Kunnskapsbasert design i militære og sivile utviklingsprosjekter. Erfaringer fra Umoe Mandal

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1 Kunnskapsbasert design i militære og sivile utviklingsprosjekter. Erfaringer fra Umoe Mandal Nere G. Skomedal Vice President Engineering KBD Forum, Kongsberg april 2014

2 Innhold Litt om Umoe Mandal Aktuelle utviklingsprosjekter MCMV Skjold T-Craft Erfaringer med KBD US Navy: Set-based design T-Craft Viktige suksessfaktorer

3 60 års militær skipsbygging i Mandal

4 Umoe Mandal: Builders of Oksøy/Alta Minehunters/sweepers Skjold Class Corvettes

5 SES MCMVs from Umoe Mandal Oksøy class minehunter (MH) Main data M341 KNM Karmøy 1994 Displacement Length Speed : 396 t : 55,2 m : 20 kn M342 M343 KNM Måløy KNM Hinnøy Crew : 37 (13/7/17) Main weapons Mistral SAM Main sensors MH: ROV, Hugin MRS, sonar MS: Elma og Agate sveip Måløy class minesweeper (MS) M350 KNM Alta M351 KNM Otra M352 KNM Rauma Agate influence sweep Hugin AUV KNM Alta

6 Skjold Class Corvettes in the Navy Skjold-class corvette Main data Skjold-class Displacement : 274 t Lenght : 47,5 m Speed : 60 kn Range : 800 nm / 40 kn Crew : 20 (13/4/3) P961 P962 P963 P964 KNM Storm KNM Skudd KNM Steil KNM Glimt Main armament NSM 76 mm OTO Mistral MANPADS P965 P960 KNM Gnist KNM Skjold KNM Storm Built by Umoe Mandal NSM

7 20 years with air cushion vehicles Umoe Mandal is the world leader in Air Cushion and Surface Effect Ships Unrivalled experience in design, building and maintenance of operational high performance naval craft Umoe Mandal has extensive experience in design and construction of naval composite structures Umoe Mandal Composite Technology Umoe Mandal has the leading experience in high speed craft gas turbine applications Umoe Mandal is the leading supplier of advanced high capacity lift fans 4 design generations in service

8 Umoe Mandal: Leading ship designers Leading ship designers for advanced ships and structures with Advanced propulsion solutions Composite materials/light weight solutions Air cushion technologies Military requirements and logistics support Extensive CFD/FEM/3D- CAD capabilities Applying lean and efficient design methods and advanced design tools to reduce development time and costs Leveraging competitive and successful design work for demanding Norwegian and international Navy customers 26 highly skilled engineers within Naval Architecture/Marine Engineering

9 Extensive CFD capabilities Umoe Mandal is designing the next generation free fall lifeboats from Harding Safety

10 10 Integrated hydrodynamics/structural design

11 SKJOLD Corvettes a success Successful operations in NATO exercises Successful first launches of the new Naval Strike Missile Last vessel delivered April 2013 First implementation of RAS (Replenishment-At-Sea) completed International promotion focusing on Brazil, Turkey, Singapore and the US

12 The formidable firepower of the Skjold class May 2013: NSM fired from Skjold Class corvette «Steil»

13 Umoe Mandal - a history of innovation

14 14 UM epoxy/carbon lift fan technology Fan blades produced with RTM Shrouds and centredisk produced with vacuum infusion 4 generations of lift fans in operation (>50 units) In operation by NAVSEA/LCAC since August 07

15 15 Design and production of composite components BAe Bofors MK3 Gun Cupola pptimized design by Umoe Increased load capacity Reduced weight Reduced part count Integrated features

16 The T-Craft Challenge 16 Vehicle transfer at sea Vehicle offloading/loading to the beach

17 T-Craft: Lite antall krav i form av targets

18 The Umoe Response: 18

19 19 The Three Modal UM T-Craft Concept Fulfills all three desired capabilities 1. Fuel economy based on fuel efficient diesel engine powering high efficiency waterjets SES vessel operating between humps 2. High speed and shallow draft CODAG Diesel engine powered waterjets, gas turbine powered air propellers SES vessel operating above hump speed 3. Amphibious mode Gas turbine powered air propellers Large air cushion area with a high air gap (1.5 m) to pass sandbars/mudflats and with beach ascending capability operating below hump speed

20 20 Long range good seakeeping and high speed shallow draft mode: SES

21 Bow tandem connection to an LSD 21 at sea cargo transfer made possible

22 Loading from the WATSON Class side port. 22

23 23 The UM T-Craft.. delivering the cargo dry feet on the beach..

24 Break-through contract in the US: TEXTRON/Ship to Shore Connector Development + Test Craft + 8 vessels Ambition to win additional series of 65 vessels 2019->:

25 Making Offshore Wind Possible UM Wave Craft Speed, Access, Comfort

26 KUNNSKAPSBASERT DESIGN

27 Vi har prøvd to utviklingsprosesser 1. Kravdrevet design (Strukturbasert design): Designprosessen går ut på å verifisere at produktet vil tilfredsstille et stort antall (>2k) detaljerte funksjonelle krav Formell prosess for evaluering og aksept Prosessfokusert ledelse (regelstyrt) Prosessen viktigere enn teknisk resultat Fremdrift baseres seg på telling av ferdige dokumenter 2. Kunnskapsbasert design: (Set-based design) Et lite antall krav ofte mer i form av målsettinger Fokuserer på tekniske alternative løsninger som vurderes og (ned)velges ved avtalte milepæler Kunnskapsbasert ledelse Norske militære prosjekt: Ex: SKJOLD Amerikanske militære prosjekt: T-Craft og SSC

28 Klassisk Point skipsdesign Omfattende loopbacks ofte nødvendig hvis man designer fra scratch. Mange runder blir nødvendig.

29 Point design i praksis Define System Concept Create Design Spec Design subsystems Integrate & Test Prototype Concurrent engineering Omfattende re-engineering ofte nødvendig Kostbare loop-backs som medfører seine endringer på store mengde «ferdige» dokumenter

30 Norske militære prosjekt: Kravdrevet design Flere tusen funksjons og ytelseskrav etablert av kunden For Umoe betydde dette: Fokus på «lukking av krav» gjennom hele designprosessen Motstridende krav gir krevende prosesser når de oppdages Resulterer i omfattende re-engineering og revisjoner av allerede utgitte dokumenter Energien brukes på prosessen og dokumentasjon av prosesstrinn enn på å finne de beste løsningene Teller krav, punch, dokument nr og revisjoner, sporbarhet, avvik, endringer, fremdrift Resultat: Kravene blir innfridd, men Forsinket og til høy kost Usikkert om resultatet er optimalt

31 US Navy Introduces Set-based Design Based on many failed, too late and too expensive ship design efforts since the 1990 ies On February 4, 2008 Admiral Paul Sullivan,Commander of the Naval Sea Systems Command, sent out a letter entitled: Ship Design and Analysis Tool Goals.

32 2009: Set-based design is used by US Navy for the SSC-program: 1. Consider a (large) number of design alternatives by understanding the design space 2. Allow specialists to consider a design from their own perspective and use the intersection between individual sets to optimize a design 3. Establish feasibility before commitment Result: a) Narrowing sets gradually while increasing detail b) Staying within a set once committed c) Maintaining control by managing uncertainty at process gates Conceptually robust designs Promises a capacity to adapt quickly to changing requirements and design discoveries. *What Is Set Based Design? DJ Singer, N Doerry, ME Buckley - Naval Engineers Journal, 2009

33 The UM T-Craft design approach A knowledge based creative ship design process successfully applied

34 A new ship design method has been used During the T-Craft Phase 1 and 2 ( ) we have actively tried out a novel (for UM) product development method inspired by Japanese* product development methods prof. Kai Levander, NTNU (Finland) Knowledge Based Design Knowledge based design is based on complete design sets where alternative solutions are tested and selected Other names: Set-based design, Lean product development + E1 or M1 + A2 or B2 C2 or *See: Michael N Kennedy: Product Development for the Lean Enterprise: Why Toyota's System Is Four Times More Productive and How You Can Implement It. Oakley Press 2003

35 Knowledge Based Design: Knowledge based design is based on complete design sets where alternative solutions are tested and selected Example: E-Drive + E1 or + A2 or M-Drive M1 B2 or C2 The decision affected the whole ship and all drawings Decision to be taken as late as possible at an agreed milestone Before drawings were made When we had acquired sufficient and quantitive knowledge to take the right decision

36 T-Craft main drive alternatives 36 M-drive: E-drive: G B 2 MW 2.5 MW Aux Gen G B Ship Service Power DC AC 2 x 2 MW Lift Fans 2.5 MW AC AC G B Ship Service Power Aux Gen 13. MW Propulsion Fan LM MW G B 7.4 MW 7 MW Water Jet G B 7 MW Water Jet AC DC S 1 2 MW Lift Fan DC 1 FM 1 F 1 PE 2 MW Bow Thruster Fan G B 9 N S AC DC BT 1 BTM 1 BT 1 PE N S G B 1 LF 1 AC DC DC 2 2 MW Lift Fan N S FM 2 F 2 PE G B 2 LF 2 DC 6 S 2 T 1 MG 1 PEA DC AC DC 5 DC MG 1 PEB AC MG 2 PEA DC AC DC 7 DC MG 2 PEB AC DC 8 DC 9 J 1 PEA DC AC DC J 1 PEB AC J 2 PEA DC AC DC J 2 PEB AC 24 MW Turbine LM M / G 1 N S 8 MW / G M ( 2 x ) M / G 2 JM 1 N S N S G B 5 G B 7 8 MW Motor ( 2 x ) JM 2 N S G B 6 PF MW Air Propeller 8 MW Water Jet WJ 1 WJ MW MW G B 2 x 2 MW Lift Fans G B 7.4 MW 19 MW LM 1500 G B G B 13 MW Propulsion Fan DC AC DC 3 F 3 PE 2 MW Lift Fan N S FM 3 G B 3 LF 3 DC AC DC 4 F 4 PE 2 MW Lift Fan N S FM 4 G B 4 LF 4 DC 11 MG 3 PEA DC AC DC 10 DC MG 3 PEB AC MG 4 PEA DC AC DC 12 DC MG 4 PEB AC T 2 M / G 3 N S 8 MW / G M ( 2 x ) M / G 4 N S LM G B 8 24 MW Turbine 8 MW Water Jet 9. 2 MW Air Propeller PF 2

37 2009: Alle snakket om LEAN Jeg fikk denne boka på pulten og beskjeden: LES

38 Development Environment - The foundation for lasting change Structure-based A Continuum Knowledge-based The basis of the engineering environment is the structure of the operational activities: procedures, control, compliance, related training (Vi i 2009?) The basis of the engineering environment is the knowledge of individual workers: Understanding of needs, information availability, responsibility and teaming interaction (Toyota) Fra Kennedy 2003

39 The Lean Development System (Knowledge-based Development) System Designer Entrepeneurial Leadership Operational Value Stream to Customer Responsibilitybased Planning & Control Set-based Concurrent Engineering Expert Engineering Workforce An operational value stream emerges from the interaction of four critical culture elements Fra Kennedy 2003

40 Decision taken at defined process gates: I II III Dates for the process gates are set and agreed by the design team And always kept! IV At the process gates (integrating events): N Evaluation and (down)selection of design sets Progress is assessed

41 Eksempel: En ny skipstype skal utvikles Fire nye teknologier nødvendig: Set-based Transformasjon fra SES til ACV 3 alternativer Fremdriftssystem som er effektivt til sjøs og til lands 3 alternativer Mekanisk eller elektrisk kraftoverføring 3 alternativer Lastoverføringssystem skip til skip 3 alternativer Anta 80% suksessrate for hver teknologi Point Design: 0.8 for transformasjon x 0.8 for fremdriftsystem x 0.8 for kraftoverføring x 0.8 for lastoverføring Sannsynlighet for suksess med alle løsningene i prosjektet: = =0.41 Set-basert design gir dramatisk redusert risiko i utviklingsprosjekter Set-basert: Sannsynlighet for at alle tre løsningene for en teknologi feiler: = (1 0.8) 3 =0.008 Sannsynlig for suksess for prosjektet: = ( ) 4 =0.97

42 Knowledge based design vs traditional ship design Knowledge based design process Set based design process Always a plan B Extensive re-use of knowledge Model testing as early as possible to learn Milestones are kept Open development process all teammembers are kept informed and involved Publish documents (knowledge) Progress is measured at milestones Active use of the 3-D model, no artificial 2-D presentations of intentions Drawings are made as late as possible to avoid changes Solutions emerge Traditional design process Revolving spiral process Point design Start from scratch Model testing as late as possible to verify Milestones are delayed People are informed on a need to know basis Archive documents Progress is measured by counting finished drawings 3-D mainly used for artists impressions Drawings are made as early as possible to show progress Solutions are given

43 Our experience from T-Craft Knowledge based process Risk is continuously reduced Fully integrate suppliers into the product development system Progress estimates are more reliable Fewer late design changes Team members are involved and motivated always learning Critical milestones never delayed Open working environment improves interdisciplinary interaction Model tests motivate design improvements Traditional process Risks are often ignored the easy solutions are done first Do not include suppliers before they can be contracted Progress is overestimated Many late design changes drawings are revised repeatedly Team members are frustrated Delays are recognized too late Interdisciplinary check is a pure formal process Late model tests are to be taken as fait accompli

44 Kravspesifikasjonen styrer designprosessen DERFOR: Bedre med få enn mange krav Reduserer motstrid mellom krav Bedre med «targets» enn absolutte krav Targets muliggjør avveininger og optimalisering ved motstridende krav Unngå at kravene formuleres for ambisiøse på ekspertnivå Kan skape store problem når det viser seg at resultatet bare nesten kan oppnås Beskriv hva utstyr man ønsker å ha i stedet for «finne på» krav til funksjoner og ytelser «Lure» funksjonelle krav fordyrer og forsinker

45 Hvorfor tar ikke alle i bruk KBD: Mange kravspesifikasjoner er ekstremt strukturstyrt Kunden har meget sterk tro på at et høyt antall detaljerte krav sikrer kvalitet Virker sannsynligvis mot sin hensikt! Vanskelig(ere?) å dokumentere fremdrift Å bruke ressurser på alternativer virker fordyrende Vurdering av fremdrift skjer ved milepæler/gjennomganger Økonomiavdeling/revisor foretrekker ting som kan telles Styring og kontroll overføres fra «ledelse» til «sjefsingeniører» og ekspertise Må tiltros økt ansvar Vanskelig å holde fokus over lang tid krever kulturendring

46 Våre erfaringer Kunnskapsbasert utvikling: Reduserer bemanningen i prosj. Reduserer tidsbruken Reduserer antall seine endringer Bedre risikostyring Mer optimale løsninger System Designer Entrepeneurial Leadership Set-based Concurrent Engineering Operational Value Stream to Customer Responsibilitybased Planning & Control Expert Engineering Workforce Mange løsninger blir tilgjengelig for neste prosjekt Tidsplanen holder....som for et bryllup! Takk for meg!