The Future of Maintenance

Maintenance & Overhaul
Digital technologies provide shipyard workers with an environment of connected solutions which accelerate maintenance/overhaul and allow real-time operational feedback. Sensors tagged to inventory racks/bins trigger automatic ordering when supplies are low. Computer Aided Design (CAD) software allows shipyard workers to examine the digital file of a damaged part, provide engineering with critical information for recommended part redesign to perform better, and put the design through a series of digital tests to ensure performance before the part is ever created. Additive manufacturing allows shipyard workers to create backordered or hard to source replacement parts on-demand. Technical authority decision-making time is also decreased dramatically as digital file transfer increases up the rate of information flow.
Perspectives
Enabling Technologies
Shipyard Workers
Shipyard Workers
Shipyard Workers
Shipyard Workers
Shipyard Foremen
icon_Replenishmentblue_SVG Sensor-Driven Replenishment
icon_AdditiveManufactureblue_SVG Advanced & Additive Manufacturing
icon_DigitalTwinblue_SVG Dynamic CAD Modeling
icon_AutoDeliveryblue_SVG Autonomous Delivery
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Sensor-Driven Replenishment via Smart Warehouse

Inside the digital warehouse, bins, racks and shelves are filled with different types of replacement parts and equipped with sensors to monitor the inventory levels of those replacement parts. As inventory levels diminish and pass defined thresholds, a replenishment order is automatically triggered in the warehouse to pick, pack and ship a replenishment order. If the exact replacement part is not available, a notification will pop up at a shipyard worker’s workstation, recommending alternate courses of action. The shipyard worker will choose which option to pursue, consulting the Shipyard foreman where necessary. This functionality allows shipyard workers to stay focused on repair operations instead of requesting more supplies.

Want to learn more? Read more here: Smart Sensors and Supply Chain Innovation

Perspectives

Advanced & Additive Manufacturing

In the back shop, there is a dedicated Additive Manufacturing space, where there are different types of 3D printers manufacturing replacement parts (i.e., polymer vs. metal printing). Here, shipyard workers are additively manufacturing replacement parts at their workstation. This additive manufacturing capability means that fewer items need to be stocked at the digital warehouse, and more space in the shop can be dedicated to operations instead of holding inventory. At the testing and validation workstations, shipyard workers examine the 3D printed part and its digital file at the same time, validating that the physical part meets its digital specifications. Autonomous vehicles then deliver these parts to their required destination.

Want to learn more? Read more here: 3D Opportunity and the Digital Thread

Perspectives

Dynamic CAD Modeling

In the back shop, shipyard workers use CAD modeling software at individual workstations to access the design file for the part in question. Multiple workers are accessing the same digital file at the same time, enabling collaboration and expediting the repair process. They can perform analysis to identify where the part is likely to fail. Other shipyard workers inspect the physical part in question and provide detailed feedback on its condition, such as the level of corrosion. The powerful combination of physical and digital information informs possible courses of action, and analysis software uses that information to ultimately recommend repair/replace actions. A supervisor makes the final decision. 

Perspectives

Autonomous Delivery

In the back shop, shipyard workers are diligently working on CAD design and Additive Manufacturing activities. As they work, autonomous vehicles quickly and efficiently carry and deliver needed supplies to workstations. The vehicles follow specified delivery paths to ensure safe routing and travel around busy work areas. After shipyard workers unload the relevant materials, the vehicles carry surplus supplies or waste from workstations to appropriate destinations.

Want to learn more? Read more here: Autonomous Trucks Lead the Way

Perspectives

Welcome to the Future of Maintenance Microsite

The digital transformation of the Nation’s depots, shipyard, and warehouses will leverage next-generation technology for everything from intelligent operations management and advanced manufacturing to digital supply network synchronization. Personnel at all levels will be better enabled to succeed in their roles through the introduction of these technologies. This digitally-transformed infrastructure will establish an architecture for the Navy to lead its mission readiness capabilities into the future.

This tutorial will provide an overview of the Microsite’s functionality to understand the benefits and potential application of these technologies. Click on the slides below to learn how to navigate the site, otherwise close this window to start exploring. Site best viewed in Chrome or Edge browsers.

Digital Shipyard Perspectives

Click on the text below to learn more about each role. 

Define my role: Define what I care about (metrics, KPIs):
  • Individuals that oversee all shipyard operations (All models within the facility)
  • Responsible for overseeing overall maintenance activity schedule and execution
  • Meeting shipyard cost, schedule, quality and safety targets
  • Maintain safe operations
  • Availability of the right skills and supporting infrastructure (equipment, etc.)
Define my role:Define what I care about (metrics, KPIs):
 
  • Individuals that oversee maintenance activities and associated shipyard workers
  • Responsible for planning, assigning, and monitoring the execution of all work associated with a vessel
  • Directs adjustments to be made based upon outside factors (i.e., schedule change, material or engineering delay, etc.)
  • Assigns tasks and priorities based on available capacity, materiel availability, and required skills
  • Managing and resolving delays
  • Daily throughput and completion of work orders
  • Availability of the right skills, materiel, and supporting infrastructure (equipment, etc.)
  • Labor and equipment utilization
  • Actual vs. budgeted direct and indirect hours
  • Oversee safe operations
1st Line Supervisors, Artisans, E&Es, and quality personnel
Define my role: Define what I care about (metrics, KPIs):
  • Skilled and nonskilled shipyard employees or contractors performing the physical labor
  • Performs maintenance/repair tasks as directed by work orders
  • Labor and equipment utilization are maximized
  • Work is performed within allotted workload standards
  • Skills and training
  • Completing tasks within the allotted time at a high level of quality
  • Ensuring that parts are returned to the fleet in acceptable repair condition
  • Executing safety measures
Enabling Technologies

A key part of digital transformation of the Nation’s depots, shipyards, and warehouses are the enabling technologies that provide the foundation for the various technologies used throughout maintenance and logistics operations. These enabling technologies ensure connectivity, enable enterprise-wide visibility, and provide the security needed for system stability. Click on the text below to learn more about each role.

A 5G network provides the connectivity that is essential when employing a broad web of interconnected technologies. A 5G network increases the speed of data transfer, lowers latency issues, increases the bandwidth capabilities, and increases the capacity of data that can be sent.  
Cybersecurity supports the protection from cyber threats for all internet-connected systems such as the hardware, software, and stored data. Strong cybersecurity systems protect against unauthorized access to the sensitive information stored within military data systems.  
A Product Lifecycle Management (PLM) solution integrates organizational data, systems, and processes. This allows artisans and depot managers to access the technical data and product specifications needed as well as create and monitor digital twins for repaired parts and weapons systems. 
Model Based System Engineering (MBSE) solutions use a model based approach to support the setup of a complex system from initial concept to ongoing operational analysis. Using an MBSE approach supports orchestrating the combination of several complex systems and deepens the understanding of processes through integrated analytics. 
Robotic and Intelligent Automation (R&IA) can drive efficiency across manual and repetitive processes. Automating tasks reduces back logs and creates time for staff to work on more value-add tasks. Given the large number of tasks that need to be performed across the shipyards, depots, and warehouses this will free up the artisans and managers to focus on higher complexity, higher value tasks. Automation can also drive analytics for leadership to make more informed decisions. 
Control Tower provides deep supply chain data visibility through intuitive and innovative dashboards. Control Tower tools enable deep dives of data analysis to understand the reason for changes behind key performance indicators and augment problem solving and continuous process improvement. Control Tower capabilities can help proactively manage supply chains in real time, allowing leaders to focus on the most critical supply chain segments, while the rest of the supply chain can continue functioning in a business-as-usual fashion. A comprehensive Control Tower provides the visibility across the entire shipyard, depot, and warehouse to view the current state of all processes and quick identification of any pain points or areas requiring action by leadership. 

Control Tower

Six months prior to an aircraft arriving at the depot and during normal on aircraft maintenance at the 0-level, depot artisans perform a conditional maintenance inspection of the aircraft. Data from this inspection is used by various maintenance systems to plan for all logistics support required to complete its future heavy maintenance event. It also provides information to production managers concerning the amount of time as well as artisan skill sets required to perform that work. This information is used to determine proper staffing levels for future work. While finalizing the repair plans for that aircraft, the depot production manager receives two automated alerts from the Control Tower regarding potential issues to depot operations. The first alert indicates throughput of an assembly cell has dropped and the second forecasts supply shortages of critical parts needed to fix the aircraft based on the digital aviation supply data feed. Based on the alerts, the production manager addresses critical personnel shortages in the assembly cell and coordinates with other agencies to develop a plan to alleviate the projected parts shortages.  

Want to learn more? Read more here: The Supply Chain Control Tower

Perspectives