risk Mitigation should be less than the reduction in the “insurance” payment.
      • Risk Mitigation must be aligned with design
  • REQUIREMENT RISKS ARE REAL (AKA Market Risk)
    • Risk that the requirements you are designing / building to will change.
      • Not mitigating this risk can be expensive if the risk is realized late in design, in production, or in-service. (Extreme: retirement before design service life)
    • Preserving flexibility in design can reduce the cost of this risk.

Capt Doerry Approved for Public Release December 2008