A U.S. Navy ManufacturinqTechnoloqy Center of Excellence

Institute for Manufacturing and Sustainment Technologies

Q U A R T E R L Y 2004 No.4

Focus OnManufacturing

Systems

DMC 2004 Concludes Navy ManTech’sCalendar Year ActivitiesMembers of iMAST recently participated in the annual Defense ManufacturingConference, held in Las Vegas, Nevada. Once again, leaders from government,industry, and academia assembled to exchange perspectives and information relativeto manufacturing technology, industrial modernization, and related DoDtransformational initiatives. This year’s theme “Advancing the Industrial Base toSupport the Warfighter” set the stage for forum discussions concerning the defenseindustrial base and its impact on sustaining the U.S. warfighter, who is currentlyengaged in full-scale combat in Southwest Asia.

Defense Manufacturing Conference 2004 was hosted by theJoint Defense Manufacturing Technology Panel (JDMTP), whichidentifies and integrates requirements, conducts joint programplanning, develops joint strategies, and oversees the executionof manufacturing technology and sustainment programsconducted by the Army, Navy, Air Force, and the DefenseLogistics Agency.

The conference featured senior guest speakers from theDepartment of Defense and industry, as well as various flagofficers from the military services. Keynote speakers includedthe Honorable Albert Frink, Assistant Secretary of Commerce forManufacturing and Services, and Ms. Sue Payton, Deputy UnderSecretary of Defense for Advanced Systems and Concepts. Mr.Elmer Doty, Vice President and General Manager of UnitedDefense (L.P. Ground Systems Division) represented industry.Congressman Donald Manzullo (R-Illinois), gave an enthusiastictalk entitled “Congressional Perspective on the Importance ofManufacturing to the United States.”

ARL’s Donald Heaney gave a presentation on metalinjection molding of warheads. Metal injection molding (MIM)is a net-shape binder-assisted forming technique that lowers

manufacturing costs while providing higher material groove detail which allowsoptimum fracture behavior in warheads. Metal injection molding techniques can beused for steel, stainless steel, titanium, and refractory metals, as well as tungstenheavy alloys.

Next year’s annual conference will be held in Orlando, Florida from 28November through 2 December. The event will be hosted by the U.S. NavyManufacturing Technology Program Office, Office of Naval Research. For moreinformation about this event, check future issues of the iMAST newsletter, or contactour institute administrator, Greg Johnson, at (814) 865-8207 or .

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2 2004 No. 4 iMAST Quarterly

IN THIS QUARTERLY

Feature Article ..................................................... 3

Institute Notes ..................................................... 7

Calendar of Events .............................................. 8

DIRECTORRobert B. Cook

(814) 863-3880 rbc5@psu.edu

MATERIALS PROCESSING TECHNOLOGIESTimothy J. Eden, Ph.D. (acting)(814) 865-5880 tje1@psu.edu

LASER PROCESSING TECHNOLOGIESRichard P. Martukanitz, Ph.D.

(814) 863-7282 rxm44@psu.edu

ADVANCED COMPOSITES MATERIALSTECHNOLOGIES

Kevin L. Koudela, Ph.D.(814) 863-4351 klk121@psu.edu

MANUFACTURING SYSTEMS TECHNOLOGIESMark T. Traband, Ph.D.

(814) 865-3608 mtt1@psu.edu

SYSTEMS OPERATIONS AND AUTOMATIONEddie C. Crow

(814) 863-9887 ecc1@psu.edu

NAVY/MARINE CORPS REPAIR TECHNOLOGIESSean L. Krieger

(814) 863-0896 slk22@psu.edu

iMAST ADMINISTRATOR and EDITORGregory J. Johnson

(814) 865-8207 gjj1@psu.edu

STAFF ASSISTANTLori L. Mowery

(814) 865-3264 llm1@psu.edu

WORLD WIDE WEBwww.arl.psu.edu/capabilities/mm_imast.html

NAVY PROGRAM MANAGERGreg Woods

(703) 696-4788woodsg@onr.navy.mil

©2004. The iMAST quarterly newsletter is published by the Institutefor Manufacturing and Sustainment Technologies of the Applied

Research Laboratory at Penn State, University Park, Pa. iMAST issponsored by the U.S. Navy Manufacturing Technology (ManTech)

Program, Office of Naval Research, under Navy Contract N00024-02-D-6604. Any opinions, findings, conclusions, or recommendations

expressed in this material are those of the authors and do notnecessarily reflect the views of the U.S. Navy. Send mail list requests

or address corrections to: iMAST Administrator, ARL Penn State, P.O.Box 30, State College, PA 16804-0030 or e-mail: llm1@psu.edu

Parcel delivery address (UPS, FedEx, USPS): N. Atherton St. Rear;Research Building West, State College, PA 16804.

Penn State is an equal opportunity/affirmative action university.This publication can be made available in alternative media on request.

U.Ed. ARL 04-04

DIRECTOR’S CORNER: NEW CHALLENGES

Bob Cook MECHANICAL DRIVETRANSMISSIONTECHNOLOGIESMATERIALSPROCESSINGTECHNOLOGIES LASERPROCESSINGTECHNOLOGIES COMPLEX SYSTEMSMONITORINGTECHNOLOGIESNAVY/MARINECORPS REPAIR

TECHNOLOGIES

ADVANCED COMPOSITESMATERIALS

TECHNOLOGIES

MANUFACTURINGSYSTEMS

TECHNOLOGIES

Happy New Year! As we end the 2004 calendar year, we have much for which we canbe thankful. Looking at 2005, we have many challenges we will be turning ourattention to. With the new year we also have some new changes. We congratulate ourprevious program manager, John Carney, who was recently selected for promotion toacting director of the Navy’ s Manufacturing Technology Program. He takes over fromAdrienne Gould, who was promoted to deputy, Industrial and Corporate Programs

and acting director, Product Innovation Division.Congratulations to Ms. Gould and Mr. Carney. I thank youboth for all the hard work, sacrifice, and dedication youprovided iMAST and the other centers of excellence. Wenow welcome aboard Greg Woods, who has assumed theresponsibility of program manager for iMAST. Mr. Woods isno stranger to us as he also serves as program manager forour Repair Technology program.

During the year, iMAST shifted the focus of itsprograms to the CVN 21—the next generation aircraft

carrier. As such, we teamed with other Centers of Excellence, Northrop GrummanNewport News, and PEO Carriers, as well as the Naval Surface Warfare Center, todevelop solutions to manufacturing issues associated with the new design. As thiscarrier design may last into the 22nd century, the impact of technology advances willbe felt for a long time. The savings we hope to achieve in total ownership costs willhopefully be significant. We are working hard to ensure a positive teaming attitude asa main focus.

We have just returned from the Defense Manufacturing Conference. I wasimpressed by the quality of the technical sessions. A lot of excellent work is beingproduced by the Manufacturing Technology program. This conference also includedseveral presentations from representatives of the Department of Commerce. Thedepartment’s focus on improving manufacturing dovetails well with the goals of theManufacturing Technology Program. Working together should benefit manufacturingin the United States.

Our feature article addresses a ManTech project aimed at optimizing theuse of a new covered modular outfitting facility at Northrop Grumman Newport News.Through the use of discrete event simulation models, operators will be able to betterplan production, resulting in lower costs. This project uses powerful tools producedby Delmia©.

As we start the new year, we’ll be initiating planning for FY06 projects.The next platform iMAST will be focusing on is the Littoral Combat Ship (LCS). Withits rapid acquisition strategy and challenging requirements, there is probably no lackof manufacturing issues. If you have a challenge for which you need a solution, or youhave a solution to an existing challenge that we can assist you in finishingdevelopment, please give us a call.

In closing, I would like to thank all of you for your continued support ofour Navy Manufacturing Technology Program at ARL Penn State. I wish you a happyand safe holiday season. As 2005 approaches, I hope you will put visiting us and ourfacilities down as one of your New Year’s resolutions, especially if you have not beenhere before.

iMAST Quarterly 2004 No. 4 3

FEATURE ARTICLE

Focus on Manufacturing Systems

Simulation-Based System Analysisand Resource Allocationby Daniel A. Finke and Christopher B. Ligetti

PROFILESDaniel A. Finke is an assistant research engineer at Penn State’s Applied ResearchLaboratory. Mr. Finke holds an M.S. in industrial engineering and operations researchfrom Penn State, as well as a B.S. degree in industrial engineering from NewMexico State University (with minors in management and mathematics). Prior tojoining ARL, Mr. Finke was a co-op student with General Electric Aircraft Enginesand Ethicon Endo-surgery. His current research interests include simulation-basedoptimization and scheduling, resource allocation optimization and decision support.Mr. Finke is currently working on new construction shipyards to improve productionperformance and provide decision support for new acquisitions. He can be reachedat (814) 865-5178 or by email at .

Christopher B. Ligetti is an assistant research engineer in the Manufacturing Systemsdepartment at Penn State’s Applied Research Laboratory. While with ARL, Mr.Ligetti has contributed to manufacturing systems simulation and modeling projectsfor Northrop Grumman Newport News and General Dynamics Electric Boat.Mr. Ligetti joined ARL following completion of an M.S. degree in industrialengineering and operations research. He also holds a B.S. degree in industrial andmanufacturing engineering from The Pennsylvania State University. Mr. Ligetti’sprevious research activities include multi-objective optimization in engineeringdesign and metamodeling. While a student at Penn State, Mr. Ligetti completedinternships with Arthur Andersen, LLP in Cleveland, OH and McConway & TorleyCorp. in Pittsburgh, PA. He can be reached by calling (814) 865-7619, or by emailat .

INTRODUCTIONIn support of the next generation aircraftcarrier, the CVN 21 class, NorthropGrumman Newport News (NGNN) hasdeveloped a long term strategic plan tomodernize their shipyard. In this plan,several new facility construction projectshave been proposed that will increase thelevel of complex outfitting and assemblythat typically occurs throughout the shipconstruction cycle. These new facilitiesprovide controlled environments thatwill enable schedule and costimprovements for work that traditionallywas performed outdoors. One facility inthe strategic plan is a new CoveredModular Outfitting Facility (CMOF). TheCMOF will be a covered, temperature-controlled facility located under the largegantry dock crane which will be usedprimarily to assemble high-value-addedproducts. NGNN believes that newfacilities similar to the CMOF willincrease productivity in several ways:decrease lost work days due to weather,reduce rework due to damage, andincrease the efficiency of the workspaceand workforce.

Even though the strategicplanning phase for these new facilitieshas been completed, several details needto be finalized to determine themaximum benefit that can be realizedfrom each. To accomplish this, ARL PennState engineers have utilized simulationmodeling to verify that higher levels ofproductivity are consistent with a newcovered facility than the currentuncovered (tarps and Quonset huts)production operations. The simulationmodels have also been used to help planthe allocation of space and utilization ofother critical resources such as cranes,

and personnel associated with theconstruction of complex ship modulesplanned for the CMOF.

BACKGROUNDShipyards have traditionally used a buildstrategy that utilizes linear buildsequences, producing larger and larger

Artist’s rendering of CVN 21 class of aircraft carrier © U.S. Navy

subassemblies (units) as they progressalong the production line. In this strategy,raw material, steel plates and shapes, arecut and joined together to form panels.These panels are then joined together toform larger subassemblies, (e.g., decks orbulkheads). The larger subassemblies arethen joined together to form large

4 2004 No. 4 iMAST Quarterly

subassemblies known as blocks orsuperlifts. These superlifts form thebuilding blocks that ultimately becomethe ship.

At NGNN, the largesubassemblies and superlifts areconstructed and outfitted on platens andare screened from the environment bytemporary shelters and tarps. Theseshelters and tarps provide minimalprotection against inclement weather. Asa result, up to 60 days of production peryear are impacted to some degree bylower efficiency or lost altogether due toweather. In addition, valuable productiontime is consumed setting up thetemporary shelters and tearing themdown when production is complete. Inan effort to reduce or eliminate theseproduction days lost due to weather andtime spent to setup and tear downtemporary shelters, NGNN has investedin a new facility (CMOF) that will be anall-weather, year-round shield against theenvironment. The CMOF will be aclimate controlled facility that willprovide cover for about 20% of the FinalAssembly Platen, the construction areathat is spanned by the large dry dockcrane.

The CMOF will beprimarily used for structural constructionand outfitting for high-value-addedproducts critical to the initial erectionsequence of the nuclear powered vesselsthat NGNN builds. Protecting theseproducts from the environment is criticalto their integrity and condition sincemany are sensitive and expensivecomponents. Such protection eliminatesthe need for rework due to waterintrusion and damage.

OBJECTIVEARL Penn State has identified threeobjectives for this effort: (1) provideanalytical proof that the new buildingwill provide the expected productivityimprovements, (2) optimize theoperations in the new facility, and (3)provide independent case-use forassembly simulation modeling tools.NGNN has conducted a high levelanalysis supporting the construction of

North Yard at Northrop Grumman Newport News

Simulation model of North Yard with proposed CMOF (note: roof not shown)

ProposedCMOF

ProposedCMOF

iMAST Quarterly 2004 No. 4 5

the CMOF; however, the timing of theconstruction has been altered from theoriginal plan. The actual timing for theconstruction of this facility has presentedanother issue, in that, the shipproduction schedule for certain criticalassemblies begins before the CMOFplanned completion date. This somewhatnegates the benefit of the facility in theconstruction of these intensely outfitteditems. The ARL Penn State simulationanalysis details the benefits and trade-offs of three configurations; (1)construction in existing facilities (2)construction in CMOF on plannedschedule, and (3) construction in CMOFon altered construction schedule.

Several build strategies andspace utilization algorithms will be testedin an attempt to determine the bestconstruction scenario for the currentconfiguration, in which the CMOFconstruction schedule is delayed.Because the facility is delayed, severalless desirable build locations will beavailable for the various process stepsrequired to build the products. Acomparative study of these options isnecessary to determine the operationalconfiguration that minimizes the spantime of the products constructed oroutfitted in the CMOF.

The third objective calledfor ARL Penn State to demonstrate thecapabilities, benefits, and drawbacks ofone commercial, off-the-shelf assemblysimulation modeling tool. Investing inthis software would require NGNN tomake a major investment in time, moneyand resources. Because of this, NGNNwould like to be certain that theinvestment would give a satisfactory return.

METHODOLOGYTwo methods and tools were used toaccomplish the objectives outlined in theprevious section. These methods includea discrete event simulation (DES) modeland an assembly simulation model. TheDES model was used as the analyticaltool for justifying the construction timingand operation optimization for theCMOF. The assembly simulation modelwas used as a verification tool as well as

a pilot to independently demonstrate thecapabilities of the tool.

The DES model was built inthe Quest© simulation software and theAssembly Simulation model was builtusing Digital Process for Manufacturing(DPM), both products of Delmia©.

DISCRETE EVENT SIMULATIONDiscrete event simulation modeling is aproven tool for providing answers tooperational questions. Knowing this,discrete event simulation models werebuilt using construction sequencesdeveloped in the planning phase of thehigh-value-added products. Thesesimulation models were used toaccomplish the first two objectives.

The foundation of the DESsimulation models developed by ARLPenn State was built from informationgathered from interviews conducted withpersonnel from NGNN. In theseinterviews, the ARL Penn State projectteam walked through the process ofbuilding the assemblies, gatheringprocesses steps, process times, resourcerequirements, and detailed buildstrategies. Through several of theseinterviews, and iteration of a “first-cut”model, a detailed simulation model wasconstructed and validated that reflectedthe actual production environment andcurrent manufacturing operations to anagreed upon level of detail. A secondDES model was developed, representingthe proposed shipyard activities,particularly, the availability of the CMOFfor the construction of several high-value-added bulkheads. The two DES modelswere then used to further demonstratethe benefits of the CMOF through acomparative study.

The DES model with theproposed CMOF and altered constructionschedule was then used as the baselineand several operational questions wereasked of it. This model was built withvarious flexible options to assist NGNNin evaluating multiple manufacturingstrategies including resource limitations(e.g., fixtures and tooling), work location(e.g., in the CMOF or other shipyardfacility), and outfitting orientation (e.g.,

horizontal versus vertical). As candidatebuild strategies continued to arise, theDES model was used to performcomparative studies to optimize theCMOF operations and to identify themost cost effective methods of buildinghigh-value-added assemblies. Theseefforts were facilitated through thecreation of Assembly Simulation modelsof the modeled products, which provideddetailed visualization of varyingassembly sequences.

The DES model with theproposed CMOF and altered constructionschedule supports the capacity analysisphase of the project as well. Thesimulation model was used to evaluateproduction alternatives in relation toschedule and space. As additionalassemblies are proposed for constructionin the CMOF, the DES model willcontinue to be used to support theacceptance or rejection of theseassemblies inside the CMOF.

ASSEMBLY SIMULATIONThe purpose of the Assembly Modelingphase was for ARL Penn State toindependently demonstrate thecapabilities of the assembly modelingsoftware and to provide a validation ofthe assembly sequence for NGNN. Toaccomplish this, one high-value-addedbulkhead was chosen as the test case.Geometry was obtained from the CADsystem and imported into the software.From there we used the tool to create anassembly sequence. In this sequence,geometry was moved along a path similarto the path that would be used duringconstruction. The sequence was thenpresented to NGNN for validation. Thefinal sequence helped provide anotherlevel of validation for the DES model.Another purpose of the AssemblySimulation model was discovered duringthe validation. This purpose was to viewcomponents with difficult installationprocedures in more detail. Several pipingassemblies are very complex and difficultto install. This tool provides a plannerthe ability to move the assembly to obtainthe best installation strategy. It alsoallows the planner to create alternative

6 2004 No. 4 iMAST Quarterly

Detailed rendering of Covered Modular Outfitting Facility

subassemblies to facilitate an easierinstallation.

It is expected that moredetailed assembly models will begenerated to help planners andconstruction personnel develop an“optimal” construction sequence. Also,other ship construction products plannedfor this specific facility will be modeledto further demonstrate the capabilities ofthis tool.

RESULTSInitial modeling efforts conducted byARL Penn State for a series of CVN 21high-value-added bulkheads constructedin the proposed CMOF resulted in a 15-day lead time reduction. These resultsassume the availability of the CMOF forthe entire construction period of theseunits. However, based on currentconstruction plans for the CMOF, thefacility will not be available for the initialbulkheads in the first in class CVN 21carrier. Therefore, the construction ofthese units must begin in other locationsthroughout the shipyard that will besubjected to inclement weatherconditions and limited access to the largecranes required throughout theconstruction process. This comparativeanalysis suggests that the construction ofthe CMOF should be moved forward tobenefit from its use.

The DES model of theCMOF was also used by ARL Penn Stateto provide information which would helpNGNN refine their current planningschedules for the candidate assembliesconstructed in this facility. Initial resultsindicate that other assemblies, inaddition to the high-value-addedbulkheads, can also be constructed in theCMOF, but only through careful planningof the release and space allocation of allcandidate units.

The Assembly Simulationmodel of one high-value-added bulkheadoutfitting process is currently being usedin an attempt to identify the assemblysequence that would minimize theoutfitting process time. Possibleopportunities for lead time reductioninclude reorientation of the bulkheadduring the outfitting process andparallelization in installing multiple pipeassemblies. The Assembly modeling toolhas proven to be beneficial, however, aquantitative value has yet to beestablished.

CONCLUSIONSResults obtained from the DES model ofthe CMOF suggest that its constructionshould commence earlier than planned.The use of the CMOF for the constructionof several high-value assemblies willresult in a lead time reduction compared

to current build methods, and processduration variability will be subsequentlyminimized due to the environmentallyprotected facility. This illustrates one ofthe primary benefits of simulation:system comparison of current operationsto proposed operations. Althoughsimulation is an abstraction from theactual environment, it still providesvaluable information and insight intosystems that could not be anticipatedotherwise. NGNN can refine theirplanning schedules using this “look-ahead” capability in an effort to optimizethe usage of their production facilities.The DES simulation model, as well as theassembly simulation model, willcontinue to be used by ARL Penn State,in conjunction with NGNN, to answervarious questions regarding theconstruction of several assemblies (e.g.,high-value-added bulkheads).Particularly, the DES model will be usedto evaluate the impact of variousmanufacturing strategies and theinclusion of additional assemblies to bebuilt in the CMOF. The assemblysimulation models will aid NGNN inidentifying the final assembly sequencesfor several complex operations.Simulation modeling techniques, bothDiscrete Event and Assembly, allowstakeholders to better understandproducts, processes, and operationalconstraints to develop the most feasibleproduction plan, and to conceptualizethe production environment. From this,simulation can decrease overall cost andlead times through detailed visualizationand analysis.

AcknowledgementThe authors wish to express appreciationfor support of this effort by the Office ofNaval Research Navy ManTech ProgramOffice and the Institute for Manufacturingand Sustainment Technologies (iMAST),a U.S. Navy ManTech Center ofExcellence. Any opinions, findings,conclusions and recommendationsexpressed in this article are those of theauthors and do not necessarily reflect theviews of the U.S. Navy.

iMAST Quarterly 2004 No. 4 7

INSTITUTE NOTES

New Navy ManTech Program DirectorMr. John Carney, the current iMAST Navy program manager, has been selected to headthe U.S. Navy Manufacturing Technology Office at the Office of Naval Research. Asdirector of Navy ManTech, Mr. Carney will be responsible for managing the ManTechProgram, which includes the Navy’s nine Centers of Excellence. Mr. Carney is taskedwith developing, coordinating, and integrating program policies, procedures, andcontent throughout the U.S. Navy. He will work in cooperation with the joint servicesand applicable agencies. He is also the Navy’s representative to the Joint Directors ofLaboratories Manufacturing Science and Technology Panel. A native of Sterling,Virginia, Mr. Carney holds B.S. and M.S. degrees from Virginia Tech in industrialengineering. Mr. Carney can be reached (703) 696-0352, or by e-mail at.

New iMAST Navy Program ManagerMr. Greg Woods has been designated as iMAST’s new program manager for the NavyManTech Program effort ongoing at ARL Penn State. No stranger to ARL, Mr. Woodshas been serving as program manager for iMAST’s Repair Technology program.

Mr. Woods succeeds Mr. John Carney who has been appointed acting-director of the ONR’s Navy ManTech Program. As iMAST program manager, Mr.Woods will provide financial and programmatic oversight to iMAST, as directed bythe Office of Naval Research. A mechanical engineer, Mr. Woods holds a bachelor ofscience degree from Tennessee State University, as well as an EMSE graduatecertificate from George Washington University. A native of Memphis, Mr. Woods hasover 20 years experience in surface ship structural integrity as well as materials designand application with NAVSEA and NSWC-Carderock Division.

Mr. Woods can be contacted by calling (703) 696-4788, or by e-mail at. We are pleased to have Mr. Woods as part of the ARL PennState-Navy ManTech team.

8 2004 No. 4 iMAST Quarterly

CALENDAR OF EVENTS

11–14 Jan. Surface Navy Association Symposium ★★★★★★★ visit the ARL booth Crystal City, VA

1–2 Feb. NCEMT Ship and Ground Advanced Materials Conference Orlando, FL

1–2 Mar. ShipTech 2005 ★★★★★★★ visit the iMAST booth Biloxi, MS

22–24 Mar. Navy League Sea-Air-Space Expo ★★★★★★★ visit the ARL booth Washington, D.C.

19–21 Apr. NDIA Science and Engineering Technology Conference DoD Tech Exposition Charleston, SC

2–4 May Navy Opportunity Forum Reston, VA

May TBA ARL Materials and Manufacturing Advisory Board (Aerospace focus) State College, PA

1–3 Jun. American Helicopter Society Forum 61 ★★★★★★★ visit the iMAST booth Grapevine, TX

2–3 Jun. Johnstown Showcase for Commerce ★★★★★★★ visit the iMAST booth Johnstown, PA

Aug. TBA TechTrends 2005 ★★★★★★★ visit the ARL booth TBA

Aug. TBA ONR Naval-Industry R&D Partnership Conference ★★★★★★★ visit the iMAST booth Washington, D.C.

Aug. TBA ARMTech 2005 ★★★★★★★ visit the iMAST booth Kittanning, PA

Sep. TBA Combat Vehicle Conference Ft. Knox, NY

13–15 Sep. Marine Corps League Expo ★★★★★★★ visit the iMAST booth Quantico, VA

Oct. TBA Expeditionary Warfare Conference Panama City, FL

Oct. TBA DoD Maintenance Conference TBA

Oct. TBA AUSA Expo Washington, D.C.

16–19 Oct. AGMA Gear Expo 2005 Detroit, MI

Nov. 28–1 Dec. Defense Manufacturing Conference ★★★★★★★ visit the iMAST booth Orlando, FL

Applied Research LaboratoryP.O. Box 30State College, PA 16804–0030

ADDRESS CORRECTION REQUESTED

Quotable“The framework of technology rests upon the foundation of learning.”

—sign seen at U.S. Military Academy