Orbital ATK JT File Use Case Matt Johnston. 5-Oct-16

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1 Orbital ATK JT File Use Case Matt Johnston 5-Oct-16

2 Overview Orbital ATK at a Glance MBD or 3D Model with PMI Model Based Plan Model in NX and JT file in TcVis What we are doing well Real time use cases using JT file for harness installation Conclusion Questions 2

3 Orbital ATK at a Glance Innovation Delivered Aerospace Systems Defense Systems The Partner You Can Count On $4.5 Billion (2013 Pro-Forma Revenue) Global Aerospace and Defense Systems Company Innovative, Affordable Products for Government and Commercial Customers Launch Vehicles, Propulsion Systems and Aerospace Structures Missile Products, Defense Electronics, Armament Systems and Ammunition Satellites, Space Components and Technical Services 12,500 Employees, Including 4,300 Engineers and Scientists R&D, Production and Test Facilities in 17 States Orbital ATK, Inc. - Overview Feb2015 3

4 Three Operating Groups and 12 Product Lines Flight Systems Group Space Launch Vehicles Rocket Propulsion Systems Missile Defense Systems Aerospace Structures Defense Systems Group Tactical Missile Products Defense Electronic Systems Armament Systems Ammunition and Energetics Space Systems Group Commercial Satellites Government Satellites Spacecraft Components Space Technical Services 42% 31% 27% Approximate Revenue Distribution Orbital ATK, Inc. - Overview Feb2015 4

5 Flight Systems Group Overview Small-Class Launch Vehicles Medium-Class Launch Vehicles Large-Class Launch Vehicle Propulsion Systems Strategic Missile Propulsion Systems Missile Defense Interceptors Suborbital Targets Commercial Aerostructures Military Aerostructures Annual Sales of About $1.4 Billion Workforce of Approximately 4,500 People Major Operations in Arizona, Utah, Virginia, Ohio, Alabama and Mississippi Orbital ATK, Inc. - Overview Feb2015 5

6 MBD or 3D Model with PMI Model Based Definition (MBD) or 3D Annotated Model MBD is a 3D Annotated CAD Model containing all the design information needed to define a product, and replaces a traditional 2D drawing. It could also be referred to as a paperless drawing (it does require a separate parts list and notes) 3D Annotation is the act of showing GD&T, Dimensions, Datum's, Flag Notes or other necessary annotation Model Based Definition/Enterprise capitalizes on the reuse of a single Engineering Model o Design Engineering o Analysis (Structural, Thermal, ect.. ) o o o o Manufacturing (Machines right from the STEP file) Quality (Inspects to the Model) Procurement (supplies Model to Suppliers) Tooling (supports Tooling development/checkout)

7 Model Based Plan Analysis Manufacturing Inspection 3D Model Tooling 2D Drawing Design Production

8 Model with PMI in NX and TcVis This item with Notes and Export Control Statements is shown as an example only, and is NOT ATK released Engineering definition

9 Where we are doing well All new Programs are Model Based with PMI Air Force Program was 3D Annotated Models, production is complete and went well NASA is allowing some 3D Annotated Models, has been baselined and into production Working with NASA to allow 3D Annotated Models on large installations (Contract Change) Multiple new programs in the development phase and are all Model Based with 3D Annotation Model Reuse Manufacturing and Quality using the Engineering model Procurement is sending the NX part and JT files to suppliers, some still request a stp Customers are reviewing the JT files instead of 2D Drawings Involvement Manufacturing and Quality are getting involved earlier in the Design Additional design iterations are able to be looked at in a shorter amount of time (design is able to mature much quicker) PMI is being authored for Process and Quality requirements Getting people comfortable using 3D Models with out a Drawing Although we are having great success, it is still a daily battle. 9

10 Real Life use case for JT files FWD Skirt AFT Skirt 10

11 AFT Skirt Cable Installation Operator planned 2 weeks for Cable Installation on the AFT Skirt 1. We handed him a 2D Drawing like always 2. We put the Schematic and JT file on 2-42 Touch Screens 3. In the JT Model the Operator would highlight the Cable he was installing 4. Then install the cable on the exact rung as it was in the Model 5. The work was completed in less than 4 days with almost no rework 6. In the end the Model and Hardware were Identical 11

12 AFT Skirt Takeaways It took a lot less time than usual Less than 4 day, compared to 2 weeks It was much easier for the operator to understand the Cable Path with the 3D model The Drawing shows where to connect but is not clear on the routing path It required little, if any rework to route cables The old way resulted in piles of Zip Ties on the floor due to rework The 12 sheet Drawing was opened a couple times, to laugh at the lack of clarity The Operators had fun because it was easy and something new 12

13 Mockup VS- NX/JT Models Forward Skirt Cable Install FWD Skirt has 180 Cables compared to 80 in the AFT Skirt Much harder to route due to its space limitations, and a lot of avionics hardware We used the FWD Skirt to validate that our NX Model could replace expensive mockups 1. The model was very successful and was impressive to see when compared to the JT file 2. Once again, the model looked identical to the JT file Simon, wouldn't this process be so much easier on something like this? This process will save Orbital ATK Time and Money 13

14 Cables Physical vs. Virtual

15 Conclusion Orbital ATK s strong commitment to PMI is seeing positive results Workforce is educated on PMI/JT and excitement abounds Many are looking for PMI improvement opportunities Program office understands what PMI provides. They are modifying current contracts and demanding new contracts be written for PMI/JT deliverables Cost savings are being recognized Reduced design cycle times and cost (no drawing) Using rapid learning cycles (quick development cycles) Reduced procurement costs (suppliers are asking for 3D models) Reduced manufacturing and quality cost (controlled model reuse) Reduced cable design cost (no need for mock-ups) Lower overall program cost and cycle time on new rocket designs due to PMI PMI/JT is here to stay and Orbital ATK will continue to improve its capabilities

16 Questions? Design Analysis Visualization Solid Model Procurement Digital Manuf. / Process Planning 3D annotated (PMI) models will allow everyone to work in the same home room Customer Deliverables

17 Other things in the Works Mobility for the shop floor Purchased several Surface Pro 3 s for a pilot program with Quality and Ops Using.jt files for installation and assembly of large rocket motors Pilot program using model-based shop floor work instructions in operations area Virtual design and collaboration room Working on creating a live digital room where we can hold table top and material reviews using large touch screens and mobile devices Virtual shop floor training for low production processes Minimizes (or eliminates) the need for physical prototypes Rapid learning cycles using 3D models The IPT (integrated product team) coming together around the 3D model to discuss how the project is progressing, road blocks, successes, etc. They allow all the team to look at the growth of the project (virtually) in real time and offer help and support Automated model validation process Developing a process that validates our derivative models (JT & STEP) against the NX.prt file for accuracy and quality

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