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Sheet Metal Modernization ManTech Project No. S2702

Learn about the project to optimize and modernize the sheet metal shop at General Dynamics. Discover the goals, objectives, and progression of the project through its phases and tasks.

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Sheet Metal Modernization ManTech Project No. S2702

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  1. Sheet Metal ModernizationManTech Project No. S2702 March 12-14, 2019 Charleston, SC DCN# 43-4995-19 Prepared under ONR Contract N00014-14-D-0377 as part of the Navy ManTech Program DISTRIBUTION A.  Approved for public release: distribution unlimited.

  2. Agenda • Project Team • Goals & Objectives • Estimated Cost, Savings & ROI • Statement of Work • Phase 1 Accomplishments • Phase 2 Work in Progress • Next Steps • Questions DISTRIBUTION A.  Approved for public release: distribution unlimited.

  3. ManTech Project Team DISTRIBUTION A.  Approved for public release: distribution unlimited.

  4. Project Goals and Objectives • Description of Task The rise in Virginia Class Submarine production rate, Virginia Payload Module construction, and upcoming Columbia Class construction is significant. This will increase required volume of production for the sheet metal shop at General dynamics, Electric Boat in Quonset Point. If this higher production need is not addressed, the risk is high that sheet metal shop production will cause future delays in the overall shipbuilding schedule. The 10-year-old sheet metal shop must be evaluated and modernized. Initially, the sheet metal fabrication process can be streamlined with implementation of automated manufacturing engineering tool(s) and the development of manufacturing product data from a 3D product model. The project also seeks to propose new shop configurations and new equipment that would benefit D902. • Project Objective The objective of this project is to optimize the sheet metal shop in 3 ways: • Reduce touch time to generate Build Authority data • Improve and increase on shop floor efficiency • Insert new machine/process technologies DISTRIBUTION A.  Approved for public release: distribution unlimited.

  5. Phase 1 (complete)Statement of Work Task 1Investigate and Map current processes in the Sheet Metal shop Research New Technologies Task 2 Research new technologies Task 3 Develop Future Requirements for shop Task 4 Develop Requirements for software tool Task 5 Develop proof of concept sheet metal software Application(s) Task 6 Identify and Implement Just-Go-Do-Its Task 7 Go/No-Go Decision DISTRIBUTION A.  Approved for public release: distribution unlimited.

  6. Phase 2 Statement of Work Task 8Design and Analyze Future State Shop Task 9 Develop Prototype Sheet Metal Software Application(s) Task 10 Test, Evaluate and Demonstrate Sheet Metal Software Application(s) Task 11 Develop Implementation Plan Task 12 Identify and Work Just-Go-Do-Its Task 13 Final Report with Updated Business Case DISTRIBUTION A.  Approved for public release: distribution unlimited.

  7. Phase 1 Task 1 • Current State Shop Issues Identified • Multiple Staging / Kitting areas (Red Boundaries) • Little room for Work In Progress (Blue Boundaries) • Process Flow direction is scattered DISTRIBUTION A.  Approved for public release: distribution unlimited.

  8. Process Flow model Current State Shop DISTRIBUTION A.  Approved for public release: distribution unlimited.

  9. Phase 1 Task 1 • Excel Capacity Model DISTRIBUTION A.  Approved for public release: distribution unlimited.

  10. Phase 1 Task 2 • Research new technologies • This task focused on identifying new technologies and equipment that will meet scheduled production demand increases. Two essential areas of shop operations and the core pieces of equipment used in each area were identified for review are as follows: • Cut Cell • Trumpf 6000L Punch Laser • Flow 6012 Water Jet • Metal Surface Preparation • Timesaver (Surface Graining) • Large volume sand blasting machine • Wheelabrator shot blasting machine DISTRIBUTION A.  Approved for public release: distribution unlimited.

  11. Phase 1 Task 2 • New and replacement Equipment • Adding increased capacity with additional Punch Laser cutting equipment (Trumpf 7000 Punch Laser) • Replacing Water Jet Cutting machine with increased efficiency equipment (Flow Mach 500) Trumpf 7000 Punch Laser Flow Mach 500 DISTRIBUTION A.  Approved for public release: distribution unlimited.

  12. Phase 1 Task 2 • Replacing Worn Surface Treatment equipment • Surface Graining • Large Volume Sand Blasting System • Shot Blasting Wheelabrator Shot Blast Machine Empire Air-Blast Cabinet Time Saver 4200 Dry Graining Machine DISTRIBUTION A.  Approved for public release: distribution unlimited.

  13. Phase 1 Task 3 • Develop Future Requirements for shop • Developed Product Families and assigned each to a dedicated “Zone” • Completed all Floor plan zone layouts • Compiled Current State data and Delivered Gap Analysis DISTRIBUTION A.  Approved for public release: distribution unlimited.

  14. Phase 1 Task 3 • Future State Shop, Initial Layout of Product Family Zones • Zone 1 Stowages • Zone 2 Consoles • Zone 3 Ventilation • Zone 4 Kitting • Zone 5 Blasting / Temporary Work • Zone 6 Cut Cell • Zone 7 Special Work • Zone 8 Nuclear and Walkways DISTRIBUTION A.  Approved for public release: distribution unlimited.

  15. Phase 1 Task 4 • Develop Requirements for software tool • Flat 3-D Solid Models: • Generate a flat, unbent, 3-D solid part model from bent sheet metal designs. • The flat solid part model will be included in work packages. • The flat solid part model will be exportable in iges and cgm formats. • Compatible With Magestic Nesting Software • Lofting and Nesting: • Provide direct numerical control (DNC) process for the Trumpf 6000L Laser/Punch and the Flow Master Water Jet plate cutting machines. • Product Manufacturing Information (PMI) and Views: • Assist/automate the generation of pre-defined model views with PMI within sheet metal product model in NX to support the development of Work Package Design Data (WPDD), work packages, and engineering analysis documentation. DISTRIBUTION A.  Approved for public release: distribution unlimited.

  16. Phase 1 Task 5 • Develop proof of concept sheet metal software application(s) • GDEB IT Began the development of manufacturing engineering software applications that met requirements set fourth in task4 • Objective was to complete demonstrable application(s) that did not focus on meeting specific user requirements, but confirmed the proposed software architecture and feasibility • User requirements will be evaluated in Phase 2, Task 9 DISTRIBUTION A.  Approved for public release: distribution unlimited.

  17. Phase 1 Task 5 • Proof of concept demonstration DISTRIBUTION A.  Approved for public release: distribution unlimited.

  18. Phase 1 Task 6 & 7 • Identify and Implement Just-Go-Its (Task 6) • The Jib boom crane motor that services the Water Jet machine was found to be inoperative • Motor replacement was researched and is awaiting disposition after the replacement of the existing Water Jet machine. • Go/No-Go Decision (Task 7) • Go decision granted 9/5/18 • Phase 1 Report submitted 9/5/18 DISTRIBUTION A.  Approved for public release: distribution unlimited.

  19. Phase 2 Task 8 • Design and Analyze Future State Shop • Using Zone concept layout produced in Phase 1 Task 1, Current State Shop is being Modeled and verified with D902 Supervision’s approval. • Additional fitting, welding and assembly capabilities added to each zone to accommodate expected work demand • Linear workflow applied to the greatest extent possible • Dedicated inspection and ship out areas for each zone DISTRIBUTION A.  Approved for public release: distribution unlimited.

  20. Future State Shop Layout DISTRIBUTION A.  Approved for public release: distribution unlimited.

  21. Phase 2 Task 8 • Linear Process Flow (Zone 1 Stowages) Surface Treatment Welding Stations Inspection & Ship Out Fitting/Assembly Assembly components from Kit Cell Machine work Work In Process/ if Req. DISTRIBUTION A.  Approved for public release: distribution unlimited.

  22. Phase 2 Task 9 • Develop Prototype Sheet Metal Software Application(s) • With user feedback and results of first iteration of software application; software development is underway. • Test, Evaluate and Demonstrate Sheet Metal Software Application(s) • Scheduled Start Date 3/25/19 • Develop Implementation Plan • Scheduled Start Date 6/3/19 Phase 2 Task 10 Phase 2 Task 11 DISTRIBUTION A.  Approved for public release: distribution unlimited.

  23. Phase 2 Task 12 • Identify and Work Just-Go-Do-Its • Kitting Cell Identified as a Just-Go-Do-It opportunity at the end of Phase 1 • Working with Penn State to gather in-depth requirements of each product family zones • A vendor that has worked with GDEB warehousing has been contacted for assistance • Floor space in the redesigned shop has been reserved for the new Kitting Cell DISTRIBUTION A.  Approved for public release: distribution unlimited.

  24. Next Steps • Continue the design of Future State Shop • Continue Software Development • Test, evaluate and demonstrate Sheet Metal Software Application(s) • Develop Implementation Plan • Continue pursuing and implement Just-Go-Do-Its • Final Report With Updated Business Case DISTRIBUTION A.  Approved for public release: distribution unlimited.

  25. Questions? David Eubank ManTech Coordinator General Dynamics, Electric Boat Corp. 401-268-1634 deubank@gdeb.com John Michael Iraci ManTech Program Manager General Dynamics, Electric Boat Corp. 860-867-3519 jiraci@gdeb.com Thomas Cooper ManTech Technical Lead General Dynamics, Electric Boat Corp. 401-268-3329 tcooper@gdeb.com

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