Performance Based Design

Transcript Performance Based Design

Performance Based Design for Fleet Affordability

ASNE Day 2009 April 9, 2009 Session 7 Joe Famme Chuck Gallagher Ted Raitch ITE NGS ITE

Agenda

1. Affordability Imperative 2. Performance Tools for Design & HSI 3. The Road to Integrated CAD-Physics tools for Design & HSI 4. Examples in Design and HSI 5. Summary 2

OMB GAO CBO

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) 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 … 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.

16 CBO March 2008 3

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) 4

Affordability Imperative Panama 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 5

ASNE Meeting NAVSEA Presentation December 2008 Capt 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 6

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, 7

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 8

The Road to Performance Based Design Tools

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 10

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 11

NSRP 2001, 2002. 2003

SIMSMART™

Key Enabling Technology: XML Electronic Data Integration CAD to Physics Modeling

SIMSMART™ Performance Metrics

Run-Time Data Trend

...

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 13

Ship Electric Plant Process Detail

I/ITSEC Paper 1564 12/7/04 and then, navigate within the ancillary process connections of the multi discipline SIMSMART™ environment.

Ship Compartments / Tanks Ballast & Drain Process Details

Ship compartments may be modeled for flooding 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 15

CAD Ship Design (New and Mod.) Using Dynamic Physics Models to Validate & provide Metrics for Ship and Crew Performance

Total Ship Model

Integrated Product Data Environment (IPDE 16

The Domains of Single and Multi-Discipline Physics Based Design Tools Domain of Single Discipline Tools Domain of Multi-discipline Real-time 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)

HSI Support

•Virtual Ship Model •Embedded Training •Manpower – Automation Analysis •Plant Performance Monitoring, Distance Support •Operational Decision Aids

Multi-Discipline Total Ship Model Operating Doctrine / Human-in-Loop Performance Models

•EOSS •EOCC •CSOSS •Human Task-Skill Actions: Time and Event based

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

MATLAB ™ ROSE ™ ACSL ™ EASY5 ™ Mentor Graphics ™ Saber ™ RTDS ™ SPICE ™ VTB SIMSMART ™ 2 EASYPOWER ™ Transition to Smart Product Model / Total Ship Model when Design Verified by Engineering Analysis, PE Certified & Defined in CPC Format Part Numbers for Acquisition

Smart Product Model

(CPC Based) (PBD - CAD By ship / class) CPC Compliant Components

NAVSEA CPC Based Libraries & Multi discipline for Total Ship Modeling

: •Electrical •Fluid •Gas •HVAC •Controls EDSA ™ 1 PSCAD ™ FLOWMASTER ™ 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.

Ship / Class 2D/3D CAD-Physics Dynamic V&V

Ship Design / Production & Lifecycle Support

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

History and Applications Performance Based Design for Fleet Affordability Integrated Ship Design Tools www.NSRP.org (Maritech) Integrated Shipbuilding Environment ONR Smart Ship System Design Common Parts Catalog

CAD = Design “FITS” Integrated PBD = Design ‘WORKS”

• •

XML or API Data Exchange

•

Create 4-D IPDE CAD-Physics Smart Product Model Tools for Dynamic Design Program Mgmt IV&V and HSI Spiral

•

Design Process IV&V

Conceptual

•

Preliminary

•

Contract

•

Program Control

•

Performance Assessment

•

Automation

•

Reduced Crew

•

Survivability

•

Safety

•

Detail

Objectives:

•

Deliver a Full Ship PBD Model to support Tests & Trials Dynamic Validation Ship Systems & Model Tests & Trials T&T using the PBD model “Virtual Ship”

Before &

During Dock Trials All Systems, Separately & Together

• •

Electrical

•

Fluid

•

Gas

•

HVAC Controls T&T of the “Actual Ship” Before & During Sea Trials All Systems, Separately & Together

• •

Electrical

•

Fluid

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Gas

•

HVAC Controls Deliver To the Navy

•

The Ship

•

Real-time Validated Dynamic Model of the Ship

•

CAD Drawings

•

Update all configuration part numbers to the ERP – TDKM IPDE Programs Lifecycle use CAD - Physics Model for HSI Objectives of:

•

Shore & Afloat Dynamic Eng / DC & Total Ship Training (BFTT)

•

Real-time Readiness Assessment ship systems (ICAS)

•

Engineering & DC Operational Decision Aids

•

Distance Support

•

Future Ship Modernization

Assess Program METRICS & PERFORMANCE, Reduce RISK & COST

NAVSEA LEAPS Today

T Physics Based Design Tools for Concurrent Dynamic V&V, Performance Model, Systems to Total Ship Level ASSET 6 Surface/Sub CAD T HLA Federate(s) STEP(214) IGES FORAN T SHIP AP’s TRIBON FASTSHIP T T STEP(216) STEP(215) T

• • –

Version 4

•

Generic Class Structure Product Model Schema NAVSEA Ship Focus Object Model Product Model Data Presentation Manager DOORS Cogent LEAPS Editor In Development Beta Code Existing STEP/IGES EXCEL CFX RTS IRENE T FKS SDWE T T T T T T M-OPT OAR SHCP SMP SVM/ASAP CONTAM EMENG NCCM VERES GMULT/GCPL RTC BAM T

Translator 19

Periodic Dynamic Performance Collaboration HM&E Component and Systems Designers – P&IDs … CAD: It Fits LEAPS TeamCenter Environment Smart Product Model Physics: It Works Integrated CAD - Physics Periodic Dynamic V&V Performance Reviews System and Total Ship Every Phase / Step of Design Shipbuilder NAVSEA Technical Will ship’s HM&E plant support ship & all missions / modules dynamically thru all scenarios?

CAD-Physics Combined Libraries Total Ship Model CAD & Physics by Deck All Systems Work Together PEO Ships

NAVSEA SBIR 2000 – 2001 PMS430 – BFTT - Total Ship Training & Operational Decision Aids Architecture Debrief Products P erformance M onitoring, T raining & A ssessment BOPC Scenario Generation & Control STOW LAN DATA COLLECTION LAN TPTS Platform Simulation USN & Coalition Combat Systems Training 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 Trainer DCAMS Trainee Wearable Computers Training Flags Perceived Truth Trainer Ground Truth Trainee Perceived Truth

Ship Interior Communications

TPTS Instructor Station (1)

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 23

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 Accession 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

24 www.ITEinc.US

Post-NAVSEA SBIR: ANZAC Frigate M&S Model

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 26

Likely Savings from Performance Based Design

Table 2 PBDC Savings First Ship in Class

Table 2 Design and Life Cycle Phases Non Recurring Cost Today First Ship Savings Using PBDC Percent and Value ($M) Ship Requirements Concept Design Preliminary Design Automation Design Contract Design Detail Design Construction First Ship V&V-Tests-Trials Live Fire Training Afloat Ashore Decision Aids Distance Support Modernization ShipAlts

Program Cost

Provided $95M $300M $25M $400M $900M $800M $85M $45M $20M $20M $200M $2,890M -25%/ ($24M) -25% = ($75M) -40% = ($10M) -10% = ($40M) -10% = ($90M) -5% = ($40M) -10% = ($9M -30% = ($14M) -50% = ($10M) -30% = ($6M) -30% = ($60M)

Savings = ($378M) Table 3 PBDC Lifecycle Savings 30 Ship in Class

Table 3. Design and Lifecycle Phases Projected Savings Reuse PBDC Models 30 Ships in Class over Life Cycle of 30 Years ($M) Ship Requirements Concept Design Preliminary Design Automation Design Updates - Full Reference Model Avail.

Contract Design Detail Design Construction Tests-Trials - Full reference Model Available as Performance Standard Training PBD models embedded for Eng-DC training reduces travel/time lost Decision Aids PBD models improve efficiency - support CSOSS-EOSS EOCC Distance Support PBD models support NAVSEA trouble repair for reduced crews Modernization ShipAlts - PBD Ref Models used to pre-validate modernization Savings per Ship 30 Yrs

Life Cycle Savings: 30 ships in Class

Given Complete Complete ($0.5M) Complete Complete Complete ($1M) ($30M) ($50M) ($60M) ($60M) ($202M)

Savings = ($6,060M)

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? 28

• • • • 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 29

End

ASNE Day 2009 “Performance Based Design Continuum ”

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

Distributive Systems Illustration

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

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

Schematic

-System network layout and topology

Diagramatic

-3D system layout and routing

Space Reservation

-Schematic level information laid out in 3D ship space -Assembly drawings -Work packages

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

-Maintenance Guides -Operational Manuals

Assembly, Builders Definition, Clearance Full Component Breakdown, Maintenance Procedures

Capt Doerry Approved for Public Release December 2008 31

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 32

• • • • ASNE Meeting NAVSEA Presentation December 2008 Capt 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.

Capt Doerry Approved for Public Release December 2008 33