digital thread for material review board (dt mrb)“the digital thread for material review board...
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Digital Thread for Material Review Board
(DT4MRB)
DT4MRB Team
21 - 24 March, 2016AA&S Grapevine, Texas
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
DT4MRB Team Members
Northrop GrummanVehicle Technology Development
John MadsenSteve EngelChuen YauElias AnagnostouJohn Crawford
Manufacturing Technology DevelopmentJason Bither Jeff GengeAditi Gobburu
2
EtegentTom SharpGary CoyanBob AyersUriah Liggett
DT4MRB AdvisorsDCMALiaison EngineeringMaterial Review BoardStructural AnalysisStructural DesignGlobal Quality
Air Force Research LaboratoryRichard MeyersAndrea HelbachSteven Turek
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Overall Program Objectives
3
“The Digital Thread for Material Review Board Processes program aims to link design and production data and analyses within integrated software tools to feed the MRB decision-making process.” – BAA
9 Task 1 - Create a Digital Thread Infrastructure (DTI) supporting a framework of COTS technologies.
9 Task 2 - Exercise the framework and quantify the reduction in the duration of MRBactivities.
– Demonstrate the capture and promulgation of lessons learned to foreshorten future MRB deliberations.
– Create provisions to document the as-built configuration for Airframe Digital Twin– Develop initial business case
• Task 3 - Exercise the framework to demonstrate a reduction in the frequency of MRB activities by facilitating changes to the manufacturing process and/or component design.
– Quantify these benefits in both cost savings and quality improvements on example airframe structures currently in production
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Generalized Top Level Architecture
4
ANCRControl
Design DataSpec
LibrarianTDP+
Root Cause
Analysis
ProbProcess Control
NonConf
Metro-logy
Work Orders
NLign
OtherData
MES
Data Exchange Layer
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Data Exchange Layer
• Cloud storage– AWS, MS Azure, Google Cloud, etc– Multiple Regions & Availability Zones– Deploy Data To The Cloud
• Suppliers• Manufacturers• Users
– Data Lake
– Security and ITAR concerns• Cloud security review criteria by DISA• FedRAMP• Additional constraints
5
* Implementing and Integrating Product Data Management and Software, p23https://books.google.com/books?id=EAUbUpxf8jMC&pg=PA22&lpg=PA22&dq=pdm+data+vault&source=bl&ots=fxbvErfZX4&sig=VbacJfMdPglvUGGUAt1dPOgEzHE&hl=en&sa=X&ved=0CEoQ6AEwBmoVChMI-uKm0pDqxwIVRZqACh04pAjv#v=onepage&q=pdm%20data%20vault&f=falseApproved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Data Exchange Layer – Cont’d
• Digital backbone– eQube-MI– Migrate and integrate data from any
source and in any format– Compatibility with the source and
destination system’s security and application context
– Pre-built comprehensive application specific connectors
• Common data interface and format– REST API– XML, PLM XML– JSON
6Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Data Exchange Layer – Cont’d
• Platform to support data analytics– KNIME, open source data analytics
platform– Effortless access to all data– Apply powerful analysis and statistics– Visualize and create compelling reports– Chaining nodes into a workflow
• End to end encryption7Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Librarian Functions
• User authentication and authorization
– Single Sign On– Access by Group or Role, especially
when crossing corporate boundary
• Support general requests for data, for example
– Request design model for a base part number for a specific tail number
– Get “latest” revision of a document– RESTful
8Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Librarian Functions – Cont’d
• Intimate knowledge of data sources, as well as any required navigation
• Part number/Serial number lookup
• Conversion from source data for format requested by the user– TranscenData’s DEXcenter, for example, CAD to IGES, STEP, DXF
• Data control, such as checkout and return, data ownership– Proprietary and/or ITAR nature of data
• Data cache
9Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Enhanced Technical Data Package (TDP+)
• Contains current Technical Data Package: As-Designed data
• Enhanced with As-Built data– Incrementally built and snapshot along the production line and final delivery– TDP+ for assembly:
• As-Designed and As-Built data for assembly• TDP+ for component parts
• Extensible in the future to contain As-Used data and As-Maintained data
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Extensible, Easy Access, Comprehensive Data Package Delivered with Each Vehicle Defining Specific Individual Details From Birth
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Current MRB Process
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Non Conformance
(NC)
Quality Assurance Opens NC Report
(Tag)
Quality Assurance Corrects Information
Rework to spec
Monitor in Later Cost
Center• Departments
Disciplines• Stress Analysis• Flight Science• Etc.
Liaison Engineer Determines Disposition
MRB disp.Req?
Information Verified?
Standard Disposition?
Interim Disposition?
Disposition
Yes
Yes
Yes
Yes
No
No
No
No
Concurrent Analysis
Preliminary Review (PR)Non-Conformance Report
(NR) in MES Reference DataCloudView
2
4
5
1
1 2
3
Verification that all components
reported in NC report are accurate and consistent with
PDM / Effectivity
Tags are tracked through MES as the ship moves through production. QA reviews traveling tags to ensure that they haven’t
been disposition.
3 4 5
Mfg Execution System (MES)
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Current Process Opportunities
• Current MRB process is time-consuming
• Need to streamline process to meet rate
• Collected data are underutilized
• No centralized database from which to pull reference material
• Many MRB issues are redundant and often require re-investigation
• The current process is manually worked by liaisons engineers
• Changes made to design or manufacturing are reactive and based on personnel experience
12Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Digital Thread MRB Process
13
14-59806-004
Yes
NC
Quality Assurance Issues NC Report
Liaison Engineer Coordinates Disposition
Non-standard Disposition
Automated Data Acquisition and Tag Initiation
Automated Pre-Tag Verification
Automated NC Research
Real-time Tag Correction “Veri-Tag”
Root Cause Analysis
Mfg. Process Optimization
Design Optimization
Mfg. Process Change
Design Change
Yes
No
No
Variance Modeling
Disposition
As-Built TDP+
Current Steps
Proposed Task 3
KEY:
Refine Process Control Plan
Standard Disposition
Proposed Task 2
Supporting Disciplines
MRB Knowledge Base
Process/Design Improvements
Optimized Scheduling
Scrap Use As Is
Rework
Department Disciplines• Stress Analysis• Flight Sciences• Manufacturing• ADT and Sustainment• Etc.
Automate Where Practical, Leveraging the Flow of Information Made Possible By The DT Infrastructure
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Veri-Tag Challenges Addressed
• Challenges with Existing System– Free form text limits tag reuse– Tags rejected due to incomplete/incorrect information– Tags information initially captured on paper and later entered into
MES is laborious and error prone• Veri-tag Solution
– Deploy tablet application at point of inspection– Reduce time required to create initial Tag (NC)– Add structure to captured data to support automated research– Reduce number of Tag Rejections due to:
• Inaccurate location• Wrong part number• Wrong criticality code(s)• Incomplete information
14 Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Veri-Tag NC Data Capture
• Real-time verification that non-conformance is consistent with Product Data Management (PDM) specifications and effectivity
• Real-time verification that NC information is complete and accurate
• Enabled by Etegent’s NLign Analytics with some enhancements to their COTS product
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Real-Time Tag Validation From The StartStreamlines Data Entry and Eliminates Manual Iterations
Initiated in MES Accurately Described within NLign
Returned back to
MES
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Veri-Tag Photo Mapping
• Nonconformance (NC) photographically registered to 3D Database
• Provides accurate location in aircraft coordinate system
• Enabled by Etegent’s NLign Analytics with some enhancements to their COTS product
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Accurate Registration of NC into the 3D Database Orients the Adjudicating Party, Providing Quick Access to Necessary Information for
Disposition Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Automated NC Research (ANCR)
• Challenges with Existing System– Access to historical data is cumbersome
• Unstructured data• Poor query tools• Inaccurate/Missing 3D location• Different groups/individuals rely on local ad-hoc databases
• ANCR Solution– Central database with links to all relevant data– Structured data customized for each type of defect– Automated generation of common queries– 3D visualization of reference and historical data
17 Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
NGC/NLign ANCR Storyboard
Displays result of Current Part State search
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List of other discrepancies associated with serialized part. User can double click on row to see details associated with discrepancy.
Other discrepancies associated with this serialized part shown on model colored by Defect Code
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Automated NC Research (ANCR)
• Searchable data knowledgebase referenced by salient features: Location, Damage Type, Serial Number, Aircraft Tail Number, Left/Right Hand, and/or any other user defined criteria
• Retrieval of standard dispositions, criteria & historical repair precedents
• Retrieval & dissemination of information for non-standard dispositions
• Eliminates redundant analyses & streamlines new analyses
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Automated NC Research Streamlines & Enables Data Driven Decisions
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Overview of Estimated Savings
20
Discovery of Defect
NC Initiation & Preliminary Review
using Veri-Tag
Rework to spec
Monitor in Later Cost
Center
Engineering Concurrence use ANCR
Liaison Engineer Determines Disposition
Use ANCR
MRB disp.Req?
Information Verified?
Standard Disposition? Use ANCR
Interim Disposition?
Disposition
Yes
Yes
Yes
Yes
No
No
No
Concurrent Analysis
2
45
3
Submit report to change required Veri-Tag
fields
No
Changes to MRB Process
Preliminary Review (PR) ANCR/Reference Data MES
2 41 3
ANCR/Reference Data
Estimated Savings
23% Savings
5
10% Savings
NC Report (NR)/Veri-Tag
1
Veri-Tag & ANCR Have Been Estimated to Save 33% of MRB Labor HoursApproved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Reduction of NC Tags
• Exercise the framework to demonstrate a reduction in the frequency of MRB activities by facilitating changes to the manufacturing process and/or component design.
• Investigating Cots (Delmia) and open source products (KNIME) for Digital Thread data reduction, root cause analysis.
• Results to data have uncovered necessary process and design changes that will reduce NC tag generation
21
14-59806-004
Yes
NC
Quality Assurance Issues NC Report
Liaison Engineer Coordinates Disposition
Non-standard Disposition
Automated Data Acquisition and Tag Initiation
Automated Pre-Tag Verification
Automated NC Research
Real-time Tag Correction “Veri-Tag”
Root Cause Analysis
Mfg. Process Optimization
Design Optimization
Mfg. Process Change
Design Change
Yes
No
No
Variance Modeling
Disposition
As-Built TDP+
Current Steps
Proposed Task 3
KEY:
Refine Process Control Plan
Standard Disposition
Proposed Task 2
Supporting Disciplines
MRB Knowledge Base
Process/Design Improvements
Optimized Scheduling
Scrap Use As Is
Rework
Department Disciplines• Stress Analysis• Flight Sciences• Manufacturing• ADT and Sustainment• Etc.
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
Conclusion
• Proposed framework and architecture utilizing COTS and open source products that provide a system for generation and easy access to airframe digital data
• Exercised the system to show time savings in NC Tag creation and adjudication of 33% while enhancing quality and accuracy of data reported
• Currently working the system to show data analytics resolution to identify process and design issues allowing corrections that will reduce tag activity
22Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.
For Additional Information Please Contact:
John [email protected]
John [email protected]
Stephen [email protected]
Rick [email protected]
Approved for public release; 88ABW-2016-1048, NGAS 16-0447 dated 3/9/16.