Technology Evaluation (RATE) Rapid Automation Technology Evaluation (RATE) March 12th – 14th, 2019 Charleston, SC DCN# 43-5060-19 Prepared under ONR Contract N00014-14-D-0377 as part of the Navy ManTech Program DISTRIBUTION A.  Approved for public release: distribution unlimited.

Rapid Automation Technology Evaluation (RATE) Northrop Grumman Corporation / Naval Shipbuilding & Advanced Manufacturing Center Rapid Automation Technology Evaluation (RATE) (New- Start Project) Nathan Meek Principal Mfg. Engineer Northrop Grumman NSRP All Panel March 2019

RATE Purpose Northrop Grumman Integrated Assembly Line (IAL) produces F35 Fuselage in Palmdale, CA Production Interval (PI) increase from 1.5 to 1.25 General Information: Project Number A2785 Funded by ONR, $2M Mantech Investment JSF Weapon System Challenges in improving machine and labor efficiencies Performing Entities: NSAM – Project Management / Technical Oversight iMAST – Technical Execution Northrop Grumman - Project Lead; Facility Support JPO – JSF Program Office Oversight Navy ManTech (ONR) – Program Oversight Significant demand for machine efficiency: Automated equipment produces large amounts of data that is under- utilized or discarded. Processing parameters and operational data from equipment can give insight into opportunities for increased performance.

Integrated Assembly Line (IAL) RATE will impact the IAL in Palmdale, CA The IAL produces the F35 Center Fuselage IAL is highly automated manufacturing line Project Objectives Identify Critical Automated Equipment Create Machine Network Establish Data Streams Develop Analytical Models to Support Operations Integrate with Manufacturing Operations Competing / Previous Development Efforts Maintenance Quality Efficiency A2656 - Assembly Metadata Integration NGC IRAD efforts

RATE Future Sheet Current Process RATE Process Nearly 4,000 hours were spent on unplanned events in 2017, 90% of which were considered reactive. Maintenance completed to OEM PM Machine Malfunction / Anomaly Normal Machine Operations Planned Downtime Normal Machine Operations Unplanned Downtime RATE Process Maintenance completed to OEM PM and RATE Recommendations Machine Malfunction / Anomaly Normal Machine Operations Normal Machine Operations Planned Downtime DISTRIBUTION A.  Approved for public release: distribution unlimited.

Integrated Project Structure and Team Implementation Team Primary PoCs: Bobby Mashburn ATI/NSAM Jeffery Banks iMAST / PSU Nathan Meek NGC Jason Bither NGC Project Oversight PoCs: RADM David Hahn ONR Paul Huang NSAM Jennifer Webb JPO

Targeted Project Goals 40% reduction in unplanned hours (both production and labor) would result in: 5-Year Savings = ~$13M* Total Savings over Life of Program = ~$45M* 80% reduction in unplanned hours (both production and labor) would result in: 5-Year Savings = ~$26M* Total Savings over Life of Program = ~$90M* *Assuming standard industry labor rates

Project Schedule and Tasks Phase I – Baseline Assessment and Concept Development (10 Months) Feb ‘19 May ‘19 Aug ‘19 Oct ‘19 Dec ‘19 Task 1: Baseline Assessment Task 2: Requirements Task 3: Concept Development Task 4: Design Architecture Task 5: Assessment Baseline Report Requirements Matrix RATE System Concept Rate Architecture Phase II – Development and Test Integrated Process (12 Months) Jan ‘20 Apr ‘20 Jul ‘20 Oct ‘20 Dec ‘20 Task 6: Develop System Task 7: Testing and Test Report Task 8: System Demo / Final Report Model Report A/R Test Report Final Report and Review 8 DISTRIBUTION A.  Approved for public release: distribution unlimited.

Accomplishments & Near-Term Activities Recent Accomplishments Established Integrated Project Team Feb 2019 Project Kickoff • Mar 2019 Immediate Action Items As-Is Process Map and Data Flow User Identification and Evaluation Concept of Operations Gap Analysis Establish Requirements

Rapid Automation Technology Evaluation (RATE) Thank you for your time and attention DISTRIBUTION A.  Approved for public release: distribution unlimited.

Appendix The following slides are included as reference.

Warfighter Benefits/Impact $2.2M Award in Q1 2019 Subject: Title Name Prior Yr FY 2019 FY 2020 Out Yrs AFP Predictive Demo Model Live Production Data - MRL 5 Predictive Production Models -MRL 6 Visibility Dashboards - MRL 7 Transition to Production Contract Dollars ($M) 2019 2020 Total Gov't Cost Share $.2M Industry Cost Share $0.1M $.1M MANTECH or SBIR Request $1.2M $1.0M $2.2M DoD Problem Warfighter Benefits/Impact Time Lot # 14 - AF324 Targeted Cut-In: 07/30/2020 Value Total Return Multiplier (TRM) = 18.4 Total Savings Potential = $45M The Integrated Assembly Line (IAL), a highly automated aircraft DoD assembly line, has several key pieces of automation producing major sections of the F-35 Center Fuselage that are required to predictably remain operational in order to ensure planned production schedules. Currently, critical maintenance operations are handled via supplier recommended PMs or as unanticipated break fix issues arise. This break fix approach cause delays to the production line are costly and can jeopardize delivery schedules. Sustainment Savings (2020-2075) Enable rapid manufacturing, dynamic response to product demands, and real- time optimization of manufacturing production and supply chain networks by networking machinery, sensors and control systems together; Predictive & prescriptive maintenance models will be created alongside real-time digital visibility boards. Approach Programmatic Develop Preventative Maintenance Capability to optimize IAL Establish Automated Data Stream on the IAL with existing assets and production data streams Develop and validate predictive maintenance models at industrial automation scale Supplement predictive maintenance models with after market sensors Transition to production Possible Team Members: PTC ManTech/SBIR’s/Sustainment: Capability and predictive models could be applied to other current Air Force, leveraged by other F-35 OEMs & potentially applied to reduce MTBF for F-35 Sustaining Operations Initial Implementation Sites: Northrop Grumman IAL. Opportunity to deploy to F-35 Composites Center & leverage capability to improve initial part quality DISTRIBUTION A.  Approved for public release: distribution unlimited.

Targeted Project Goals Parameter Baseline Value Requirement Threshold Value Requirement Objective Value How to Measure Date to be Achieved Achieve-ment Value Achieve-ment Date How Demonstrated Objective: Reduce Per Aircraft Production Hours Resulting from Unplanned Downtime of Key IAL Assets Production Hours (per aircraft) 178 hrs. per aircraft 108 hrs. (40% reduction) 35.6hrs (80% Time Studies of Production and Support Organizations Task 7 Testing TBD Comparison to baseline value and System Demonstration Objective: Reduce Unplanned Labor due to Non-Conformance Rework Labor Hours (per aircraft) 56 hours per aircraft 33.6 hrs. 11.2 hrs. Time Studies of Production and Support Organizations Comparison to baseline value and System Demonstration Exit Criteria: Demonstrate the Automation Prediction Monitoring and Visualization Through System Testing Transition Activity Requirement s Pass/Fail How to Measure Date to be Achieved How Demonstrated Successful Completion of Integrated System Testing Defined in the Test Plan In accordance with the Test Plan TBD – Subtask 7.3 Execution of the Test Plan