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

2. 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

3. 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.

4. 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
A Assembly Metadata Integration
NGC IRAD efforts

5. 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.

6. 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

7. 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

8. 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.

9. 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

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

11. Appendix
The following slides are included as reference.

12. 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 ( )
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.

13. 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