3D TDPs for the DoD OR

Reduce Time by going drawing less with 3D PDF Strategies the Department of Defense is employing to meet new Military Standard MIL-STD-31000

Rich Eckenrode

3D MBD in Solidworks

PresenterPresentation NotesThis is Model Based Definition or MBD.

Agenda

Introduction Issues at DoD concerning TDPs MBE; A method for solving the problem MBE/MBD overview MBE data reuse in the product lifecycle. Future MBE Opportunities Solidworks examples

Rich Eckenrode, RECON Services

Spent 36+ years working in the MFG/MAINT environment.

Aircraft maintenance using technical manuals.

Machine shop all jobs from inspection, machinist to lead man.

CNC Programmer 24+ years using CAD/CAM tools CAD Designer Process Engineer Project Engineer Project Manager Small Business Owner, providing consulting services

Introduction

PresenterPresentation NotesIm not here looking for work, work I have. I want to share with you what is happening at the DoD with regard to 3D TDPs and the push that is on for going without 2D drawings.

My experience in the working environment started in the Air Force as an aircraft mechanic. It was here that the frustration of ambiguous technical documents first made their impression on me. Since then Ive used various Auto repair manuals that have left me less than happy.

After the Air Force I spent over 32 years working my way through the ranks as a machinist, Machine Shop Lead Man, CNC Programmer, Manufacturing Engineer and Project Manager.

After 31 years at BAE Systems, I left last year to become a service provider to the DoD in an effort to mentor their Design Engineers and Manufacturing Engineers in the use of CAD models in areas where they were previously not used.

DoD TDP Problems

TDPs incomplete A10 wing replacement

TDPs not able to satisfy modern manufacturing requirements. 50 CAL Machine gun parts procurement.

PresenterPresentation NotesIm going to touch on a couple of real world problems that were encountered at the DoD regarding TDPs which sometimes are acquired but most of the time not.

DoD TDP Problems

TDPs incomplete A10 wing replacement

PresenterPresentation NotesTell the A10 story; major cost per foot on re-design due to missing TDP. Redesign effort is being accomplished with the resulting TDP being 3D models and associated drawings . This effort is being spearheaded by the Air Force and Defense Logistics Agency.

When Product data is introduced to DoD CM is a big issue. (We dont do a good job of managing the data.)

DoD TDP Problems

TDPs not able to satisfy modern manufacturing and quality control requirements. 50 CAL Machine gun parts procurement.

John Browning circa 1919

PresenterPresentation NotesM2 Machine Gun: Currently Weapons platforms at the DoD are having lifecycles of 50, 90, >100 years. The integrity of older TDPs is starting to become an issue. Drawing standards have changed, Tolerances applied are being looked at differently, Quality assurance planning and practice has changed dramatically over just the last 20 years. Currently distance measurements are being validated using laser and time in the labs at the National Institute of standards and technology.

When trying to procure parts during the wars in Iraq and Afghanistan procurement activities were receiving No Bids on machine gun replacement parts. The issue was due to a 2D drawing package that was antiquated and ambiguous causing the potential suppliers to not risk bidding on parts they were not sure they could produce.

After updating the TDP to a modern 3D TDP the number of bidders for the parts rose significantly.

DoD TDP Problems

Drawings are expensive to create. Drawings are expensive to procure from OEMs. Drawings are especially expensive to maintain. Drawings are often somewhat ambiguous. Perhaps we could work without drawings and

leverage the CAD Models as the Authority for the product definition throughout the Product Lifecycle.

But Drawings are needed to communicate product

requirements. I love my drawings

PresenterPresentation NotesDrawing creation cost is sometimes estimated to be between 20% to as high as 40% of the design effort.

The procurement of Technical data is still going to be expensive

Drawing creation cost pales to the cost of maintaining drawings over the lifecycle of products.In a time not quite long gone we had departments where paper and Mylar media was stored and people watched over this stash of data.We also had micro-fiche with the associated viewer and print machines.Now we all store this data digitally and it costs us what? IT people to maintain the servers and disk arrays, all the hardware and software to make the files available to the folks who need access. Now that this is in place keep the data safe for Long Term Archival and Retrieval. This requires a following a plan that is constantly checking the storage media, data format, viewing/editing software and hardware.After you have all these procedures and hardware in place, now its time to start making revisions to the stored data.

Solving the Problem

Lets use the CAD Models, we can call it MBE/MBD

Lets go without drawings

Lets use 3D Product Definition

Lets reuse MBD Data

Lets make 3D PDFs

PresenterPresentation NotesIn my past I've worked on projects where we started to build product before the drawings were ready Using just Models. The issues are that just raw models do not communicate information that was traditionally found on drawings. We did a project where my boss had me send models to a supplier and I spent all day on the phone answering questions until the supplied had created drawings. This wasnt of much value because now there were drawings that we couldnt use because we were drawing less. During these kind of experiences I quickly came to realize that some kind of communication is required to convey design intent.

Solving the Problem

Team

Technology

Standards for Technology Use

Policy to require use of Technology per Standard

PresenterPresentation NotesWe needed a plan, We knew that at every turn someone would try to stop this insanity that we truly believe will save tremendous amounts of dollars. These savings will be realized in providing better definition at the early stages of product design. The configuration costs will be reduced by managing one Product Definition file, in this case the CAD Model instead of the model and the drawing. We needed to demonstrate that the CAD models could be reused many times over the product lifecycle in applications like manufacturing planning and documentation, technical manuals. (We discovered that in some form or another TDP elements are re-created many times over rather than reusing the results of someone elses efforts.)

In order to cover our bases we needed a strong team. We needed to insure the technology (i.e. CAD software and light viewable software) was ready to be implemented for use. We needed to insure that standards and standard procedures were in place. Finally we needed some policy maker to direct that the technology and standards would be put to task.

Solving the Problem

Team: Government, Industry and others

PresenterPresentation NotesIn order to affect change at the level that is required for MBE and MBD to become standard practice you need a diverse team of organizations to desire and work towards adoption. Over the past ten years working with the organizations listed here and others Ive failed to list here; we set about affecting technology by providing requirements to various software providers. You can see that this list includes industry and government agencies. While government tends to stay neutral with regard to the various software providers, industry works very hard to insure that the CAD and other software suppliers they work with have very specific list of requirements to make their processes work better.

Solving the Problem Technology

We partnered early with Standards Organizations, Prime CAD software vendors and 3rd party software suppliers.

PresenterPresentation NotesOver 10 years ago we started working with Dassault Systems, PTC, and Siemens. This early work was to insure technology was available to create models that could contain enough product information to begin to eliminate drawings. Very soon after the first pilot projects we determined the need for light viewing capabilities and included light viewable formats as a technology target. More about this later.

Solving the Problem Processes

Disposal / De-commission Planning

Design Engineering Manufacturing/Sustainment End-of Lifecycle/ Disposal

MBE (Model Based Enterprise) A fully integrated and collaborative environment founded on

3D product definition detail and shared across the enterprise; to enable rapid, seamless, and affordable deployment of products from concept to disposal.

PresenterPresentation NotesMode Based Enterprise restate the definition.

3D MBD, Part of Native Model

2D Drawing, Derivative of Native Model

Native CAD Model (Engineering Data Source)

MBD (Model Based Definition) A 3D annotated model and its associated data elements,

that fully define the product definition in a manner that can be used effectively by all downstream customers in place of a traditional drawing.

Solving the Problem Processes

PresenterPresentation NotesIm working with the folks who are trying to define the Taxonomy and terminology definitions of MBE/MBD and related processes If you have any suggestions we are always looking for more folks to help spread the word.

MBD (Model Based Definition)

Solving the Problem Processes

PresenterPresentation NotesModel Based Definition:In the beginning there were only 2d drawings that were created on drawing boards with huge amounts of labor.Then as the age of CAD started we could base the 2d drawings on 3d CAD models. The 2d was the master even though it was a derivative of the 3D.Next we were able to create 3d annotations called PMI inside the 3d model, this was the beginning of Model Based Definition.. We even have standards to define how to display the information.

Then we get to the Model Based Environment which enables the Model Based Enterprise. We can reuse the 3d annotations in manufacturing plans and documentation as well as maintenance manuals.

If you look at the raw model you might see a Furball.

Solving the Problem Processes, MBD

PresenterPresentation NotesMBD (Model Based Definition) is one key component of effectively working within a Model Based Enterprise. Since everything needs to revolve around the product model, lets examine it for a few moments. We call this the Furball; it is the raw CAD model with all of the data contained within visible for human consumption.

Taming the Furball.

Solving the Problem Processes, MBD

PresenterPresentation NotesWe knew that from a technology standpoint we needed to get the info pared down to something the individual users could deal with. So efforts began to tame the Furball. This is done using procedures and functions contained within all CAD systems. Filtering certain entities to hide the distracting information.

Furball Transformation Complete .

Solving the Problem Processes, MBD

PresenterPresentation NotesWe developed a Schema for displaying CAD model and PMI data to begin to replace the need for 2D Drawings. This Schema is based on view components to describe how a designer or draftsman would communicate the Story of what the part definition is. We defined Levels of PMI creation. We realize that in order to save money we can reduce the amount of PMI displayed in a model to fit the required manufacturing or inspection circumstances. Fully annotated models would only be required when sending designs to certain suppliers who needed more complete definition.

Solving the Problem Standards

Standards for Technology Use MIL-STD-31000 AIA 3500 ASME Y14.41 ASME Y14.5 ASME Y14.5.1.M

PresenterPresentation NotesThere are plenty of standards that already exist and only require some tweaking to make completely usable with MBE/MBD processes. Our MBE team has representatives on the committees who prescribe these standards. We are working to insure all standards allow and specify the proper use of 3D Fully annotated product models.

Solving the Problem Policy

Policy to require use of Technology per Standards OSD will require DoD procurements to acquire

3D TDP

PresenterPresentation NotesWe are working with all these agencies to insure that we can provide feedback that the Technology, Processes and standards exist so that they can begin to specify the use of 3D TDP packages as part of weapons systems procurement.

MBE Data reuse in Product Lifecycle

Predictions for the Future of MBE

Fully Symantec PMI allowing: Auto generation of MBD (PDFs) Auto generation of QA Plans Auto generation of G-Code Auto generation of Process Plans

MBD Model Based Definition Data Set

MFG. Process Plan 2D Drawing

CNC Program

Disposal / De-commission Planning

QA Planning

PresenterPresentation NotesIn the near future there will be a push for Fully Symantec PMI. There also new standards on the horizon STEP AP 242 which will allow Symantec data to flow from one CAD to another. This will allow product design in one system and definitions of various processes to be derived from the model in any CAD system.

Questions

http://model-based-enterprise.org/default.aspx

http://www.action-engineering.com/

3D TDPs for the DoD3D MBD in SolidworksAgendaIntroductionDoD TDP ProblemsDoD TDP ProblemsDoD TDP ProblemsDoD TDP ProblemsSolving the ProblemSolving the ProblemSolving the ProblemSolving the ProblemTechnologySolving the ProblemProcessesSlide Number 14Slide Number 15Slide Number 16Slide Number 17Slide Number 18Solving the ProblemStandardsSolving the ProblemPolicyMBE Data reuse in Product LifecyclePredictions for the Future of MBEQuestions