1. Sheet Metal Modernization ManTech Project No. S2702
March 12-14, 2019
Charleston, SC
DCN#
Prepared under ONR Contract N D-0377 as part of the Navy ManTech Program
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2. Agenda Project Team Goals & Objectives Estimated Cost, Savings & ROI
Statement of Work
Phase 1 Accomplishments
Phase 2 Work in Progress
Next Steps
Questions
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3. ManTech Project Team
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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
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5. Phase 1 (complete) Statement of Work
Task 1 Investigate 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
Task 1 Accomplished with an initial review and documentation of current shop floor layout and work flow and the identification of product families
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6. Phase 2 Statement of Work
Task 8 Design 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
Task 1 Accomplished with an initial review and documentation of current shop floor layout and work flow and the identification of product families
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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
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8. Process Flow model Current State Shop
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9. Phase 1 Task 1 Excel Capacity Model
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10. Phase 1 Task 2 Research new technologies Cut Cell
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
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11. Phase 1 Task 2 New and replacement Equipment Trumpf 7000 Punch Laser
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
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12. Time Saver 4200 Dry Graining Machine
Phase 1 Task 2
Replacing Worn Surface Treatment equipment
Surface Graining
Large Volume Sand Blasting System
Shot Blasting
Wheelabrator Shot Blast Machine
Time Saver 4200 Dry Graining Machine
Empire Air-Blast Cabinet
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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
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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
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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.
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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
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17. Phase 1 Task 5 Proof of concept demonstration
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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
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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
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20. Future State Shop Layout
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21. Assembly components from Kit Cell
Phase 2 Task 8
Linear Process Flow (Zone 1 Stowages)
Assembly components from Kit Cell
Surface Treatment
Fitting/Assembly
Machine work
Welding Stations
Inspection & Ship Out
Work In Process/ if Req.
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22. Phase 2 Task 9 Phase 2 Task 10 Phase 2 Task 11
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
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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
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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
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25. Questions? Thomas Cooper ManTech Technical Lead
General Dynamics, Electric Boat Corp.
David Eubank
ManTech Coordinator
General Dynamics, Electric Boat Corp.
John Michael Iraci
ManTech Program Manager
General Dynamics, Electric Boat Corp.