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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. 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

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  1. Performance Based Design for Fleet Affordability ASNE Day 2009 April 9, 2009 Session 7 Joe Famme ITE Chuck Gallagher NGS Ted Raitch ITE

  2. Agenda • Affordability Imperative • Performance Tools for Design & HSI • The Road to Integrated CAD-Physics tools for Design & HSI • Examples in Design and HSI • Summary

  3. 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

  4. 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)

  5. 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

  6. 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

  7. 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,

  8. 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

  9. The Road to Performance Based Design Tools

  10. 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

  11. 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

  12. NSRP 2001, 2002. 2003 SIMSMART™ Key Enabling Technology: XML Electronic Data Integration CAD to Physics Modeling SIMSMART™ Performance Metrics Run-Time Data Trend ...

  13. 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

  14. 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

  15. 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

  16. 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

  17. 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

  18. 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

  19. 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

  20. 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

  21. 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

  22. TPTS Instructor Station (1)

  23. 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

  24. 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

  25. Post-NAVSEA SBIR: ANZAC Frigate M&S Model

  26. 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

  27. Likely Savings from Performance Based Design Table 3 PBDC Lifecycle Savings 30 Ship in Class Table 2 PBDC Savings First Ship in Class

  28. 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?

  29. 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

  30. End ASNE Day 2009 “Performance Based Design Continuum”

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  32. 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

  33. 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

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