NIST Technical Note 1820 

Model-Based Enterprise 

Summit Report 

Joshua Lubell 

Simon P. Frechette 

Robert R. Lipman 

Frederick M. Proctor 

John A. Horst 

Mark Carlisle 

Paul J. Huang 

 

 

 

 

 

NIST Technical Note 1820 

Model-Based Enterprise 

Summit Report 

Joshua Lubell 

Simon P. Frechette 

Robert R. Lipman 

Mark Carlisle 

Systems Integration Division 

Engineering Laboratory 

Frederick M. Proctor 

John A. Horst 

Intelligent Systems Division 

Engineering Laboratory 

Paul J. Huang 

United States Army Research Laboratory 

Aberdeen, Maryland 

November 2013 

U.S. Department of Commerce 

Penny Pritzker, Secretary 

National Institute of Standards and Technology 

Patrick D. Gallagher, Under Secretary of Commerce for Standards and Technology and Director 
 

 

 

Certain commercial entities, equipment, or materials may be identified in this 

document to describe an experimental procedure or concept adequately. Such 

identification is not intended to imply recommendation or endorsement by the 

National Institute of Standards and Technology, nor is it intended to imply that the 

entities, materials, or equipment are necessarily the best available for the purpose. 

National Institute of Standards and Technology Technical Note 1820 

Natl. Inst. Stand. Technol. Tech. Note 1820, 151 pages (November 2013) 

CODEN: NTNOEF 
 

 

 

Abstract 

This report summarizes the presentations, discussions, and recommendations from the ModelBased Enterprise Summit held at the National Institute of Standards and Technology in 

December of 2012. The purpose of the Summit was to identify challenges, research, 

implementation issues, and lessons learned in manufacturing and quality assurance where a 

digital three-dimensional (3D) model serves as the authoritative information source for all 

activities in a product’s lifecycle. The report includes an overview of model-based engineering, 

technical challenges, summaries of the presentations given at the workshop, and conclusions that 

emerged from the presentations and discussions. 

Acknowledgment 

We wish to acknowledge the individuals who organized and participated in the 2012 ModelBased Enterprise Summit – particularly those who presented to the group as a whole. We would 

also like to thank Charlie Stirk (Cost Vision) for his insightful and helpful suggestions regarding 

section 3. We are particularly grateful to Phil Zimmerman (Office of the Secretary of Defense), 

Ric Norton (Defense Logistics Agency), Curtis Brown (Department of Energy), Richard Neal 

(Integrated Manufacturing Technology Initiative), Charlie Stirk, Garth Coleman (3DVIA), and 

David Stieren (NIST Manufacturing Extension Partnership) for providing us with draft 

summaries of their presentations for inclusion in section 4. Finally, we thank Chris Brown 

(NIST) and Roy Whittenburg (U.S. Army) for their helpful review of this document. 

Keywords 

Model-based, manufacturing, quality, inspection, scanning, MBE, MBD, technical data package, 

digital thread 

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Acronyms 

AMT	 Association for Manufacturing 

Technology 

ASME American Society of Mechanical 

Engineers 

ASTM American Society for Testing and 

Materials 

CAD	 Computer Aided Drawing 

CAE	 Computer Aided Engineering 

CAM	 Computer Aided Manufacturing 

CMM Coordinate Measurement Machine 

CNC	 Computer Numerical Control 

CSI	 Customer-Supplier Interoperability 

DARPA Defense Advanced Projects 

Research Agency 

DoD	 Department of Defense 

DLA	 Defense Logistics Agency 

DMSC Dimensional Measurement Standards 

Consortium 

EL	 Engineering Laboratory 

FAI	 First Article Inspection 

FEA	 Finite Element Analysis 

GD&T Geometric Dimensioning and 

Tolerancing 

IBIF	 Industrial Base Innovation Fund 

ISO	 International Organization for 

Standardization 

LOTAR Long-Term Archiving and Retrieval 

ManTech Manufacturing Technology 

MBD Model-Based Definition 

MBE Model-Based Enterprise/Engineering 

MEP Manufacturing Extension Partnership 

NASA National Aeronautics and Space 

Administration 

NC Numerical Control 

NIST National Institute of Standards and 

Technology 

OEM Original Equipment Manufacturer 

OSD Office of the Secretary of Defense 

PDPMI Product Data with PMI 

PLM Product Lifecycle Management 

PMI Product Manufacturing Information 

PRC Product Representation Compact 

PREVIEW Predictive Environment for 

Visualization of Electromechanical Virtual 

Validation 

QC/QA Quality Control / Quality Assurance 

QIF Quality Information Framework 

SE Systems Engineering 

SME Small or Medium Enterprise 

STEP Standard for the Exchange of Product 

Model Data 

SysML Systems Modeling Language 

TDP Technical Data Package 

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1 Overview 

The National Institute of Standards and Technology (NIST) Engineering Laboratory (EL) and 

the Office of the Secretary of Defense (OSD) hosted the fourth in a series of annual ModelBased Enterprise (MBE) Summits on December 11 -13, 2012, at NIST in Gaithersburg, 

Maryland. Over 170 participants from industry and government met to share the latest 

technological developments and best practices for MBE. Table 1 lists the organizations that were 

represented at the 2012 Summit. 

Table 1. Organizations Participating in the Summit 

3D PDF Consortium ICF International Purdue University 

3D-Via Imagecom Raytheon Company 

ACI Technology Imaginistics RECON Services/Army 

Action Engineering Integrated Manufacturing 

Technology Initiative Rensselear Polytechnic Institute 

Aerospace Industries Association ITI TranscenData Sandia National Laboratories 

Anark Corporation ITT-Exelis Siemens Energy Systems 

BAE Systems Jacobs Engineering Siemens PLM Software 

BE Aerospace Jotne North America. SolidWorks 

Bell Helicopter Textron L-3 Combat Propulsion Systems STEP Tools 

Boeing Company Lattice Technology South Carolina Research Authority 

Booze Allen Hamilton LMI Government Consulting Subsystems Technologies 

Capvidia Lockheed Martin Tech Soft 3D 

Cost Vision Lucrum Group Tetra 4D 

CT Core Technologies M-7 Technologies Trimech Solutions 

Cubic Defense Applications Marel TSR Optima 

Dassault Systèmes Metrosage U.S. Air Force 

Decision / Analysis Partners MFG.com U.S. Air Force Research Laboratory 

Defense Advanced Research 

Projects Agency Milltronics Manufacturing U.S. Research, Development, and 

Army Engineering Command 

Defense Logistics Agency Mitutoyo America Corporation U.S. Army Tank Armament Research 

Development and Engineering Center 

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Delcam National Aeronautics and Space 

Administration U.S. Coast Guard 

Department of Energy 

National Institute of Standards and 

Technology U.S. Marine Corps 

EOS Software Nextec Applications U.S. Naval Air Systems Command 

Exelis Northrop Grumman U.S. Naval Sea Systems Command 

GE Aviation Office of the Secretary of Defense: 

Manufacturing Technology University of Iowa 

GE Global Research Oracle UTRS. 

General Dynamics PAS Technology Verisurf 

George Mason University Pratt & Whitney 

Honeywell PTC 

The purpose of the Summit was to identify challenges, research, implementation issues, and 

lessons learned in manufacturing, quality assurance, and system acquisition where a digital threedimensional (3D) model serves as the authoritative information source for all activities in the 

product lifecycle. The 2012 Summit was organized around four model-based technical thrusts: 

• Acquisition – including a Special Session on Lightweight Viewers 

• Manufacturing – including a Special Session on Manufacturing Process Data 

• Inspection 

• Systems Engineering (SE) 

The Summit also included demonstrations of manufacturing software applications and optical 

scanning for inspection. This report collects and summarizes information presented at the 

Summit. Section 2 describes the importance of digital manufacturing for increased productivity 

and agility. Section 3 highlights the role and importance of standards. Section 4 summarizes each 

of the technical presentations. Conclusions and recommendations are in Section 5. The appendix 

contains the summit agenda and all presentation slides approved for public distribution. 

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2	 Manufacturing Goes Digital 

The key to success in manufacturing today is the ability to adapt. Constant change has become 

the norm. Manufacturers must implement new solutions that allow them to respond quickly to 

customer demands and competition. Several factors are contributing to the need to be agile: 

•	 Development time is getting shorter. 

•	 Manufacturing costs are rising due to increasing demand for raw materials and energy. 

•	 Globalization is increasing competition. 

•	 The demand for custom-configured products is growing. 

Digital manufacturing evolved from the need to optimize designs for manufacturing, to decrease 

the time required to go from design to first production, and to reduce expensive downstream 

changes. We characterize digital manufacturing as follows: 

•	 It is information-based, enabling rapid design-to-production and dynamic, distributed 

production systems. 

•	 It depends on virtual process modeling, systems integration, simulation analysis, data 

analytics, and data validation capabilities. 

•	 It requires integrated engineering software systems comprising 3D computer-aided 

design (CAD), simulation, analysis, computer-aided manufacturing (CAM), and various 

collaboration mechanisms to create manufacturing process plans. 

•	 It is a key point of integration, enabling the exchange of product-related information 

between design and manufacturing groups within an enterprise. 

Digital manufacturing led to the creation of the “digital thread” – extending the digital 

integration of design and production throughout the entire product lifecycle. The digital thread 

connects conceptual design, requirements, analysis, detail design, manufacturing, inspection, 

operations, refit, and retirement. The finished assembly can be traced back to the original 

requirements and design model. The unbroken data link through the lifecycle is the digital 

thread. 

The digital thread helps transform rigid supply chains into dynamic production systems by 

making data directly available to all the actors in the system. A dynamic production system is a 

fully-integrated, collaborative manufacturing system that responds in real time to changing 

demands and conditions in the factory and in the supply network. The primary characteristic of a 

dynamic production system is the ability to easily and rapidly reconfigure factory production and 

supply networks to optimize system performance. Such systems deal effectively with uncertainty 

and abnormal events, and learn from past experience to enable continuous improvement. They 

provide seamless interoperability between factory processes and supply networks, and between 

large manufacturers and small manufacturers. 

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With a valid digital thread, suppliers can trust that data will work in their manufacturing 

processes. When design changes come through the supply network, the information is 

immediately available to suppliers in a physics-based exact model. Digital processes eliminate 

transfer time and data validation time. Differences between drawings require human 

interpretation. Differences between digital models are flagged automatically. 

Another benefit of the digital thread is that it reduces the use of special-made physical (hard) 

tooling for system assembly. Particularly sensitive or critical subassemblies have to come 

together in exact true positioning at tolerances that require expensive, custom hard tooling to 

verify correct alignment. Manufacturers can reduce physical tooling requirements by using 

optical tooling and digital datums in the assembly model. A digital datum is a mathematical 

reference from which measurements can be taken, such as the axis of a hole or a plane that lies 

on a mating surface. Laser alignment, production processes, and automated assembly processes 

trace back to the assembly model through the digital thread. The use of optical measurement 

devices rather than physical tooling to establish measurement references eliminates the cost, 

maintenance, and storing and moving of dedicated hardware over the production life. 

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3	 The Role of Standards in Digital Manufacturing 

Standards-based exchange of product data has been very successful [1], with widespread 

commercial support of formats like ISO 10303 (also known as STEP, the Standard for the 

Exchange of Product Model Data) [2], ISO 14306 (also known as JT) [3], and ISO 14739 (also 

known as 3D-PDF) [4]. The exchange of manufacturing process data, however, has had minimal 

success. Despite the benefits of being able to exchange process data, the idea is controversial for 

several reasons: 

•	 Manufacturing processes are often highly customized to fit in-house production 

capabilities, types of machines and processes, tooling, fixturing, and rules, guidelines, 

and conventions. The associated manufacturing data would be useless to anyone other 

than the original manufacturer. 

•	 Process descriptions are considered proprietary information by most manufacturers. 

Making process descriptions available to customers, who could in turn distribute the 

information to competitors, would diminish the original manufacturer’s competitive edge. 

Even if manufacturing data were available to customer facilities or third parties, the 

engineers or machinists would choose to re-create the processes from the original design 

requirements, to have confidence in the resulting product. 

•	 There are few neutral formats for manufacturing process data, and native formats are so 

specific to particular machines that there is little chance for portability. The most 

prevalent data format, numerical control (NC) code for machine tools, is nominally 

standardized as ISO 6983 [5], but the variation in dialects and customization for machine 

options makes it almost impossible to share. Indeed, even understanding NC code in the 

absence of the original programming system is a forensic exercise. 

However, there are compelling business drivers for standardizing the exchange of manufacturing 

process data: 

•	 Within a large or global company’s manufacturing facility, high-level “macro” process 

plans can be defined by one facility, and sent to other facilities for refinement into 

“micro” process plans suitable for the actual tooling and fixturing available. Much of the 

work needed to translate design requirements into manufacturing features and operations 

could be done once, and shared. 

•	 Nominal manufacturing data for a baseline process could be included with design data 

when soliciting bids from suppliers. This would save the suppliers the time and effort to 

develop a candidate process needed to determine cost and lead time estimates. 

•	 Well-developed manufacturing processes could be sent out to the local supply chain for 

quick response when surges in need arise (the “Kinkos” model, where production is 

outsourced to a third party). 

•	 Manufacturing data can be used to drive simulation and training, reducing the time 

needed to recreate manufacturing processes on similar equipment. 

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•	 Manufacturing data standards are essential for long-term sustainment of complex 

products with a decades-long service life such as aircraft and military hardware. Without 

standards, even if a government or private sector procurer were able to obtain proprietary 

process information from the manufacturer at the time of purchase and validate that the 

information is correct and complete, there is little assurance that this information will be 

usable throughout the entire product lifecycle as process technologies and manufacturing 

software change. 

•	 Critical manufacturing processes, where the process is the only known way to produce 

something [6], have become increasingly commonplace as more specialized and 

proprietary technologies continue to be developed. Not having a standard for representing 

information for a critical manufacturing process increases the risk of losing the capability 

to refabricate, disassemble, repair, or inspect an item produced using the process. 

Standards, such as ISO 10303-238 (STEP-NC) [7], have been used to successfully exchange part 

programs for machining. Other recently developed standards cover auxiliary data needed to fully 

describe manufacturing. These include ISO 13399 [8] for cutting tool data representation and 

exchange, and the draft ASME B5-59 standard [9] for representing machine tool capabilities and 

performance. More recently, ISO/DIS 10303-242 [10] (also known as STEP AP242) enables the 

representation of semantic manufacturing and assembly information, such as assembly 

tolerances, surface finish, and manufacturing process information. Together, these standards can 

be used to much more fully automate the job of preparing manufacturing processes from design 

requirements, and sharing those processes throughout a model-based enterprise. 

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4 Presentation Summaries 

This section provides summaries of the presentations, grouped by technical thrust. Subsection 

titles are presentation titles. Italicized text following the subsection title identifies the presenter 

and organization represented. Summary text for the most part paraphrases the actual ideas 

communicated by the presenter. An exception is Jim Osterloh’s summary (4.3.1, second 

paragraph), where we describe a real-time demonstration. 

4.1 Model-Based Acquisition 

A military acquisition strategy must be based on centralized policies and principles, yet must 

also allow for decentralized and streamlined execution of acquisition activities. Such an 

approach provides agility and encourages innovation, without sacrificing discipline and 

accountability [11]. This subsection summarizes the presentations discussing model-based 

approaches to meeting acquisition challenges. Many of the presentations focus on the Technical 

Data Package (TDP), a collection of all product data needed to manufacture and maintain the 

product. The MIL-STD-31000 standard [6] specifies TDP requirements, and was recently 

updated to support 3D model-based, digital TDPs. 

4.1.1 DoD Modeling and Simulation Support to Acquisition 

Philomena Zimmerman, Office of the Deputy Assistant Secretary of Defense for 

Systems Engineering, System Analysis 

Modeling and simulation are key enabling tools for SE support to all phases of acquisition. 

Fundamental aspects of application of modeling and simulation have been documented for 

program support. These aspects underpin changes and assessments in both SE guidance and in 

application to program support. System modeling is expected to become a more prominent 

aspect of the modeling and simulation landscape and will be a key aspect of future initiatives, 

such as Engineering Resilient Systems. 

4.1.2 A-10 Pilot Program Overview “DLA Engages Model-Based Enterprise” 

Ric Norton, Defense Logistics Agency 

The A-10 wing replacement program is the first large-scale provisioning effort for a major 

weapons system platform that uses the 3D model as the master reference (rather than a 2D 

drawing) for the TDP deliverable. The supply chain user community is working with a 3D PDF 

derivative rather than STEP or native CAD file to perform specific logistics activities, such as 

cataloging. DLA Logistics Information Service has completed their preliminary review of the A10 wing provisioning parts lists using the 3D PDF TDPs. Updates and resulting comments were 

provided to the Air Force customer. 

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4.1.3 Contracting for Technical Data Packages within a Model-Based 

Enterprise 

Ric Norton, Defense Logistics Agency 

This DLA project identifies how the government currently drives TDP contract deliverables 

within an MBE environment. Gap and trend analyses will highlight current policy, procedure, 

directives, standards, systems and contract language used to drive 3D model data requirements 

and exchange. A business case will suggest a path forward to better satisfy model data 

requirements in a contract. The research compiled in this project will be a valuable source of 

information for those engaged in future MBE Concept of Operations development. 

4.1.4 Technical Data Package Lifecycle Management 

Howard Owens and Brent Gordon, Naval Air Systems Command 

At the Naval Air Systems Command, there are many issues and risks related to TDP lifecycle 

management. Those risks take place during the acquisition, quality assurance, storage, 

translation, and use stages. For quality assurance, there are no standardized 3D model acceptance 

criteria. For translations between multiple CAD systems, there are no standardized 3D model 

validation criteria. Model defects are not recognized until the model is used. Models do not often 

match the Original Equipment Manufacturer (OEM) “As-Built” or “As-Delivered” manufactured 

part. The evolution of technology has enabled programs to leverage 3D models in acquisition. 

However, those advances have outpaced policies, processes, tools, and infrastructure. 

There is a need to transition from non-integrated development environments to interoperable 

Product Lifecycle Management (PLM). PLM is the relational environment that ties all of the 

program data to the assembly structure and vice versa. Current initiatives supporting 

interoperable PLM include (1) the OSD /DoD Engineering Drawing & Modeling Working 

Group and (2) the Optical Generation of 3D Models for Computer Aided Manufacturing pilot 

project through OSD with the National Center for Manufacturing Sciences. The pilot project 

scope includes 3D model-based scanning and inspection. 

4.1.5 Special Session: Lightweight Viewers 

Lightweight viewers are software applications offering a low-cost way for humans to view and 

potentially for applications to consume geometry and Product Manufacturing Information (PMI). 

These viewers are helpful for implementing TDPs and enable collaboration without requiring 

that business partners buy expensive CAD systems. This subsection summarizes presentations 

discussing several data formats implemented in current lightweight viewers. 

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4.1.5.1 Effective MBE Using 3DPDF and 3D HTML 

Chris Garcia and Paul Perreault, Anark 

3D PDF and 3D HTML viewers are both well suited for 3D MBE deployment. 3D HTML 

provides maximum flexibility and is the preferred approach when deployed inside a corporate 

firewall. 3D PDF is best for use cases requiring communication with external suppliers, 

customers, and collaborators outside a corporate firewall. Unlike proprietary CAD viewers, 3D 

PDF and 3D HTML viewers are based on open formats and are deployable on most computers 

without the need for special downloads or browser plug-ins. 

4.1.5.2 3D PDF Overview 

David Opsahl, 3D PDF Consortium 

The three principal activities involving Model-Based Definition (MBD) data are exchange, 

visualization, and communication. Communication differs from visualization in that it conveys 

additional information such as precise geometry and supporting documentation. Product 

Representation Compact (PRC) [4], a content standard for 3D PDF, supports not only 

visualization, but also communication. PRC originated as an Adobe specification and is now 

undergoing standardization in Subcommittee 2 (Application issues) of ISO Technical Committee 

171 (Document management applications). Commercial software tools are available that can 

validate whether a 3D PDF document correctly represents the information in an authoritative 

model. Although websites and HTML-based technologies can also support exchange, 

visualization, and communication of MBD data, 3D PDF documents are better suited for offline 

access, long-term archiving, and as deliverables to regulators and compliance authorities. 

4.1.5.3 JT Overview 

Dennis Keating, Siemens 

JT is a 3D data format developed by Siemens PLM Software and is used for visualization, 

collaboration, and CAD data exchange. It can contain any combination of approximate (faceted) 

data, boundary representation surfaces, PMI, and model metadata (attributes). JT can be exported 

from a native CAD system, and information can be inserted into a JT file by other systems such 

as Product Data Management systems. 

Open JT is a free standard subset version of JT. The JT Open program is a community of 

software vendors, users, and interested parties that share JT knowledge and influence the 

direction of JT technology. The goal is to encourage widespread adoption of JT for 3D 

visualization, collaboration, interoperability, and data archiving. Open JT has been established as 

an ISO standard. There is a no-cost viewer, published file format (free to download), and 

developer toolkit available through the JT Open program. 

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4.1.5.4 Creo View 

Madhavi Ramesh, PTC 

PTC is moving to complete 3D workflow in its product lifecycle applications because drawings 

are not well suited for wide-spread collaboration across geographical barriers and because 2D 

drawings are more prone to errors than 3D models. An Aberdeen study found that 30% - 40% of 

part non-conformances are due to inaccuracies and interpretation errors using 2D drawings [12]. 

Creo View provides interactive viewing of 3D information and is integrated with PTC’s 

Windchill product data management system and Arbortext technical publishing engine. Creo 

View provides application programmer interfaces for Java, web applications, and Microsoft 

Office. Built-in scalability allows for very large datasets. Creo View also provides remote data 

access through mobile and cloud applications. 

4.1.5.5 Lightweight Graphics 

Garth Coleman, 3DVIA 

The 3DVIA mission is to empower anyone, at any skill level, to create and share professional 

quality 3D content and experiences through highly interactive software applications. Effective 

communication requires much more than a simple presentation. It requires a new way of 

connecting with your audience: one that is effective, engaging, and real. 3DVIA leverages 3D 

CAD and the 3DEXPERIENCE Platform from Dassault Systèmes with a suite of authoring and 

publishing applications for desktop, cloud, and mobile delivery. Virtual training is one notable 

area of application for 3DVIA lightweight graphics visualization, communication, and 

experience technology. 

4.2 Model-Based Manufacturing 

This subsection summarizes presentations focusing on the use of 3D digital models to drive 

process planning and manufacturing applications. Included in this subsection is the summary of a 

special session on manufacturing process data. 

4.2.1 GE Model-Based Manufacturing 

Dean Robinson, GE Global Research 

GE defines model-based manufacturing as the integration of digital design information with 

manufacturing process models. The goals of model-based manufacturing at GE include design 

and manufacturing cycle time reduction, manufacturing process yield and quality improvement, 

and product/component cost reduction. Key challenges include the introduction of new materials, 

material systems, and manufacturing processes such as additive manufacturing. GE’s modelbased manufacturing laboratory is working not only in manufacturing and inspection, but also in 

design for manufacturing, and tolerance modeling. GE reduced their tooling design time 75% by 

using model-based methods. 

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GE is using model-based methods to enable adaptive manufacturing for repair of expensive 

components. GE’s Intelligent Turbine Airfoil Manufacturing will make use of the “industrial 

internet” for tying information together, resulting in better decisions. GE is focusing on data 

quality for in-process models to maintain consistency between in-process models and the master 

model. Model edits in downstream processes such as computer aided manufacturing (CAM) 

break the link to the engineering design model. GE is working to use MBE and process 

knowledge to maintain design intent, improve quality, yield, and productivity. Most 

manufacturers need more modeling and simulation to optimize processes. There is too much 

overhead with starting from scratch in each different simulation/modeling system. We need to be 

able to bring models into these systems automatically. 

4.2.2 MEP: Connecting and Assisting U.S. Manufacturers with MBE 

Approaches to Defense Business Opportunities 

David Stieren, Manufacturing Extension Partnership, NIST 

The NIST Manufacturing Extension Partnership (MEP) program mission is to promote business 

growth and connect manufacturers to public and private resources essential for increased 

competitiveness and profitability. There are over sixty MEP centers with nearly 400 field 

locations throughout the United States. MEP serves over 30,000 manufacturers and conducts 

more than 10,000 projects annually. According to client data reported in 2011, aggregate MEP 

impacts include $8.2B increased/retained sales; $1.9B new client investment, $1.3B cost savings, 

and 60,497 jobs created or retained. 

MEP has several ongoing initiatives with the goal of improving manufacturers’ profitability. One 

area of emphasis is providing support for implementing advanced engineering practices and 

integrating engineering with production and other manufacturing execution functions. This 

includes working with DoD to implement MBE approaches throughout the supply base. NIST 

MEP is working with the Army Research Laboratory, BAE Systems, and the MEP centers to 

transition the DoD supply base to MBE. A 2009 MBE Supplier Capability Assessment reported 

that two-thirds of participating suppliers are ready to operate in a model-based environment. 

U.S. manufacturers are looking for specific MBE requirements and implementation guidance 

from DoD. Preliminary toolsets developed by DoD Manufacturing Technology (ManTech) have 

been well received by the industrial community. MEP assessed 3D TDP software tools and data 

formats in 2012. A survey of manufacturers in the Army supply chain indicated a strong 

preference for 3D TDPs over 2D drawings. A large majority said they plan to use 3D TDPs in 

their CAM processes. 

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4.2.3 Customer - Supplier Interoperability (CSI) Program 

John Gray, ITI TranscenData 

The CSI program was sponsored by DoD and the U.S. Air Force Research Laboratory to develop 

software solutions addressing engineering inefficiencies associated with data exchange and to 

accelerate the adoption of a Model-based Enterprise (MBE) in defense supply chains. 

The CSI project focused on the problem of sharing system information during the collaborative 

phase of design. Challenges included: 

•	 Supporting differing data requirements across contracts, including submittals in
 

standards-based and native CAD formats
 

•	 Supporting versions and model manipulation rules 

•	 Enabling companies to support very complex requirements based on the depth and 

complexity of the supply chain and the product 

•	 Minimizing the investment that companies make to manually convert the data or to 

install, maintain and train engineers on the systems and data requirements 

The CSI solution provides automation that eliminates the manual effort required to support 

variations in data submittal requirements. Workflows include execution of software in a 

specified sequence based on specified translation paths. Workflows can dynamically change to 

improve the conversion results. The benefits of the CSI project include cost reduction in the 

upfront design phases when collaboration requirements drive data sharing on a day-to-day basis, 

and reduced time-to-market by eliminating delays in manual preparation of manufacturing data 

for sharing and delivery. The CSI solution will tackle the highest cost elements of 

interoperability in the context of collaborative design, TDPs, “design to” packages, and “build 

to” packages. Through the automation of manual tasks, CAD validation, and advanced toolsets, 

the CSI program developed an interoperability framework for the defense industrial base. Using 

side-by-side comparisons with current best practices, CSI technologies will generate projected 

cost savings of approximately $50M per year when fully adopted by all supply chain members in 

a large defense acquisition program. 

4.2.4 Enabling the Digital Thread 

Karen Kontos, Honeywell 

MBE at Honeywell is driven by complexity of products and communication of design intent. 

Design collaboration occurs across hundreds of design communities (internal and external). 

Honeywell acts as the design integrator of complex cyber-physical (mechanical and electrical) 

assemblies. Honeywell’s MBE architecture must take into account the following factors: 

•	 Complexity of the aerospace supply chain 

•	 Complexity of products 

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•	 Product lifecycle support – long-lifecycle services are a large portion of Honeywell’s 

business 

•	 Demands for re-use 

•	 Outsourced manufacturing for more than 50% of Honeywell’s products 

Communication and exchange processes associated with digital data must become more efficient 

and robust to support a sustainable business. “Model is the master” is a fundamental enabler for 

tracing design intent, streamlining inspection process development time, reducing errors in 

design and manufacturing through early identification of manufacturing issues, and eliminating 

redundant efforts to re-create information. MBE also supports early analysis of manufacturing 

cost during design phase, and design for manufacturability. 

Honeywell achieved the following MBE milestones in 2012: 

•	 Formally established an MBE organization as a part of product lifecycle
 

management/engineering operations in Honeywell Aerospace
 

•	 Started internal MBE/TDP initiatives 

•	 Completed (with ITI TranscenData – see 4.2.3) the CSI project 

•	 Completed TDP and manufacturing pilot projects 

Honeywell’s external industry initiatives and standards support includes the DoD MIL-STD 

31000 TDP specification, participation in PDES, Inc., STEP AP242 development, and 

participation in the Aerospace Industries Association Long Term Archiving and Retrieval 

(LOTAR) standards development effort (http://www.lotar-international.org). 

4.2.5 PTC's MBE Solution 

Madhavi Ramesh, PTC 

PTC’s solution for MBE uses a digital “master model” (not necessarily CAD) from which all 

downstream activities can be derived to create the final product. In this context, “design” is 

merely creating geometry, while “engineering” is the use of physics-based rules to develop new 

products. The master model contains not only CAD geometry, but also additional information 

needed for production, assembly, and field support. This additional information could include 

Geometric Dimensioning and Tolerancing (GD&T), material specifications, bills of material, 

process specifications, and inspection data. 

The MBE approach requires engineers to model and simulate an entire system operating in its 

setting to fully understand the system’s behavior. An advantage to this approach is that 

integrating engineering-design models within a model-based environment helps pinpoint designperformance problems as they arise. 

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4.2.6 DARPA Open Manufacturing 

Mick Maher, Defense Advanced Research Projects Agency (DARPA) 

The goal of the DARPA Open Manufacturing program is to lower the cost and speed the delivery 

of high-quality manufactured goods with predictable performance. The program aims to do so by 

creating a manufacturing framework that captures factory floor and materials processing 

variability and integrates probabilistic computational tools, informatics systems, and rapid 

qualification approaches. Target applications will include metals additive manufacturing and the 

manufacturing of bonded composites structures. 

Driving Open Manufacturing is the need to: 

•	 Maintain legacy systems longer 

•	 Maintain a robust industrial base that is not dependent upon DoD, but can be responsive 

when called upon 

•	 Increase agility and rapid manufacturing capabilities 

•	 Increase performance while reducing cost and weight 

•	 Build more prototype systems to keep performance innovation alive 

•	 Establish confidence in these new processes – if risks are not known and controlled, nontraditional/innovative processes will not be implemented 

The Open Manufacturing Program is developing four primary technologies: 

•	 Probabilistic, physics-based process-property models to predict and guarantee that a 

manufactured product’s range of performance lies within design requirements 

•	 A rapid qualification schema that employs statistical methods and probabilistic
 

simulation tools for low-cost, high-confidence prediction of system performance
 

•	 New manufacturing and fabrication processes that result in improved performance, 

reduced production times, and more affordable manufacturing 

•	 Military-service-affiliated manufacturing demonstration facilities that serve as
 

repositories of focused manufacturing knowledge and infrastructure
 

4.2.7 Smart Manufacturing Research Programs in the NIST Engineering 

Laboratory 

Simon Frechette, National Institute of Standards and Technology 

U.S. manufacturing must adapt to a changing world and more aggressive and adept competition. 

Innovation, productivity, and quality are critical factors for the success of U.S. manufacturers. 

NIST’s Engineering Laboratory (EL) helps manufacturers to innovate and compete more 

effectively by providing measurement science to help advance technology and reduce risk. EL 

manufacturing programs focus on the development of measurement and testing methods, 

predictive modeling and simulation tools, protocols, and reference artifacts. EL programs 

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develop the technical basis for manufacturing-related standards and practices. EL manufacturing 

programs work closely with U.S. industry, industrial consortia, standards development 

organizations, and academia. 

The EL smart manufacturing strategic goal and sustainability strategic goal currently include the 

following manufacturing programs: 

• Smart Manufacturing Processes and Equipment 

• Next-Generation Robotics and Automation 

• Smart Manufacturing and Construction Systems 

• Systems Integration for Manufacturing and Construction Applications 

• Sustainable Manufacturing 

The Smart Manufacturing Processes and Equipment Program advances measurement science to 

enable rapid and cost-effective production of innovative, complex products through advanced 

manufacturing processes and equipment in the following research focus areas: Additive 

Manufacturing Measurement Standards, Machine Tool Performance, Machining Process 

Modeling, and Nano Manufacturing Measurement. 

The Next Generation Robotics and Automation Program advances measurement science to 

safely increase the versatility, autonomy, and rapid re-tasking of intelligent robots and 

automation technologies for smart manufacturing and cyber-physical systems applications in the 

following research areas: Sensing and Perception Manipulation, Mobility, and Robot Autonomy. 

The Smart Manufacturing and Construction Systems Program advances measurement science to 

enable real-time monitoring, control, and performance optimization of smart manufacturing 

systems at the factory or site in the following research areas: Factory Networks, Information 

Modeling & Testing, and Performance Measurement and Optimization. 

The Systems Integration for Manufacturing and Construction Applications Program advances 

measurement science for integration of engineering information systems used in complex 

manufacturing networks to improve productivity. Research areas include: Engineering Systems 

Integration, Production Network Integration, and Production Network Data Quality. 

The Sustainable Manufacturing Program advances measurement science to achieve sustainability 

across manufacturing processes, enabling resource efficiency and production network resiliency 

in two research areas: Sustainable Processes and Resources, and Integration Infrastructure for 

Sustainable Manufacturing. 

4.2.8 The Army’s Implementation of a Net-centric Model-based Enterprise 

Sanjay Parimi, Armament Research Development and Engineering Center 

The major objectives of net-centric MBE are (1) enterprise adoption, (2) deployment of technical 

and business processes, (3) development and deployment of Product Data Management, and (4) 

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development of standards-based model-based technologies. Industry assessments we conducted 

jointly with NIST MEP (see 4.2.2) show widespread acceptance of our 3D TDP approach. 

Accomplishments to date include: 

•	 Development and implementation of fully-annotated CAD models 

•	 Establishment of a CAD validation capability 

•	 Creation of a 3D TDP for the M2A1 machine gun’s quick change barrel 

• Development of animated Digital Work Instructions for fielded systems 

Our current activities include: 

•	 Creating and deploying a Service Information System to support logistics operations 

•	 Developing a new version of MIL-STD-31000 

•	 Implementing MBE capabilities at Anniston Army Depot 

•	 Developing an Interactive Electronic Technical Manual for installing the Self-Protection 

Adaptive Roller Kit, equipment providing pre-detonation of pressure-plated improved 

explosive devices, and blast dampening for Mine Resistant Ambush Protected and other 

tactical wheeled vehicles 

•	 Evaluating and implementing reverse engineering technologies 

The Accelerated, Adaptive Army Fabrication is a new ManTech-funded project whose output 

will be a prototype weapon system employing Army-owned design and manufacturing 

knowledge for next-generation improvement and sustainment. Accomplishments so far include 

development of software tools to handle requests for quotes, deployment of an MTConnectenabled [13] platform for inspection data, testing and validation of additive manufacturing 

equipment, and piloting of machining optimization tools. 

4.2.9 PREVIEW 

Timothy Marler, University of Iowa, Advanced Manufacturing Technology Group 

The Predictive Environment for Visualization of Electromechanical Virtual Validation 

(PREVIEW) project will demonstrate the utility of providing designers with advanced modeling, 

simulation, and visualization capabilities to analyze various design alternatives early in the 

design process. Partners on this project include Rockwell Collins and the South Carolina 

Research Authority, with funding provided by the Air Force Research Laboratory. PREVIEW 

uses video game technology to provide physics-based simulation, visualization, testing, and 

analysis. Future plans include virtual circuit testing, inter-process communication to support 

people in different locations working on same model at the same time, additional analysis 

capabilities to reduce requalification costs, and automating a feedback loop from analysis to 

design. 

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4.2.10 Implementing Model-only at Cubic Defense Applications 

Peter Buzyna, Cubic Defense Applications 

Cubic Defense Applications employs model-based technologies including CAD, 3D printing, 

and 3D scanning. Cubic partnered with Anark to develop a 3D PDF-based publishing tool for a 

MIL-STD-31000 implementation. The tool can export a PMI-annotated model from SolidWorks 

to 3D PDF. 

4.2.11 Special Session: Manufacturing Process Data 

Barriers to incorporating process data into MBE include: 

•	 Lack of trust in process data produced by someone else 

•	 Impact of even minor changes in tooling, setup, or machine tool performance on 

portability
 

• Concerns about divulging intellectual property to competitors 

On the other hand, there are compelling use cases for process data sharing, including: 

•	 Collaborative process development between experts using different software applications 

•	 Modeling and simulation of manufacturing 

•	 Data interchange between CAM systems 

•	 Long-term preservation of process descriptions and associated tooling, fixturing, and 

machine tools 

•	 Supply chain management – 3D models plus high-level process plans can be sent to 

candidate suppliers, or posted to e-bid sites, enabling a quicker and more accurate 

response 

•	 Optimizing the use of a distributed enterprise’s manufacturing resources 

Presentations summarized in this session include talks about CAD-to-CAM interoperability and 

the STEP-NC standard for CAM-to-CAM data exchange, and also talks discussing specific 

CAM software applications. Also summarized is a panel addressing questions and issues raised 

by the audience. 

4.2.11.1 Overview of Siemens CAM Systems 

Sada Reddy, Siemens 

The Siemens NX-CAM software application is organized into modules for milling, turning, 

electrical discharge machining, feature-based machining, motion control, post-processor 

customization, shop document preparation, and simulation. Milling includes 2.5-axis geometry 

typical of machinery and electronics components, and full multi-axis contour machining for 

applications such as tool and die, aerospace, and medical components. Turning support includes 

typical 2-axis applications, and also synchronized mill-turn machines and B-axis turning where 

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the tool pivots around a designated point. Turning operations can be created and customized 

from a collection of parameterized operations. General motion control provides customization of 

tool paths, especially probing sub-operations that can be highly customized using a collection of 

motion and probing elements. 

NX/Open allows external software access to technology data at the operation level. This allows 

the reading and setting of operation parameters, and simplifies the writing of post-processors. 

Feature recognition is enabled based on colors and attributes, where the user defines feature 

types with corresponding colors and attribute criteria through a machine knowledge editor. Users 

can add face attributes and assembly information such as tolerances to features. The target 

application is complex feature geometry. 

NX-CAM automates the generation of shop documentation to provide graphical and tabular 

descriptions of machining operations. The entire setup or selected operations within a setup can 

be documented. Documentation templates can be customized using Microsoft Excel, making 

them easy for non-experts to modify. Documentation includes descriptions of each operation and 

associated tooling. Tooling libraries are integrated with Siemens’ Teamcenter product, providing 

a link to databases of tools and material properties. A comprehensive set of post-processors is 

available for download from Siemens’ post-processor library. 

Graphical tool path simulation and full machine tool motion simulation are supported, so that 

manufacturing operations can be visualized before running on the actual equipment. Dynamic 

machine tool positioning lets users add machine tools to the simulation display, showing the 

machine tool motion as the tool is tilted, and detecting axis limits and collisions. 

A software application programming interface allows third-party developers to write 

supplemental applications. Geometry standard output is provided in STEP, JT, and numerous 

other formats. Direct interfaces exist for several third-party CAD applications. 

4.2.11.2 Computer Aided Manufacturing with Dassault Systèmes 

Israel Flores, Dassault Systèmes 

Dassault Systèmes wants to extend the 3D master model to include manufacturing information 

and procedures. The company’s main design product, CATIA, has evolved from 3D design in 

Version 3, through 3D digital mock-up in Version 4, 3D product lifecycle management in 

Version 5, to a full 3D experience in Version 6. Even in the presence of full 3D model data, 

some master data can only be accessed through 2D drawings. Therefore, Dassault is moving 

toward 100% 3D definition as the single master reference, with 2D representations used only for 

presentation. This 3D master model covers engineering (requirements and design), 

manufacturing process planning (work instructions, equipment programs, and technical 

publications), and production (shop floor review and quality inspection). Suppliers, customers, 

partners, and authorities all interface to this 3D model. 

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The shop floor and part ordering systems need executable, clear, and precise work instructions 

with associated configuration-managed 3D master information that includes all engineering 

changes. This information communicates model-based engineering requirements (tolerances, 

standard parts, specifications, etc.) based entirely on a parameterized 3D dataset, moving design, 

engineering, and simulation analysis data downstream through work instructions, supplier 

condition, and technical documentation. Manufacturing information includes manufacturing and 

routing sequences, assembly validation, work instructions, manufacturing views, buy-off and 

sign-off certificates, data collection, and quality check results. Design intent is conveyed to upfront activities such as planning, off-line programming, simulation, and validation. 

STEP is the Dassault strategic format for long-term archiving and interoperability. STEP 

evolution has been driven by customer consortia: ProSTEP, PDES Inc., and LOTAR. Dassault’s 

involvement in STEP has taken place over a long period, with support for AP203 [14] and 

AP214 [15] available since CATIA Version 4, circa 1994. Dassault has extended STEP support 

to a wide variety of applications: geometry, assembly, 3D dimensions and tolerances, 

composites, and electrical systems. 

Dassault has advocated for representation of manufacturing information such as GD&T using 

polylines as the simplest and most reliable way to achieve PMI exchange for human 

interpretation. The representation of validation properties improves the quality of data transfer 

and archiving for LOTAR; these properties include the distances between control points on 

surfaces, and the length, center of gravity, and validation strings for PMI. 

For long-term archiving of manufacturing information, low-level process information such as 

Automatically Programmed Tool language [16] or direct tool path data are not useful. When 

exchanging process information between CAM systems, higher-level information is the record of 

authority. Specific numerical control code programs can be recreated from this high-level 

exchange information. A neutral format for the exchange of high-level CAM data would be a 

welcome advancement, but the complexity and wide range of this information makes it difficult 

to standardize. Intellectual property protection is an important consideration for long-term 

archiving of CAM data. An industry effort should take place to develop a standard CAM data 

format meeting the above requirements. 

4.2.11.3 Engineering Data Exchange and the Manufacturing Supply Chain 

H anan F i s hm a n, D e l c am 

Delcam uses a “direct modeling” approach that reduces some problems with geometry data 

exchange: part complexity, productivity, data reuse, litigation, longevity, and traceability. The 

cost of data translation was highlighted in a 1999 NIST report [17] that calculated a $1B cost to 

the automotive industry, and in a 2008 report in MoldMaking Technology [18] that claimed 90% 

of toolmakers receive less than half their customers’ models in the toolmaker’s preferred format, 

with 42% of toolmakers using four or more CAD systems in a given month. 

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Costs arise from several activities: 

• Data translation 

• Model repair 

• Confirming that repairs are correct 

• Maintaining multiple CAD systems 

• Hiring or training staff to operate multiple systems 

• Translating files to return to the customer 

Attempting to solve these problems by relying on a single vendor’s application suite won’t work 

because OEMs and contract manufacturers use different systems, OEMs change the systems they 

use, new versions of the same system often aren’t compatible, and systems disappear from the 

market. Reliance on a single application suite also reduces effectiveness. No single software 

suite is the best for everything. The needs of the OEM manufacturer are not the same as those of 

the contract manufacturer. Being the best at data management and design does not make one the 

best at NC programming. And OEMs can afford to pay more for software than smaller contract 

manufacturers. 

Sophistication of geometric modeling, from wireframes to surfaces to solids, is increasing. 

However, solid models still suffer from problems that can be characterized as “dumb” versus 

“smart”. A dumb model is one without any history of modeling operations, perhaps arising from 

a conversion of a surface model. A dumb model may have intentional benefits, though: designers 

may not want to send outside manufacturers the actual modeling details for concern of divulging 

intellectual property, and designers don’t want to send out more information than they need to 

get the part made. 

A direct modeling approach is useful for data repair. Automated or semi-guided tools can fix 

problems such as gaps or overlaps in surfaces, duplicated or missing surfaces, or poor quality of 

trimmed edges. Direct modeling allows for making rapid, history-free edits to solids where 

surrounding faces automatically extend and re-intersect, maintaining a fully closed solid at all 

times. 

4.2.11.4 CAM to CAM Data Exchange 

Martin Hardwick, STEP Tools, Inc. 

The ISO 10303-238 STEP-NC standard is the manufacturing process component of a TDP that 

serves to exchange information across a variety of activities: design, tooling and fixture design 

and configuration, machining resource descriptions, the manufacturing processes themselves, 

and overall factory control. 

Time and monetary costs differ in three alternative scenarios in which an OEM contracts with a 

supplier for manufacturing assemblies. In the traditional scenario where the OEM owns the 

process and the related resources (machines, tools, and fixtures), direct monetary costs to the 

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OEM are highest. If the supplier owns the process and resources – a recent trend in the aerospace 

industry, the OEM incurs more time costs. However, in a standards-based scenario, where the 

OEM and supplier share the process, both monetary and time savings result. 

If process information cannot be shared between customers and suppliers, unnecessary costs 

arise: visits to suppliers to explain models, maintenance of additional machines, repetitive errorprone data entry, misunderstandings over drawing symbols, and incomplete simulations. The 

desired solution is based on science, not art. Recent editions of information exchange standards 

include true manufacturing information (such as tolerances) in a meaningful form, and are a big 

step toward realizing the science-based approach. Having manufacturing information semantics 

enables accurate simulations of machining processes and the ability to determine whether a 

combination of machine and tools will fulfill tolerance requirements. 

The STEP-NC standard models information to make machining faster and more accurate. STEPNC information supports activities such as supply chain interoperability, on-machine feed-speed 

and tool-wear optimization, on-machine simulation and collision detection, and closed-loop 

machining and measurement. STEP-NC is based on machining features rather than point-to-point 

tool motion, is platform independent, and is intended to support “plug and play” between CAD 

and CAM systems. STEP-NC describes “what” rather than “how,” that is, “Make this geometry 

from this stock, by removing these features, in this order, with these tolerances, using tools that 

meets these requirements.” 

Ten years of testing have gone into validating STEP-NC in production applications, in five 

phases: tool path generation from manufacturing features; CAM-to-CNC (Computer Numerical 

Control) data exchange without post processors; integration of machining and measurement; 

cutting tool and cutting process modeling; and modeling of tool wear, machine tool properties, 

closed-loop compensation, and accuracy prediction. Use of STEP-NC reduces process planning 

time for routine machining by an estimated 35% and machining time by an estimated 50% [19]. 

CAM vendors stand to gain an increase in the value of their software products by supporting 

STEP-NC for such capabilities as new applications (e.g., adaptive fixturing), advanced functions 

(e.g., automated feed/speed optimization), access to a much larger database of machine types, 

and support for long-term archiving. 

In the coming months, the STEP Manufacturing Team responsible for AP 238 plans a 

deployment path using the so-called “boxy” test part developed by the Royal Technological 

University in Sweden. The deployment is split into two six-month phases, the first focusing on 

CAM systems writing STEP-NC output files, and the second focusing on reading these files as 

input. A software tool provided by STEP Tools Inc. will be used to view and verify STEP-NC 

files during the project. 

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4.2.11.5 Panel Session 

Fred Proctor, Israel Flores, Hanan Fishman, and Martin Hardwick finished the session with a 

panel discussion during which they fielded questions from the audience, paraphrased as follows. 

Q: Does STEP-NC cover additive manufacturing?
 

Hardwick: Yes, some models have been developed.
 

Proctor: An advantage to additive manufacturing is that it’s largely process-free, so there is no 

need for tool paths. This may change as the technology becomes more widespread.
 

Q: What is happening in standards for additive manufacturing?
 

Hardwick: Draft standards need to undergo validation testing. 

Proctor: An issue is that other standards committees, such as ASTM Technical Committee F42, 

are also working on additive manufacturing formats. It remains to be seen how this will shape 

up, and what harmonization is needed. 

Fishman: Additive manufacturing is much more of a hardware challenge than a software 

challenge at this point. 

Q: Has anyone attempted to share process data (as opposed to product data) for machining? 

Fishman: Yes, it’s difficult. A general consensus among the attendees is that there’s always 

going to be a reluctance to share process information, for many reasons: intellectual property 

disclosure, possible embarrassment, and possible liability. 

Proctor: The issues are largely the same as for computer software source code. 

Audience Participant: There is an example from the Colt/Remington firearms manufacturer,
 

where the government owns the technical data including some process information. 

Q: Can we get the new PMI models from AP242 into AP238?
 

Hardwick: It could be incorporated into the next edition.
 

Proctor: Using STEP-NC for direct CNC programming could lead to a big productivity increase. 

NIST researcher Tom Kramer showed how this could be done. 

4.3 Model-Based Inspection 

Speakers in the Model-Based Inspection technical thrust represented a wide range of companies 

and expertise, with one end user and four vendors. All speakers had decades of experience of 

relevance to model-based manufacturing, including model-based metrology, standard metrology 

information modeling, and GD&T. This subsection summarizes the Model-Based Inspection 

presentations, two of which (4.3.2 and 4.3.4) describe efforts to address the information 

requirements of metrology systems for upstream activities [20]. 

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4.3.1 3D Model-Based Scanning and Inspection 

Jim Osterloh, M-7 Technologies 

3D imaging and advanced prototyping techniques are the fastest way to provide the most detailed 

and complete information on the size, shape, and surface variation of complex objects. These 

objects can be as common as an industrial manufacturing facility or as unique as the wing spar of 

a recently developed unmanned high altitude surveillance aircraft. An accurate “as-built” 

visualized representation of an object can be fully integrated into the digital manufacturing 

process, whether it is the part itself or the plant that manufactures that part. 3D imaging results in 

increased reliability, more accurate documentation, decreased manufacturing cost, and improved 

quality and extended service lifetimes. M-7’s primary motivation for optical metrology research 

is speed – touch probing is slow. One of M-7’s goals is to increase machining center 

effectiveness via in-situ measurement and closed loop control. 

M-7 is currently working in collaboration with Milltronics Manufacturing to develop on-machine 

laser probing. A video demonstration of this work illustrates the performance differences 

between a touch probe and a laser probe. The demonstration currently requires manual feedback, 

although automating the feedback loop would be more desirable. Surface reflectivity is a 

challenge when using a non-contact laser to measure locations and compare them with 

tolerances. A touch probe might be more suitable for measuring transparent or translucent 

components. 

4.3.2 Model-Based Quality Metrology Enabled by Quality Information 

Framework Interoperability 

Curtis Brown, Department of Energy/National Nuclear Security Administration 

Kansas City Plant 

Quality is a customer requirement and is not optional. The critical requirements for successful 

implementation of model-based quality metrology are a fully semantic assembly tolerance 

representation, domain-specific shape features (i.e., measure features) and digital interoperability 

standards for manufacturing, assembly, and quality information. The Dimensional Metrology 

Standard Consortium’s (DMSC) Quality Information Framework (QIF – 

http://www.qifstandards.org) is a digital interoperability standard for quality information. 

QIF includes an integrated information model for the real-time exchange of data between 

software and equipment modules in quality measurement. QIF is a suite of XML Schemas 

consisting of a library of reusable components and various application schemas such as Quality 

Measurement Plans (QMPlans) and Quality Measurement Results (QMResults). QIF was 

successfully piloted at the 2012 International Manufacturing Technology Show by a team of 

seven metrology software and equipment vendors. The team performed a live demonstration of a 

First Article Inspection (FAI) report compliant to the AS9102 FAI documentary standard [21]. 

Components of the QIF will soon emerge as an American National Standard. The DMSC is 

23
 
 

 

 

preparing a “Product Data with PMI” (PDPMI) XML schema, a new QIF data exchange 

specification for CAD with PMI. 

4.3.3 Model-based Inspection: Leveraging MBD for Quality Assurance 

Ron Branch, Verisurf 

A model-based quality measurement process offers the following advantages over a process 

involving 2D drawings: 

•	 A single-source definition of all information needed to produce a quality product 

•	 Integrated inspection processes, including the supply chain 

•	 Elimination of errors of incorrect source referencing 

•	 Elimination of discrepancy errors between the CAD model and separate 2D
 

documentation
 

At the large scale, the goals of MBD are to accelerate time-to-market, decrease time and 

expense, and improve quality. MBD can be considered an integral part of achieving lean 

operations through the elimination of waste, particularly the time it takes to create and maintain 

paper-based model drawings, by allowing in-process inspection to catch possible production 

problems before they occur. 

As more manufacturers adopt the MBD approach: 

•	 MBD will enable digital global supply chains. 

•	 MBD will eliminate most 2D drawings. 

•	 The new STEP standard (AP242) will significantly enhance interoperability. 

•	 The use of non-contact inspection and 3D scanning will increase significantly. 

•	 Model-based inspection will lead to the emergence of cloud-based inspection databases. 

•	 Faster closed-loop manufacturing and inspection cycles will lead to a resurgence of 

statistical process control. 

4.3.4 Using Open CAD Formats to Bridge the Gap between Today’s and 

Tomorrow’s Standards 

Tomasz Luniewski, Capvidia 

In a Model-Based Enterprise, it is challenging to exchange 3D geometry using open standards 

that include metadata and semantic relations as defined in native CAD systems. Although 

information can be exchanged via native CAD formats and STEP files, there are gaps. Capvidia 

has developed CAP XML, a data format that captures topology, geometry, auxiliary objects, 

relations, features, and metadata. Metadata includes GD&T information. CAP XML arose from 

an internal proprietary data structure used to handle data from various CAD systems. The 

benefits of CAP XML are that it is open, human- and machine-readable, flexible and easy to 

extend, compact, has bi-directional compatibility with AP242, and covers all CAD system 

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structures. Capvidia is negotiating with the DMSC to donate the CAP XML schema. DMSC will 

harmonize it with QIF. 

4.3.5 Model-Based Predictive Technologies for Dimensional Measurement 

J on B al dw i n, M e t r oSa ge 

Model-based measurement planning does a number of things well, such as generating collisionfree probe paths and facilitating sensor orientation selection. However, model-based 

measurement planning does not validate GD&T, nor can it guarantee traceability or optimality. 

Tools such as FBTol [22] for GD&T validation can alleviate these issues. 

Measurement uncertainly evaluation is important to understand many issues related to 

Coordinate Measurement Machines (CMMs). Model-based simulation methods can evaluate 

many GD&T parameters in one “experiment.” There are measurement risks and costs such as 

false positives (classifying a good part as bad) and false negatives that usually have worse 

consequences than false positives. 

4.3.6 Model-based Definition Enables Inspection Lifecycle Management 

Sam G ol a n, P A S T e c h nol og y 

PLM is the process of managing the entire lifecycle from its conception, through design and 

manufacture, to service and disposal. A key to PLM success is integration, where integration 

provides a manufacturing information backbone. Integration involves people, data, processes and 

business systems. 

Quality assurance is an integral part of PLM. The outsourcing of Boeing 787 systems led to 

quality assurance challenges that resulted in delays and increased costs. To make quality 

assurance a real integral part of PLM, there needs to be inspection lifecycle management. One of 

many inspection challenges is that it takes longer to develop a CMM program than a CNC 

program from the same CAD model. Inspection lifecycle management automates and manages 

the entire integrated quality assurance process from design to manufacturing to inspection to 

trusted inspection results. 

4.4 Systems Engineering 

The Handbook of Systems Engineering and Management defines SE as “the management 

technology that controls a total system lifecycle process, which involves and which results in the 

definition, development, and deployment of a system that is of high quality, trustworthy, and cost 

effective in meeting user needs” [23]. In the context of MBE, SE involves ensuring that a model 

captures functional and behavioral requirements, and that design information is traceable to these 

requirements. This subsection summarizes presentations focusing on the capture, tracking, and 

maintenance of requirements information. 

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4.4.1 Update on Key Model-based Engineering (MBE)-related Pursuits at 

NASA 

Paul Gill, National Aeronautics and Space Administration (NASA) 

The NASA manufacturing environment is unique. NASA is composed of independent centers. 

Centers have different missions, but all include engineering of some kind. Interactions between 

centers tend to be project-specific. NASA projects are dependent on prime contractors. Projects 

usually have long development and operational life cycles. Long life cycles complicate change 

management because they make it difficult to converge on any common approach (e.g., 3D CAD 

did not exist for Voyager 37 years ago). Unlike many other manufacturing enterprises, NASA 

builds very low volumes of complex products. 

NASA’s MBE development must meet the following requirements: 

• Improved systems integration 

• Long-term access to design data 

• Integrated SE 

• Conceptual engineering integration with modeling and simulation 

The following are non-requirements for NASA: 

• Manufacturing or supply chain coordination (due to low rates) 

• Unit cost reduction (typically no more than three units of any design are built) 

• Reuse of design data for new products (because missions are unique) 

NASA has a long tradition of pioneering new engineering technologies to meet big challenges. 

The NASA Langley Research Center developed custom hardware for Finite Element Analysis in 

the late 1970s [24]. More recently, findings from the Columbia Accident Investigation Board 

[25] resulted in NASA developing new insights into the flow of data between NASA 

Engineering and downstream activities. Today, discipline-focused NASA Working Groups are 

converging on solutions addressing challenges in model-based SE, modeling and simulation, 

CAD interoperability, and PLM. 

NASA views MBE as a way to increase efficiency and quality of critical activities such as: 

• Systems modeling and simulation 

• Verification and validation 

• Vehicle systems integration 

• Flight operations 

• Prototyping and test article production 

• Post-event analysis and review (e.g., in-flight anomalies) 

• Concept development and proposal reviews 

• Prime contractor interfaces 

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• Systems integration (e.g., science payloads) 

• Vehicle acceptance 

NASA currently has two initiatives related to MBE. The NASA Integrated Model-centric 

Architecture program seeks to increase affordability and interoperability within and among 

programs/projects, centers, and external partners through the use of a common model-centric 

architecture. NASA benchmarked companies using a model-centric architecture for engineering 

and manufacturing. Companies benchmarked included Whirlpool Corporation, Ford Motor 

Company, Lockheed Martin, and Pratt &Whitney Rocketdyne. 

The second initiative is the Product Data Management & Interchange program. The goal of this 

project is to provide some data commonality among NASA projects. NASA has over ten PLM 

systems and numerous CAD, simulation, and analysis systems. Many current tools and 

architectures were selected before 3D CAD and prior to large programs like Constellation. 

NASA cannot dictate what systems its primes use. Detailed design work is often outsourced or 

handled by the primes. Individual NASA projects have a lot of authority to choose their own 

engineering tools, mostly because of the long duration of the projects. Many new tools are 

available for new projects. Project and SE policies are very inconsistent on the topic of 

“models.” For example, one project substituted “model” wherever they had the term “drawing.” 

Modeling practice is driven by NASA center-level policies, procedures, and handbooks. 

Future goals at NASA related to MBE are: 

• Cross-mapping of model maturity states to support pre-release exchange 

• Improving modeling and simulation 

• Moving away from document-centric engineering practice 

• Digital records retention and archiving 

• Configuration management for complex hybrid systems 

4.4.2 Some Imperatives for Realizing Model-Based Products 

Richard Neal, Integrated Manufacturing Technology Initiative 

It is both possible and reasonable for the U.S. to gain and maintain a position of leadership in 

design and manufacturing in the global economy. However, realizing this achievement requires 

that we embrace new technologies, emerging processes, and cultural norms. One of the greatest 

enablers for success is the deployment of model-based design and manufacturing systems. 

The move to a model-based manufacturing environment is not new. It has been in process for 

more than two decades, and dramatic and impressive successes have been realized. However, 

these successes are mainly isolated examples that come from implementation of parts and pieces 

of the total solution package. The methods and tools are now mature enough to embrace a 

holistic view that changes the process by which products are developed. This new environment 

will enable the unbounded evaluation of ideas, the extraction of requirements, the definition and 

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evaluation of concepts (including quantification of cost, schedule, and risk), the creation of 

detailed designs, and the production and sustainment of products. 

SE is becoming increasingly emphasized. In today’s most advanced manufacturing companies, 

every design or manufacturing engineer must also become a systems engineer. MBE must be 

integrated across the lifecycle, and should be optimized early with a clear definition of costs and 

risks. 

4.4.3 Model Standards Interoperability across Domains, the Life Cycle, and 

the Supply Chain 

Charlie Stirk, Cost Vision 

There are many complementary interoperability standards for models across functional domains 

such as program and project management, SE, mechanical design, visualization, simulation, 

logistics, and data management and lifecycle stages. The interfaces between these data model 

standards need to be defined to enable interoperability across the functional domains. These 

interfaces must specify where standards overlap as well as fill gaps. Managing all of these 

standards and the interfaces between them, while at the same time promoting deployment, is a 

challenge. 

Several ongoing efforts and developments are helping to manage standards complexity and 

facilitate implementation and adoption. The LOTAR International consortium is developing and 

portfolio-managing a standards technology roadmap for ISO 10303 (STEP) and related standards 

to ensure that changes improve interoperability. Technologies for model transformation, web 

service interfaces, web browser interfaces, and secure collaboration are maturing and enabling 

applications such as supply chain collaboration and integrated data environments. Standards 

development frameworks such as the STEP modular architecture for ISO 10303 standards and 

the Product Life Cycle Support framework (http://www.plcs.org) for data exchange 

specifications lower standards development costs by providing repositories of reusable building 

blocks and automating quality assurance. Implementer forums are conducting interoperability 

testing, providing feedback to standards bodies, and documenting best practices for 

implementing standards. Finally, open source reference implementations such as STEPcode 

(http://stepcode.org) can increase standard quality and adoption in software. 

Additional investment is needed in these efforts. In particular, road mapping efforts should be 

expanded to standards other than those in the ISO 10303 family. Also, more resources are 

needed to improve existing standards development frameworks, expand the number of 

implementer forums, and encourage the development of additional open source implementations. 

28
 
 

 

 

 

 

 

 

4.4.4 Evolving Lockheed Martin’s Engineering Practices through the 

Creation of a Model-centric Digital Tapestry 

Tom Hannon, Lockheed Martin Corporation 

There is a lack of effective integration across different engineering disciplines. Most existing 

integrations are point-to-point. The Model-centric Digital Tapestry is a framework and strategy 

for achieving a more holistic and cross-cutting integration that meets the challenge of DoD’s 

Systems 2020 vision. The digital tapestry is a single source of truth. Systems Modeling 

Language (SysML) [26] enables the digital tapestry by allowing us to tie together all the 

different, cross-disciplinary pieces of information. 

SysML is the hub of the digital tapestry. It allows us to connect threads of information together 

and link requirements across domains. System-level analysis drives the CAD reference 

architecture. An integrated propulsor analysis pilot successfully used this SysML-enabled digital 

tapestry approach to increase the accuracy of vehicle assessments. 

Our business case analysis for using SysML determined that the benefits exceed the upfront costs 

of doing the modeling, assuming that the necessary information technology infrastructure already 

exists. 

4.4.5 IBIF Projects and Business Case Analyses 

Denise Duncan and Cindy Flint, LMI Government Consulting 

The Industrial Base Innovation Fund (IBIF) is part of OSD’s Defense-Wide Manufacturing 

Science and Technology program. IBIF’s two technical areas are (1) Comprehensive TDPs for 

next generation business exchanges, and (2) TDP integration and validation for government 

delivery. LMI is helping IBIF TDP project teams develop high-level business case analyses and 

is completing a white paper making the case for MBE. MBE practitioners (including those 

participating in this Summit) are increasingly making use of business case analyses. The 

community can benefit if we consolidate our respective business cases and make them available 

as a common resource. 

Although the template for a business case varies depending on agency or Service, size of dollar 

investment, and type of investment (e.g., research, information technology, major system), the 

following are standard steps in developing any business case: 

•	 Define the “as is” case, i.e., the status quo. 

•	 Define alternatives for addressing problems with the status quo. 

•	 State assumptions made in the business case analysis, document pertinent policies, name 

stakeholders, and describe potential benefits. 

•	 Conduct an economic analysis using methods such as Net Present Value, statistical 

modeling, and cost/benefit ratio. 

29
 
 

 

 

 

 

 

 

5 Conclusions 

The 2012 MBE Summit brought together a wide variety of organizations spanning both public 

and private industry sectors. Speakers included manufacturers, quality experts, researchers, and 

software solution providers. Industry attendees were from both large and small companies. The 

following are among the conclusions that emerged from the Summit. 

Model-based methods and tools are increasing manufacturing productivity, but challenges 

remain. 

Dean Robinson (4.2.1) reported that his employer was able to reduce tooling design time 75% by 

using model-based methods, yet he also acknowledged the key challenges of introducing 

advanced materials such as composite structures, and advanced processes such as additive 

manufacturing. Lack of a full 3D representation and good visualization methods limit the 

application of MBE to manufacturing involving composite materials [27]. Because additive 

manufacturing information requirements are complex and additive processes are faultsensitive, even the smallest data error in a model can lead to part defects that are not detectable 

by visual examination [28]. 

Martin Hardwick (4.2.11.4) asserted that removing barriers to sharing process data has the 

potential to greatly lower manufacturing costs, reduce data entry errors and misunderstandings 

over drawing symbols, and reduce the need for suppliers to explain models. However, new 

research and development are needed to address challenges such as intellectual property 

protection and adapting to changes in tooling, setup, or machine tool performance. 

Model-based inspection combined with optical measurement techniques is a potential game 

changer. 

As Jim Osterloh (4.3.1) pointed out, optical scanning is faster and more accurate than touch 

probing, and enables “as-built” visualized representations of objects to be generated prior to 

manufacturing. The 2012 Summit presentations and subsequent panel discussions on modelbased inspection indicate a groundswell of interest in the integration of the inspection, design, 

and production activities in manufacturing via a standards-based digital model-based approach. 

Jim Osterloh (4.3.1) demonstrated and Ron Branch (4.3.3) discussed the dramatic potential for 

optical scanning combined with MBE. Curtis Brown (4.3.2) described a successful pilot 

implementation of the QIF standards for model-based inspection. 

Lightweight visualization formats are making MBE feasible for SMEs. 

Lightweight formats such as 3D PDF are gaining traction in TDP implementations, and 

companies accustomed to 2D engineering drawings are now experiencing the benefits of MBE. 

Ric Norton (4.1.2) reported on U.S. Air Force deployment of a 3D PDF TDP for A-10 wing 

30
 
 

 

 

 

 

replacement. David Stieren (4.2.2) and Sanjay Parimi (3.2.8) both reported a strong and growing 

preference among manufacturers in the Army supply chain for 3D TDPs over 2D drawings. 

Systems Engineering is an increasingly important component of MBE. 

Manufacturing is becoming more assembly-centric, and products are becoming increasingly 

complex and multi-functional. The consequence, as Richard Neal (4.4.2) pointed out, is that 

“every design or manufacturing engineer must also become a systems engineer.” Tom Hannon 

(4.4.4) reported success using SysML to improve integration across multiple engineering 

disciplines throughout his company. Charlie Stirk (4.4.3) recommended that industry standardize 

more interfaces across functional domains, and that those creating the standards should use 

roadmaps to better coordinate and manage standards development and deployment. 

Open standards and reference implementations are critical. 

The continued success of MBE requires deployment of open standards for representing and 

exchanging product and process data. As we stated in Section 3, product data standards are 

widely implemented today, but manufacturing process data standards have only had limited 

industry success. Harold Owens and Brent Gordon (4.1.4) highlighted the need for standardized 

3D model acceptance criteria to ensure product quality. Charlie Stirk (4.4.3) made a case for 

open source reference implementations as a catalyst for standards deployment. Martin Hardwick 

(4.2.11.4) pointed out that when manufacturing processes are non-proprietary and standardsbased, OEMs can save both time and money. 

31
 
 

 

 

 

 

 

 

 

 

 

6 References 

[1]	 J. Lubell, K. Chen, J. Horst, S. P. Frechette, and P. Huang, "Model Based Enterprise / 

Technical Data Package Summit Report," NIST Technical Note 1753, August 2012. 

[2]	 ISO 10303-203:2011. Industrial automation systems and integration – Product data 

representation and exchange – Part 203: Application protocol: Configuration controlled 

3D design of mechanical parts and assemblies. 

[3]	 ISO 14306:2012. Industrial automation systems and integration – JT file format 

specification for 3D visualization. 

[4]	 ISO/PRF 14739-1. Document management – 3D use of Product Representation Compact 

(PRC) format – Part 1: PRC 10001. 

[5]	 ISO 6983-1:2009. Automation systems and integration – Numerical control of machines 

– Program format and definitions of address words – Part 1: Data format for positioning, 

line motion and contouring control systems. 

[6]	 MIL-STD-31000A Department of Defense Standard Practice: Technical Data Packages. 

26-Feb-2013. 

[7]	 ISO 10303-238:2007. Industrial automation systems and integration – Product data 

representation and exchange – Part 238: Application protocol: Application interpreted 

model for computerized numerical controllers. 

[8]	 ISO 13399-1:2006. Cutting tool data representation and exchange – Part 1: Overview, 

fundamental principles and general information model. 

[9]	 ASME B5/TC56, 2005, ASME B5.59-2: Draft: Information Technology for Machine 

Tools, Part 2. Data Specification for Properties of Machine Tools for Milling and 

Turning, June 2005. 

[10]	 ISO/DIS 10303-242. Industrial automation systems and integration Product data 

representation and exchange – Part 242: Application protocol: Managed model-based 3D 

engineering. 

[11]	 Defense Acquisition Guidebook: Defense Acquisition University, 2010. 

[12]	 "The Transition from 2D Drafting to 3D Modeling Benchmark Report," Aberdeen Group 

2006. 

[13]	 J. Michaloski, B. E. Lee, F. Proctor, and S. Venkatesh, "Web-enabled Real-time Quality 

Feedback for Factory Systems Using MTConnect," presented at the ASME International 

Design Engineering Technical Conferences & Computers and Information in Engineering 

Conference, Chicago, 2012. 

[14]	 ISO 10303-203:1994. Industrial automation systems and integration - Product data 

representation and exchange - Part 203: Application protocol: Configuration controlled 

3D designs of mechanical parts and assemblies. 

32
 
 

 

 

 

 

[15]	 ISO 10303-214:1994. Industrial automation systems and integration - Product data 

representation and exchange - Part 214: Application protocol: Core data for automotive 

mechanical design processes. 

[16]	 D. F. Noble, "Social choice in machine design: The case of automatically controlled 

machine tools," in Case Studies on the Labor Process, A. Zimbalist, Ed., ed: Monthly 

Review Press, 1979, pp. 18-50. 

[17]	 G. Tassey, S. B. Brunnermeier, and S. A. Martin, "Interoperability cost analysis of the 

US automotive supply chain," Research Triangle Institute Final Report. RTI Project, pp. 

7007-03, 1999. 

[18]	 J. Bondy, "CAD Interoperability and Model Repair for Additive Fabrication," 

MoldMaking Technology, April 2008. 

[19]	 S. Suh, D. Chung, B. Lee, J. Cho, S. Cheon, H. Hong, et al., "Developing an integrated 

STEP-compliant CNC prototype," Journal of manufacturing systems, vol. 21, pp. 350­

362, 2002. 

[20]	 J. A. Horst, C. Brown, R. Brown, L. Maggiano, K. Summerhays, and T. R. Kramer, 

"Information Required for Dimensional Measurement," presented at the Matador 2012 

Conference, 2012. 

[21]	 SAE International. AS9102A. Aerospace First Article Inspection Requirement. 2004-01­

13. 

[22]	 C. Brown, "Integration of FBTol into CADKEY," Kansas City Plant, Kansas City, MO 

(US)2000. 

[23]	 A. P. Sage and W. B. Rouse, Handbook of Systems Engineering and Management: 

Wiley, 2011. 

[24]	 S. H. Bokhari, "On the Mapping Problem," Computers, IEEE Transactions on, vol. C-30, 

pp. 207-214, 1981. 

[25]	 R. Godwin, Columbia accident investigation report vol. 39: Burlington, Ont.: Apogee 

Books, 2003. 

[26]	 OMG Systems Modeling Language (OMG SysML). Version 1.3. 2012. 

[27]	 K. A. Hunten, A. Barnard Feeney, and V. Srinivasan, "Recent advances in sharing 

standardized STEP composite structure design and manufacturing information," 

Computer-Aided Design, vol. 45, pp. 1215-1221, 2013. 

[28]	 "Measurement Science Roadmap for Metal-Based Additive Manufacturing," Prepared by 

Engergetics Incorporated for the National Insitute of Standards and Technology. May 

2013. 

33
 
 

 

 

 

Appendix: Final Agenda and Presentation Materials 

The following pages contain: 

1.	 The final MBE/TDP Summit agenda 

2.	 Presentation materials from all Summit speakers who gave NIST permission to distribute 

their slides. 

To minimize page count, each page of presentation materials contains six slides. In some cases, 

we deleted slides determined to be content-free (e.g., "Thank you" and "Any questions?" slides) 

and slides that were partial builds of other slides (useful for "animating" presentations but not of 

much value in a printed hard copy). 

With the exception of the two presentations given by NIST staff (4.2.2 and 4.2.7), inclusion in 

this Appendix implies neither endorsement nor approval by the National Institute of Standards 

and Technology. 
 

MBE Summit
 

NIST, Gaithersburg, MD
 

Green Auditorium, Bldg101
 

Tuesday, 11 December, 2012 

Time Topic Speaker(s) 

0830-0840 Introductions and Admin Simon Frechette, NIST 

Paul Huang, ARL 

Shyam Sunder, Director, NIST Engineering 

0840-0940 Welcome and Opening Remarks Laboratory 

Adele Radcliff - OSD ManTech 

Phil Zimmerman - OSD AMSWG 

0940-1010 Model-Based Manufacturing Dean Robinson, GE Global Research 

1010-1040 DLA Overview Richard Norton, DLA-LIS 

1040-1100 Break 

1100-1130 NAVAIR EIPT Howard Owens, NAVAIR 

1130-1200 3D Model Based Scanning & Inspection Fred Persi, M7 Technologies 

1200-1240 Vendor Updates 

1240-1330 Lunch Break & Vendor Demos 

1330-1400 The Quality Information Framework: MBE and XML 

Schema Models Curtis Brown, Honeywell FM&T 

1400-1430 Model Based Inspection: Leveraging Model Based 

Definition for QA Ron Branch, Verisurf 

1430-1500 Using Open CAD Formats to Bridge the Gap Between 

Today’s and Tomorrow’s Standards Tomasz Luniewski, Capvidia 

1500-1530 Break & Vendor Demos 

1530-1600 Model-Based Predictive Technologies for Dimensional 

Measurement Jon Baldwin, Metrosage 

1600-1630 Inspection Lifecycle Management Sam Golan, PAS Technology 

1630-1700 Model Based Inspection Panel: Q&A Moderator: John Horst 

1700-1830 Wrap-Up and Vendor Demos 

Website: http://www.nist.gov/el/msid/mbesummit_2012.cfm 
 

MBE Summit
 

NIST, Gaithersburg, MD
 

Green Auditorium, Bldg 101
 

Wednesday, 12 December, 2012 

Time Topic Speaker(s) 

0800-0810 Announcements & Admin Simon Frechette, NIST 

Paul Huang, ARL 

0810-0840 NIST EL Manufacturing Program Overview Simon Frechette, NIST 

0840-0910 Air Force Advanced Manufacturing Overview Brench Boden, AFRL 

0910-0940 NASA MBE Effort Paul Gill, NASA 

0940-1010 Break 

1010-1040 Open Manufacturing Mick Maher, DARPA-DSO 

1040-1110 Implementing Model Only at Cubic Defense Applications Peter Buzyna, Cubic Defense 

1110-1140 The Sustaniable Enterprise: Enabling the Digital Thread Karen Kontos, Honeywell 

1140-1210 NDEMC, Affordable Access to Modeling & Simulation and 

High Performance Computing for SMEs Dennis Thompson, SCRA 

1210-1230 NAMII Overview Ed Morris, Director NAMII 

1230-1330 Lunch Break & Vendor Demos 

1330-1345 Lightweight Formats/Visualization Overview Rich Eckenrode, Recon-Services 

1345-1410 3D PDF Format David Opsahl, 3D PDF Consortium 

1410-1435 Repurposing of Engineering Data Chris Garica, Anark 

1435-1500 A New Dimension in Data Sharing Tom Barth, EOS 

1500-1530 Break & Vendor Demos 

1530-1555 JT Overview Dennis Keating, Siemens 

1555-1620 Creo View Mark Nielsen, PTC 

1620-1645 3D Via Dassault Systems 

1645-1700 Vendor Panel Discussion Moderator: Rich Eckenrode 

1700-1830 Vendor Demos in Hall of Flags 

Website: http://www.nist.gov/el/msid/mbesummit_2012.cfm 
 

MBE Summit
 

NIST, Gaithersburg, MD
 

Green Auditorium, Bldg101
 

Thursday, 13 December, 2012 

Time Topic Speaker(s) 

0800-0810 Announcements & Admin Simon Frechette, NIST 

Paul Huang, ARL 

0810-0830 NIST MEP Update David Stieren, NIST MEP 

0830-0900 TDP for the Digital Enterprise Denise Duncan, LMI 

0900-0930 Army Advanced Manufacturing Overview Sanjay Parimi, ARDEC 

0930-1000 Break 

1000-1050 Imperatives for Achieving Model-Based Product 

Realization Richard Neal, IMTI 

1050-1140 Model Standards Interoperability Across Domains, the 

Life Cycle, and the Supply Chain Charlie Stirk, CostVision 

1140-1230 The Lockheed Martin Model-Centric Digital Tapestry Tom Hannon, Lockheed Martin 

1230-1330 Lunch Break 

1330-1345 Manufacturing Processes Overview Fred Proctor, NIST 

1345-1410 Siemens Overview Dennis Keating, Siemens 

1410-1435 Dassault Overview Israel Flores, Dassault Systems 

1435-1500 Delcam Overview Hanan Fis, Delcam 

1500-1515 Break 

1515-1540 CAM Standards Martin Hardwick, STEPTools 

1540-1645 End-User Panel Discussion Moderator: Fred Proctor 

1645-1715 Wrap-up and Path Forward Paul Huang 

Website: http://www.nist.gov/el/msid/mbesummit_2012.cfm 
 

 -1854.

 

 

 

 

 

 

 

 

Modeling and Simulation

 

 

 

 

g

NIST MBE Summit 

2012/12/11 Page-1 Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. 

Ms. Philomena “Phil” Zimmerman 

ODASD(SE)/System Analysis 

National Institute of Standards and Technology (NIST) 

Model-Based Enterprise Summit 

December 13, 2012 

DoD Modeling and 

Simulation Support to 

Acquisition 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-2 

Agenda 

• Modeling and Simulation within ODASD(SE) 

• Modeling and Simulation Observations 

• Modeling and Simulation Fundamentals 

• System Modeling and DoD Acquisition 

• Engineered Resilient Systems 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S NIST MBE Summit 

2012/12/11 | Page-3 2-S-1854. 

DASD, Systems Engineering Mission 

Develop and grow the Systems Engineering capability of the 

Department of Defense – through engineering policy, 

continuous engagement with component Systems Engineering 

organizations and through substantive technical engagement 

throughout the acquisition life cycle with major and selected 

acquisition programs. 

A Robust Systems Engineering Capability Across the 

Department Requires Attention to Policy, People and Practice 

We apply best engineering practices to: 

– Support and advocate for DoD Component initiatives 

– Help program managers identify and mitigate risks 

– Shape technical planning and management 

– Provide technical insight to OSD stakeholders 

– Identify systemic issues for resolution above the program level 

g 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-4 

Addressing Emerging Challenges on 

the Frontiers of Systems Engineering 

Analysis of Complex Systems/Systems 

of Systems 

Program Protection/Acquisition Cyber 

Security 

University and Industry Engineering 

Research 

Systems Engineering FFRDC Oversight S t E i i FFRD 

Modeling and Simulation 

Mission Assurance 

Nicholas Torelli 

Major Program Support 

James Thompson 

Systems Analysis 

Kristen Baldwin (Acting) 

DASD, Systems Engineering 

DASD, Systems Engineering 

Stephen Welby 

Principal Deputy 

Kristen Baldwin 

Supporting USD(AT&L) Decisions with 

Independent Engineering Expertise 

Engineering Assessment / 

Mentoring of Major Defense 

Programs 

Program Support Reviews 

OIPT / DAB / ITAB Support 

Systems Engineering Plans 

Systemic Root Cause Analysis 

Leading Systems Engineering Practice 

in DoD and Industry 

Systems Engineering Policy & Guidance 

Development Planning/Early SE 

Specialty Engineering (System Safety, 

Reliability and Maintainability 

Engineering, Quality, Manufacturing, 

Producibility, Human Systems 

Integration (HSI)) 

Technical Workforce Development 

Standardization 

Providing technical support and systems engineering leadership and oversight to 

USD(AT&L) in support of planned and ongoing acquisition programs 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-5 

Observations: Call for Action 

• Modeling and Simulation is not consistently applied in the

acquisition lifecycle 

– It is not consistently recognized as a component or enabler of Systems 

Engineering 

– It is not consistently productive for the program management team 

– It is inconsistently applied in phases of the acquisition lifecycle 

• They are never used as a continuum of tools, or as a supplier

of rationale and justification for analysis, evaluations, and

assessments across the acquisition lifecycle 

– It is not consistently represented in Service and component organizations 

– It is not, as a community, organized to answer questions, fill SE gaps, or share 

best practices 

• Modeling and simulation has a long-standing strategy, but it

does not have a current roadmap for improvement in

application 

– Acquisition modeling and simulation needs, capabilities, messages from PEO, 

PM not reaching OSD; and vice versa 

• Contemporary challenge: Mr. Kendall’s remarks at CSIS, 6 Feb

2012 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-6 

MS&A Fundamentals 

DISTRIBUTION A: Approved for Public Release; Distribution is unlimited 

• Purpose: One page that conveys 

a high-level, concise, and 

comprehensive set of truths for 

Mod/Sim usage in Systems 

Engineering support to programs 

• Key Areas Emphasized: 

– Program Systems Engineer is 

responsible for Mod/Sim planning and 

coordination 

– Mod/Sim is included in key schedule 

and programmatic plans 

– SE uses models to define, understand, 

and communicate technical artifacts 

– Models are continually updated 

throughout program life-cycle 

– Project success is dependent on 

appropriate Mod/Sim training of team 

http://www.acq.osd.mil/se/docs/SE-MSA-Fundamentals.pdf 
 

 

 

 

 

PreEMD 

 

 

impacts of 

M

 

 

–

–

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-7 

Using the Modeling and Simulation 

Fundamentals 

The M&S Fundamentals 

support the consideration of 

modeling and simulation as a 

tool for systems engineers to 

use in support to Acquisition 

activities 

The M&S Fundamentals provide the modeling and simulation basis of support 

for programs, posturing modeling and simulation as a part of systems 

engineering, not separate from it. 

DoDD 5000.1 

Defense 

Acquisition 

System 

Operation 

Modeling and Simulation 

Support Documentation 

(MSMP, SSP, ETC) 

Defense 

Acquisition 

Guidance (DAG) 

M&S Fundamentals 

Acquisition Program Support 

• The Fundamentals connect 

the M&S community to the 

acquisition use of M&S 

• The Fundamentals suggest 

how M&S should be 

incorporated into the SE 

position on the program, but 

do not dictate how 

• The Fundamentals assist 

both OSD and the programs 

maintain a common 

understanding of M&S use 

for acquisition program 

support 

Service/Agency 

Specific Mod/Sim 

Guidance 

System Engineering 

Plan, etc. 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-8 

Systems Modeling Use in Acquisition 

A 10,000 Ft View of the Practice 

The concept is still maturing 

• In far more use that often 

recognized 

• Has proven to be powerful when 

used 

• Is not perfected, and requires 

intelligent use 

• Adoption has been uneven across 

DoD to date 

• The use of models and the insights gained 

from their use, aid in the conceptualization, 

resource estimation, design, deployment and 

sustainment of systems 

• It is not limited to engineering; it enables 

engineering rigor across all acquisition 

functions 

• The tools and processes for systems 

modeling use enable acquisition functions to 

be more efficient 

• “Modeling” refers to a wide range of artifacts, 

to include physical and computer based 

• Application of models supports reduction of 

program uncertainties, at any point in time, in 

cost, schedule, and performance 

Model based acquisition does not diminish the importance of simulations; it increases the 

relevance of simulation output through consistent use of complete models 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-9 

Acquisition Life Cycle Framework

“Weapon System Development” 

Pre-acquisition 

Concepts, 

Experimentation 

and Prototyping 

C 

TEMP 

Post-PDR 

Assessment 

PPP 

ICD 

SEP 

Materiel Solution 

Analysis 

AOA 

MDD A B Technology 

Development Enabling 

S&T 

Post-CDR 

Assessment 

CDD CPD 

LCSP 

SEP 

TEMP 

PPP 

LCSP 

Engineering and 

Manufacturing 

Development 

AS 

PPP 

LCSP 

AS 

Operations and 

Support 

FRP IOC FOC DR Production 

and 

Deployment 

TEMP 

PPP 

SEP 

LCSP 

AS 

Disposal 

PDR CDR 

SE Tradeoff 

Analyses 

TEMP 

TRA 

Pre-EMD 

Review 

TDS 

PreEMD 

... ... ... 

... 

... = Additional documentation 

requirements, 

may be approved below MDA 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-10 

Systems Representation and Modeling 

– Physical, logical structure, behavior, interactions, interoperability... 

Why? Engineered Resilient 

Systems Key Technical Areas 

Characterizing Changing

Operational Contexts 

– Deep understanding of warfighter needs, 

alternative designs 

Cross-Domain Coupling 

– odel interchange & composition 

across scales, disciplines 

Data-driven Tradespace

Exploration and Analysis 

– Multi-dimensional 

generation/evaluation of 

alternative designs 

Collaborative Design and Decision Support 

– Enabling well-informed, low-overhead discussion, 

analysis, and assessment among engineers and 

decision-makers 

Operational C 

Deep understa 

impacts of alte 

Cross- Domain Coupling

Mod 

acro 

en Tradespace 

Cross 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-11 

Summary 

• The Modeling & Simulation Fundamentals are one of the 

Keystones (NOT POLICY) of Consistent Modeling and 

Simulation Support to Programs 

– Established by the Acquisition Modeling and Simulation Working Group as a 

simple way to bridge the M&S community with the acquisition community. 

• Prove the best practices (real and expected) before applying the 

System Model 

– Discover/Identify best practices based on examples from the Services/Agencies 

– Develop definition, build business case by studying elements in existence today 

• Develop the System Model from elements and artifacts of 

acquisition activities which already exist 

– Do not invent anything new; instead, use ‘aim points’ from that which already 

exists 

– Population of the system model should not require separate contract clauses 

Distribution Statement A – Cleared for public release by OSR Cases 13-S-0102, 13-S-0103, 12-S-1854. NIST MBE Summit 

2012/12/11 | Page-12 

MS&A Presentations 

Richard Neal - The Integrated Manufacturing Technology 

Initiative 

“Imperatives for Achieving Model-Based Product Realization” 

Charlie Stirk - CostVision Inc 

"Model standards interoperability across domains, the life 

cycle, and the supply chain” 

Tom Hannon - Lockheed Martin Corporation 

“The Lockheed Martin Model-Centric Digital Tapestry” 
WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 1 

’

 

 

WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

2 

 

WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

3 

 WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

4 

 

HANCEMENT 5 

e 

 

 

6 

DEFENSE LOGISTICS AGENCY AMERICA S COMBAT LOGISTICS SUPPORT AGENCY 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

A-10 Pilot Program 

Overview 

“DLA Engages Model 

Based Enterprise”

Defense Manufacturing 

Conference 

November 26, 2012 

Ric Norton 

Distribution Statement A: Approved for public release; distribution is unlimited 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

2 

Overview 

• Needs and Benefits 

• Data for National Stock Numbers (NSN) 

• Why Quality Data is Important 

• A-10 Existing and Emerging Technologies 

• Metrics, Results of using Model Data 

• Progress to date with A-10 

• DLA Moving Closer to use of Model Data 

• Questions 

2 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

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Needs.... 

‘As Is’ environment 

Current DLA information 

systems rely on flat files and 

face data quality problems 

Move Capability from 

2D drawings to 3D 

digital data 

‘To Be’ environment: 

Comprehensive Product Life Cycle 

System that uses 3D models, digital 

data, to include logistics product 

data,... married in the Product 

Lifecycle Management (PLM) 

system and exported downstream 

80-Column Coded Data 

Degraded 2D drawings 

Modernize Data and 

Data Exchange 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

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...and Benefits 

• “R4” -Right Part, Right Place, Right Time, Right 

Money 

• Fewer people will be needed to develop, use, 

reuse, and archive better quality data 

• Digital Thread (data exchange) between PLM, 

AF Legacy, FLIS, DLA Supply Chain ERP 

• “Light, standard, economical, highly effective” 

Model Data for “Supply Chain User” 3D PDF 

• Model Data, early on, enhances “Rapid Fielding” 

without sacrificing “Sustainment” 

WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

WARFIGHTER SUPPORT EN STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

NSN 

Safety 

Security 

HAZMAT 

Storage 

Acquisition 

Financial 

Asset 

visibility 

Shipping 

Handling 

I&S 

DEMIL 

Disposal 

Item 

Criticality 

vis 

Customs 

Packaging 

MIL 

Shelf Lif 

Pricing 

Data for National Stock Numbers (NSN) 

Data to identify, classify 

and describe an item is 

extremely important. 

Equally important is the 

management information 

or the Logistics Product 

Data (LPD) codified 

under each NSN used 

throughout a product’s 

total lifecycle- ref the 

“NSN Wheel” 

WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

Why Quality Data is Important 

6 
WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 7 

 

 

WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

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 WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 1

’

 

 

WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP

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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

A-10 Existing/Emerging Technologies 

Prime DLA

AF 

TCUA 

D220 LPD 

EDFP/SDFP, 

LPD & Model 

SlicWave or 

data export 

enhanced 

APR 

PowerLOG-J 

Manual & Automated Configuration Management Processes 

Report 

Generation Tool 

(Anark, or other) 

LSA-036 

LSA-032, LSA-025 

DLA AF 

DLA PDM 

Federal 

Catalog (Stds-based) 

EDFP/SDFP, 

LPD & Model 

Prime 

TC 

AF 

Prime 

TCUA? 

1 

2 

3 

4 

FLIS 

Expose PLM/MBE 

Data 

Search/Report 

Interface 

Data Analysis/ 

Correlation 

FLIS 

Transformation 

Improved 

Automation 

• Maintenance 

• Training 

• End-user 

• Contracting 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

8 

Metrics- Results of using Model Data 

18% 

51% 

27% 22% 

Fully Described NSNs Partially Described NSNs Non-described NSNs 

Active NSNs in FLIS* Database A-10 Wing Replacement Initial 

NSN Assignment 

*Federal Logistics Information System – 6.6M active NSNs as of Oct 2012 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

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9 

Progress to date with A-10 

• A-10 Wing Replacement Program (WRP) 

Provisioning Parts List (PPL) (36,000+ items 

• PPL is scheduled to be delivered with supporting 

Technical Data Package (TDP) to Air Force and 

DLA Provisioning Offices November 30 

• Approximately 856 items have been identified as 

procurable (P coded) items. 

• Engineering Data for Provisioning will include 

approximately 690 3D PDF Models and some 

vendor provided 2D data. 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

10 

DLA Moving Closer to use of Model Data 

• Model data provided to DLA Logistics 

Technicians will be a 3D PDF “derivative” aka 

“Technical Part Report” (TPR) 

• TPR will be embedded in Associated 

Provisioning Data Report (APDR), a 2D PDF file 

which contains attribute fields for analytical and 

management associated data not in TPR 

• DLA will identify, classify, and codify parts with 

Model Data...48 Technicians trained in October 

DEFENSE LOGISTICS AGENCY AMERICA S COMBAT LOGISTICS SUPPORT AGENCY 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

Contracting for Technical 

Data Packages (TDP) 

within a Model Based 

Enterprise (MBE) 

Defense Manufacturing 

Conference 

November 29, 2012 

Ric Norton Distribution Statement A: Approved for public release; distribution is unlimited 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

2 

Overview 

• Needs.... and Benefits 

• Contracting for What Types of Data 

• Existing and Emerging Technologies 

• Intended Results of this Project 

• Progress to Date 

• Why DLA is a Major Stakeholder 

• Questions 

2 
WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP

 3

 WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP

 4

 

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nction CNs

 

i

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i ics 

st s

c 

r ls

L i i s 

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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP

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 WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP

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WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

3 

Needs.... 

• Ensure Standards and Specifications used as references 

to drive all TDP requirements are adequate 

• Ensure Data Item Descriptions (DIDs) are written and 

tailored properly within the Contract Data Requirement 

Lists (CDRLs) 

• Ensure those who write these requirements in contract 

are prepared to do so or are facilitated by Subject Matter 

Experts (SMEs) who are 

• Ensure Program Executive Officers and Managers are 

prepared to implement efficient and effective Data 

Management Strategies 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

4 

....and Benefits 

• Technical Data Requirements that allow for an 

efficient digital means to exchange valid 

quality data from authoritative sources to all 

downstream supply chain users. 

• The contract will clearly state these 

requirements so there is no question on 

producing deliverables that meet the “how, 

what, when, where, why criteria...” 

• Will ensure interoperability 

4 

WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

Contracting for What Types of Data 

WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT

 DLA Developed Process 

Logistics Support Analysis 

Design 

Phys N 

Manufactu n 

Fu al L 

Manufacturing BOM 

Engineering BOM 

Logistics BOM 

(Physical/Functional LCNs) 

Technical Data (TD) 

Supplemental Data for 

Provisioning (SDFP) 

A subset of Engineering/ 

Manufacturing Technical Data 

Log stics Product Data 

(LPD 

Mapping of LPD 

to EDFP/SDFP 

Correlations of Engineering Parts to 

Manufacturing Parts 

Mapping of 

EBOM/MBOM to LBOM 

(Physical, Functional 

LCNs) 

nnotated Part 

Report 

LSA 

Reports, 

LPD 

Log st 

Sy em 

Feedback, 

Corrections, 

Changes 

Feedback, 

Corrections, 

Changes 

Includes 

corrections, 

changes 

MBE/PLM 

Data Extra tion and 

Fo matting Too 

og st c 

Activitie 

Functions 

Digital 

APR 

Data 

(XML) 

DLA-developed Enablers 

• Engineering and Logistics Business 

Objects 

• Logistics BOM Structure 

• Associated PLMXML 

C 

o 

n 

f 

i 

g 

u 

r 

a 

t 

i 

o 

n 

M 

a 

n 

a 

g 

e 

m 

e 

n 

t 

• Part Descriptions 

and Attributes 

• Part Relationships 

• Part Engineering 

and Manufacturing 

Specifications 

• 3D Part Models 

Supplemental Data for 

Engineering Data for 

Provisioning (EDFP) 

A t t d 

D 

(X 

Logis ic 

Database 

Using Existing/Emerging Technology 

“Seamless Exploitation of Digital 

MBE/PLM Data” 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

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Intended Results of this Project 

• Gap and Trend Analysis will identify what we 

have and what is needed in: 

– Policies/procedures 

– Referenced Specifications and Standards 

– Statements of Work (SOWs) 

– Data Item Descriptions (DIDs) 

– Contract Data Reference Lists (CDRLs) 

– Implementers and Systems 

• BCA will identify what is effective and 

recommend what is needed to improve 

“Contracting for TDP within MBE” 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

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Progress to Date 

• Representative sample programs (RSPs) are 

being analyzed to determine how TDP and data 

exchange requirements are currently being 

satisfied. 

• This data coupled with other research is being 

used to prepare a Gap and Trend Analysis as 

well as a Business Case Analysis (BCA) 

• RSPs include programs from all Military Services 

USCG, NASA... different depots, primes, and 

category programs are being researched. 
 9

i i

i l

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WARFIGHTER FOCUSED, GLOBALLY RESPONSIVE SUPPLY CHAIN LEADERSHIP 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

Progress to Date 

9 

Task 1 

Project Planning 

and Management 

Task 2 

Interviews and 

Data Collection 

Task 3 

User Commun ty 

Research 

Task 6 

Trend and Gap 

Analysis 

Task 7 

Business Case 

Analysis 

Repositor 

y 

WWW 

Collaboratio 

n Portal 

Task 5 

Recommendat ons 

SME 

Support 

Task 4 

Reference 

Standards, Policies 

& Procedures, 

Credent a s 

Research 

SME 

Support 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

10 

Why DLA is a Major Stakeholder 

• DLA is a major parts provider for most fielded 

weapons systems 

• We do business with all the Primes, all the 

Services, and the Supplier Base in support of 

the Warfighter. 

• We must proactively seek or develop an 

“Interoperable Digital Data Exchange Strategy” 

that will enable us to continue.... 

10 

WARFIGHTER SUPPORT ENHANCEMENT STEWARDSHIP EXCELLENCE WORKFORCE DEVELOPMENT 

WARFIGHTER-FOCUSED, GLOBALLY RESPONSIVE, FISCALLY RESPONSIBLE SUPPLY CHAIN LEADERSHIP 

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Key Points Contract Number: SP4701-09-D-0032 

Title: Contracting for Technical Data Packages (TDPs) 

within Model Base Enterprise (MBE) 

Performing Activity: Defense Logistics Agency 

Objectives: Research & Develop effective means to contract 

for TDP Deliverables within MBE 

- Determine how to contract for Model Data 

- Determine how to contract for Logistics Product 

Data 

Start / End Dates: Start 12/2010 End 12/2012 

DLA Investment: $500K Budgeted 

Cost Share: $ N/A 

Weapon System: N/A 

Implementation: 

System: N/A 

Site: DLA Logistics Information Service 

Schedule: 

Status: Analyses being compiled for Gap Trend and 

Business Case 

Cost Within budget 

Schedule On schedule 

Technical Drive Deliverables in contact for 3D Models, 

Data exchange of XML Schema and Data 

Exchange Sets (DEXS) 

Payoff: Source for Effective means to drive TDP 

contract requirements 

Performing Entities: 

• DLA J334- DLIR Program management 

• DLA J62 – Executive Sponsor 

• DLA Logistics Information Service – Co-sponsor/Project Lead 

• Decision/analysis Partners LLC 

Technical Achievement: 

• N/A 

Support the Warfighter with good Data 

Technical Data Package Lifecycle 

Management 

Presentation for 

NIST 

Howard Owens/Brent Gordon 

December 11, 2012 

1 

• Purpose 

• TDP Lifecycle Management Issues/Risks 

3⁄4Magnitude of the Problem 

• What are we doing? 

3⁄4Enterprise IPT 

3⁄4PLM Projects/Pilots 

2 

Agenda 

12/04/2012 

• Provide summary of Technical Data Package 

(TDP) Lifecycle Management issues and risks 

• Advise leadership of current efforts with 

Technical Data Package Lifecycle management 

oEnterprise IPT established and chartered as 

a result of risk associated with native 3D 

models 

oProduct Lifecycle Management (PLM) pilots 

and projects initiated 

3 

Purpose 

12/04/2012 
 

 

 

 

rt

 

 

n s lts

 

 

 

 

 

 

 

 

 

 

 

9 

TDP Lifecycle Management Issues and Risks 

• Acquisition Requirements non-standardized 

3⁄4 Inadequate exit strategies from OEM PLMs 

3⁄4 New acquisition programs (e.g. BAMS, UCLASS, H-53K) looking for enterprise PLM/repository solution 

• QA - No standardized 3D model acceptance criteria 

• Storage - No central repository /workflow tool 

• Multiple online CITIS/IDE solutions 

3⁄4 OEM Managed & Owned 

• Static/Baseline Deliveries via Hard Drive 

• Multi CAD translation - lack of software, hardware, connectivity, and training 

3⁄4 No standardized 3D Model validation criteria for translated/healed models 

3⁄4 Creates potential void in first article testing/air worthiness item compliance 

• Digital file availability and lack of control may compromise design agency 

• Model defects not recognized until used 

3⁄4 Model often does not match OEM “As Built” or “As Delivered” requiring reverse 

engineering efforts 

3⁄4 Item cannot be correctly manufactured or re-procured from the model delivered 

Acquisition QA Store DoD/N Repository 

or CITIS 

Translation(s)/ 

Healing(s)/QA Use 

4 12/04/2012 

Pro g ram 

P r o ject 

T ask 

Co n tr act 

Line Item 

WBS Item 

014 Bu ild 

Co nfigur ation Item 

P r o d u ct Baselin e 

Geometry 

Pa 013 

012 

014 

12345-654 

12345-655 54000-041 

ABC P r o gr a m 

P h ase 3 Master 

ABC-200 Cert. 

Propos a l 

Task 1001 

T ask 1002 

Task 10021 

Task 10022 

Task 10023 

Task 10024 

Task 10025 

ABC-200 Dev. 

P r oduct Line 

Mo d el 

ABC-200 Blo ck 

- 20 

ABC-2 00 

Develo p m en t 

Co m m er ci al A/C 

ABC-100 

ABC-200 

CM & Design 

Portfolio 

Management Programs & Projec t 

Management 

012 

Unit Tracking 

S cen ario 

An alysis Mo d el 

A alysi Resu 

T ask 10011 

Task 10012 

Simulation 

& Test 

Contract 2003 

Contr act 2004 

CLIN 102 

CLIN 101 

WBSE 5 0 1 

WBS 500 

WBSE 5 0 3 

WBSE 5 0 2 

CLIN 103 

CLIN 104 

WBSE 5 0 3 -1 

WBSE 5 0 3 -2 

Contr act 2004-1 

Contr act 2004-2 

Flt Lo ads ABC200 -34 

Taxi Loads ABC200 -12 

The rma l Model 

S truc tura l Mode l 

Electrical Model 

54020-041 

ABC-200 Blo ck 

- 10 

54021-041 

54021-042 

54021-043 

Task 1003 

C ontrac t 

Management 

Status Quo: 

Core Data & TDP on OEM Server 

Data is organized in Silos 

Data is static(no real time collaboration), 

Data Format may not be compatible for our tools 

Uses non nmci approved software. etc 

Millions Spent Annually on IDE’s to Maintain Data That is Disconnected and Controlled by OEM’s 

5 

TDP Lifecycle Management Issues and Risks 

12/04/2012 

What are we doing? • Enterprise Cross Competency IPT chartered: 

– Project Sponsor: Dan Nega (SES) AIR 6.8 

– Process stakeholders: Dennis West COMFRC (SES), Stu Young AIR 4.1 (SES), Jack 

Summers (SES), AIR-00-CIO, Anthony Manich, AIR 1.0A Deputy Assistant 

Commander for Acquisition 

• Goal Statement: 

– Standardize the acquisition and sustainment of TDPs 

– Provide our work force with the tools, training, infrastructure, and processes 

required to be successful. 

• Problem statements: 

– NAVAIR Engineering remains disconnected from OEM/Vendor Engineering 

environment, leading to continued lengthy development cycles, late discovery of 

deficiencies, and misinterpretation of requirements, perpetual engineering 

approval loops, and overall poor communication 

– Current acquisition environment emphasizes the need for the government to act as 

the Lead Systems Integrator (LSI), but it does not emphasize the procurement of 

the TDP. 

– NAVAIR logistics, engineering, and production information systems used for 

sustainment are not integrated, lack standardization throughout the enterprise, 

and were not designed to handle CAD/CAM/CAE data used for 21st century 

platforms. 

6 12/04/2012 

NAVAIR 3D Enterprise IPT 

3D EIPT Leadership: 

• Dan Nega AIR-6.8, Dennis West COMFRC, Stu Young AIR-4.1 

3D EIPT Membership includes: 

• 1.1.3 Configuration Management 

• 2.5.1.6 A/C Support Contracts, Logistics & In-Service Support Centers Contracting Br 

• 4.1.9 Systems Engineering, Manufacturing & Quality Div 

• 4.5.8.2 Air Traffic Control Systems, Approach Systems Br 

• 5.4.3.1 Battlespace Simulation & Test, Enterprise Operations Br 

• 6.0H COMFRC 

• 6.6 DPMLs 

• 6.8.4 Aviation Readiness & Resource Analysis, Logistics & Maintenance Information Systems & Technology Div 

• 6.8.5 Aviation Readiness & Resource Analysis, Logistics Product Data Div 

• 7.1F Command Operations and leadership Support , Office of Small Business Programs 

• 7.2. Information Technology /Information Management Dept 

• NAWCAD Lakehurst 

• FRCE Cherry Point/FRCSW North Island/FRCSE Jacksonville 

• NAWCTSD Orlando 

• Army 

• Air Force 

• DLA Extended Team Members 

• DCMA 

• OSD 

7 12/04/2012 

8 

ACQUISITION RISK: NOT IMPLEMENTING CORRECT TECHNICAL 

DATA ACQUISITION 

12/04/2012 

Issues: 

• Contract Language does not 

adequately define TDP 

requirements, Product Data 

Delivery Requirements and TDP 

acceptance. 

• Insufficient TDP Acquisition 

Training. 

• No resources for TDP 

management positions. 

Consequence: 

• Buying unusable data. 

• Waste of Funds 

• Significant Rework of existing 

Parts/Data 

• Readiness Impacts 

Mitigations: 

• Develop Comprehensive Data Rights Management Policy 

• Identify appropriate contract language 

• Develop Training Curriculum/Certification for TDP LEM in 

conjunction with Engineering Requirements. 

3DS.COM/CATIA © Dassault Systèmes | Confidential Information | 2/19/2013 | ref.: 3DS_Document_2012 

PLM/PDM System 

• The quest to find pertinent solutions to the specific problems encountered 

keeps returning to a PLM/PDM system for the following reasons: 

3⁄4Serves as the Single Source/access point for authoritative Product and 

Process design information as well as other authoritative product and 

process data/information 

3⁄4Establishes the authoritative source for product configuration 

management, configuration relationships and end item data and as the 

single access point to other authoritative data/information sources 

3⁄4Utilizes standardized/standards-based data information exchange 

capabilities between systems and/or technology environments at various 

sites 

3⁄4Facilitates data re-use within and across organizations as well as across 

products/commodities/sites 

12/04/2012 9 
10

 

 

 

 

 

 

 

 

 

 

3DS COM CAT A © Das aul Sy èmes Conf dent a n ormat on 2/19/2013 ref.: 3DS_Do umen 2012 13

 

 

 

 

 

3DS.COM/CATIA © Dassault Systèmes | Confidential Information | 2/19/2013 | ref.: 3DS_Document_2012 

How can we gain more insight, buying power and process acceleration? 

IDE 

Functions as a document 

management vault 

Basic workflow 

Does not drive process 

Not intuitive to navigate 

Cannot collaborate in real 

time 

Only contains select, released 

data and documentation 

PLM 

Enables dynamic interaction and 

process execution 

Includes enterprise Workflow 

Management 

Project management tools 

Can use 3D graphics to aid 

navigation 

Enables real-time collaboration 

in 3D context . 

Enables full traceability from 

Requirements to Function to 

Logical definition to 3D Physical 

models, simulation and 

engineering analysis 

PLM can bring fundamental transformation of our acquisition process 

10 

What are we doing? 

Initiating PLM Pilots/Projects 

12/04/2012 

From IDE to 

PLM 

Synchronized Data Environment 

located at PAX 

Worldwide 

Worldwide 

PAX PLM 

OEM 1 

Sub 

Vendor 

Sub 

Vendor 

OEM 2 

Sub 

Vendor 

11 12/04/2012 

Requirements Management 

Systems Synthesis 

System Architecture Management 

Systems Integration 

Requirements Validation/Verification 

Trades and Analysis 

Preliminary Design Competitive Sourcing 

Supplier Quality Management 

Major Subcontracts 

Management 

Inventory Management 

Purchasing / Material 

Receiving and Payments Release BOM to ERP 

Support Manufacturing 

Execution 

Tool Asset Management 

As Built BOM Capture 

Build Record Capture 

What Does PLM Cover? 

Product Engineering 

Process Engineering Logistics Support 

Supplier Management 

Quality Assurance 

Program Management 

n 

Manufacturing Operations 

Contract Management 

Program Management 

Systems Engineering 

Product Engineering 

Process Engineering 

Quality Assurance 

Supplier Management 

Manufacturing Operations 

Logistics Support 

WBS Management 

Cost Account Management 

Earned Value Measurement 

Integrated Program Schedules 

Make/Buy Board 

Risk Management 

Configuration Management 

Contract Deliverables 

Management 

Non-Conformance Management 

Quality Trend Analysis 

Materials Review Board 

Physical Inspection 

Supplier-Part Quality Planning 

Technical Publication 

Management 

Maintenance Process 

Engineering 

Logistics Support Analysis

(LSA) 

Maintainability Analysis 

Reliability Analysis 

Engineering Projects

Management 

MBOM Release to Enterprise Engineering Projects Management 

Mechatronics Sub-systems 

Management 

Materials Compliancy 

Change Management (ECR, ECO) 

Components Engineering 

Proposal Management 

Pricing and Estimating 

Regulatory Compliance 

CLIN Management 

Contract Compliance 

Action Item Management 

Correspondence Tracking 

Award Fee Management 

Contract Billing 

Contract Closure 

Contracts Management 

Systems Engineering 

12 12/04/2012 

. / I s t st | i i l I f i | | c t_ 

PLM Consolidates and Connects Data to the Product with relationships and context: 

Program 

Project 

Task 

Contract 

Line Item 

WBS Item 

014 Build 

Configuration Item 

Product Baseline 

Geometry 

Part 013 

012 

014 

54000-041 

ABC Program 

Phase 3 Master 

Proposal 

Task 1002 

Task 10021 

Task 10022 

Task 10023 

Task 10024 

Task 10025 

ABC-200 Dev. 

Product Line 

Model 

ABC-200 

Block - 20 

ABC-200 

Development 

Commercial A/C 

ABC-100 

ABC-200 

CM & Design 

Portfolio Programs & Project Management Management 

Scenario 

Analysis Model 

Analysis Results Task 10012 

Simulation 

& Test 

Contract 2003 

Contract 2004 

CLIN 102 

CLIN 101 

WBSE 501 

WBS 500 

WBSE 503 

WBSE 502 

CLIN 103 

CLIN 104 

WBSE 503-1 

WBSE 503-2 

Contract 2004-1 

Contract 2004-2 

Flt Loads ABC200 -34 

Taxi Loads ABC200 -12 

Thermal Model 

Structural Model 

Electrical Model 

Case 1 

Case 2 

Case 3 

54020-041 

ABC-200 

Block - 10 

54021-041 

54021-042 

54021-043 

Task 1003 

Contract 

Management 

Qty =1 

Qty =2 

Unit Tracking 

12345-655 

Task 1001 

ABC-200 Cert. 

12345-654 

Task 10011 

13 

12/04/2012 

PLM Benefits 

• PLM is “relational” environment that ties all of the program 

data to the product structure and vice versa 

• By implementing a PLM suite on the government side we 

will have the ability to take a targeted approach at TDP 

acquisition. 

• PLM accelerates communication between stakeholders and 

greatly reduces the time to develop and acquire the system. 

(Future Brief) 

• PLM will allow the PMA to execute LSI functions and ensure 

implementation of open architecture. 

• PLM will allow open and broad competition to rapidly add 

capability at lower cost for the life of the program. 

14 

12/04/2012

Current Initiatives • OSD /DoD Engineering Drawing & Modeling Working Group (DEDMWG) 

– Digital Depot Project focused on transition of Methods and Technology to MBE in DoD 

maintenance and manufacturing facilities. 

– MIL-STD-31000 Project to update the standard for 3D Modeling and MB Enterprise 

activities. 

• OPTICAM Pilot Projects through OSD with National Center for Manufacturing Sciences (NCMS) 

– OptiCAM is a collection of COTS hardware and software applications tied together with 

custom integration. Its core differentiator is based on a 3-D Imaging system (VZX Imaging) 

developed by SIS, and industry leading PLM software (NX with Teamcenter Unified) from 

Siemens. 

• NAVAIR 

– AIR-4.1.9 led effort to implement a pilot Model-Based Systems Engineering solution 

utilizing a IBM/ Dassault Systems software suite to manage/collaborate PMA activities in 

an enterprise context. 

– COMFRC Technology Investment Team working with FRCs to develop BCA for 

implementation of Industrial COI for FRCs and an enterprise PLM/PDM Solution; each FRC 

documenting requirements. 

15 01/30/2012 

Integration of initiatives required to achieve holistic approach. 
2012 MBE Summit

-

-

 

• Evolution of technology has enabled programs to leverage 

3D Models in acquisition 

• Technology advances have out-paced update/development 

of ASME and DOD 3D Model standards and Service/SYSCOM 

policies, processes, tools, and infrastructure 

• Multiple initiatives without a NAVAIR focal point and 

cohesive IPT approach 

• Scope of 3D Model issues includes Acquisition, Quality 

Assurance, Configuration Management, repository 

management, and use. 

16 

Problem Summary 

01/30/2012 

2012 Model Based 

Enterprise Summit 

The Digital Future Today 

Effective 3D MBE with 

3D PDF & 3D HTML 

UNCLASSIFIED FOR PUBLIC RELEASE 1

“Cost Effective 3D CAD & PLM data 

deployment” (aka FREE) 

Chris Garcia – Paul Perreault 

Anark Corporation 

2012 MBE Summit 

Introduction to Anark Corporation 

Anark Corporation is a leader in 3D 

visualization software and solutions 

serving the manufacturing enterprise. 

Our customers include the largest 

Aerospace & Defense manufacturers in 

the world and many of their tier-1 

suppliers and defense customers. 

Anark Corporation was founded in 1995 

and is based in Boulder, Colorado. 

Venture backed. 

2012 MBE Summit 

Anark Key Customers 

• US Army 

• Lockheed Martin 

• Boeing 

• Honeywell 

• Rockwell Collins 

• Cubic Defense 

• ElOp / Elbit 

• Canadian Dept. Nat’l Defence 

• General Dynamics 

• Sikorsky Helicopters 

• Textron 

• Cessna 

• Siemens 

• L3 Communications 

• B&W Y-12 

• NASA 

• Canadian Space Agency 

• Northrop Grumman 

• Atlantis Systems 

• 20-20 Technologies 

• Herman Miller 

• Visteon 

• Bretford 

• DiSTI Corporation 

• Best Buy 

• Ericsson 

• European Space Agency 

• Naval Surface Warfare Center 

• Krueger International 

• KSSI 

• CCAT 

• JPL 

2012 MBE Summit 

3D PDF MBEs 

for external supplier 

Outside the Firewall 

(using 3D PDF templates) 

3D HTML MBEs 

for internal manufacturing 

Inside the Firewall 

(using html templates) 

maximum flexibility & rapid customization 

3D PDF and 3D HTML Viewers Provide... 

2012 MBE Summit 

UNCLASSIFIED FOR PUBLIC RELEASE 5 

3D PDF Viewer vs Proprietary CAD Viewers 

FREE 3D PDF Viewer FREE Hardcoded Viewers 

• Free to View 

• No downloads or plug-ins 

• Open Format 

• Fully Functional 

• on 98% - 99% Worlds Computers 

• Approved for all DOD use 

• Free to View 

• Requires Downloads & plug-ins 

• Proprietary Format 

• Limited Functionality in Free Viewer 
-

-

2012 MBE Summit

-

2012 MBE Summit 

UNCLASSIFIED FOR PUBLIC RELEASE 6 

3D PDF and 3D HTML can “HOST” 

a variety of user defined applications which 

are “Fit for Purpose”... 

3D PDF / 3D HTML vs Proprietary CAD Viewers 

Proprietary CAD viewers only do 

what the CAD Vendors 

wants/allows them to do. 

They both make phone calls, 

but which one is better for your business ? 

like your iPhone 

2012 MBE Summit 

Fit for Purpose 3D PDF MBOM 

2012 MBE Summit 

Fit for Purpose 3D PDF Work Instruction 

2012 MBE Summit 

Fit for Purpose 3D PDF Inspection Document 

2012 MBE Summit 

UNCLASSIFIED FOR PUBLIC RELEASE 10 

Effective 3D MBE with 3D PDF and 3D HTML 

3D PDF & 3D HTML are the best platforms for 

Deployment of 3D MBE: 

• Flexible and Customizable 

• “Fit for Purpose” vs “Hard Coded by the CAD Vendor ” 

• Based on Open Formats (3D PDF and 3D HTML) 

• No Proprietary downloads required 

• Fully functional and FREE to View & FREE to Deploy 

2012 Model Based 

Enterprise Summit 

The Digital Future Today 

Exchange vs. 

Visualization vs. 

Communication 

Enabling the Model Based 

Enterprise 

UNCLASSIFIED FOR PUBLIC RELEASE 1
-

’

agemark LLC all rights reserved; used by permission –

2012 MBE Summit 

Claim #1 

• There are three (3) principal MBE activities 

related to the use of MBD data: 

1. Exchange 

2. Visualization 

3. Communication 

UNCLASSIFIED FOR PUBLIC RELEASE 2 

2012 MBE Summit 

MBD authoring 

application 

• design authority 

• CAD and PLM data 

• Archivable 

STEP data 

• Multiple AP s possible 

• XML data 

• Archivable 

MBD receiving 

application 

• Modeling, NC, etc. 

• Derivative 

representation 

• CAD and PLM data 

• Maybe archivable 

Data Exchange 

2012 MBE Summit 

• MBD/MBE represented 

(usually) by 

CAD/CAM/PLM system 

Application1

• STEP 

• JT 

• PRC 

Derivative 

format • Another MBD/MBE 

application 

• CAD 

• CAM/NV 

• Virtual factory 

Application2

Transformation 

Transformation 

Data Exchange Process 

2012 MBE Summit 

Claim #2 

• Visualization is not the same as communication. 

2012 MBE Summit 

The Role of Visualization 

©2012 Sagemark LLC– all rights reserved; used by permission 

2012 MBE Summit 

Lifecycle Functions Require More 

©2012 Sagemark LLC – all rights reserved; used by permission 
 

-

2012 MBE Summit 

This is Visualization 

A rats nest of 3D Notes, Labels, Dimensions & GD&T 

2012 MBE Summit 

This is Communication 

Fully consumable with Acrobat Reader in document and web forms 

2012 MBE Summit 

Engineering TDPs & RFQs 

3D MBE RFQs / RFI 

(in assembly context) 

3D MBE TDP 

(no 2D Drawings) 

2012 MBE Summit 

Manufacturing Processes 

3D MBE 

Welding Best Practices 

3D MBE 

Shop Floor Assembly 

2012 MBE Summit 

Inspection and Field Service 

3D MBE 

First Article Inspection 

Field Repair 

Instructions 

2012 MBE Summit 

Validation Matters 

UNCLASSIFIED FOR PUBLIC RELEASE 13 
-

-

2012 MBE Summit 

MBD data 

• design authority 

• CAD and PLM data 

• Archivable 

STEP & PRC data 

• Geometry 

• Product structure 

• Product 

manufacturing 

information 

3D PDF 

• derivative 

representation 

• Any data type 

• Universal access 

• Archivable 

Visualization App 

• DMU/VMM use cases 

Claim #3 - PRC is the MBE Enabler 

2012 MBE Summit 

Format Domains 

UNCLASSIFIED FOR PUBLIC RELEASE 15 

2012 MBE Summit 

Future of Documents 

• Yes, web sites can present composite data 

• But... 

– Is bandwidth ubiquitous? 

– Who manages a 10,000 person portal? 

– Which browser? 

– How do you LOTAR web content? 

– What do you give the regulators/compliance 

authority? 

UNCLASSIFIED FOR PUBLIC RELEASE 16 

2012 MBE Summit 

ISO32000 is PDF... 

Forms 

Presentation 

Audio & Video 

3D Models 

w/PMI 

Text & Graphics 

Images 

3D Model 

PMI, GD&T, FT&A 

Geometry: Meta Data 

Product Structure PM

XML Form Data 

Business Logic 

JavaScript XML Schema 

Security 

Encryption Dig Signatures 

Rights Management 

Acrobat SDK – Free & Open API 

p 

Interactive Form 

Fields 

2012 MBE Summit 

3D PDF Content Standards Status 

• U3D 

– U3D developed by 3D Industry Forum (3dif.org) 

– U3D currently an ECMA standard (363) under TC43 

– U3D Edition 1 is specified by PDF/E (ISO 24517-1) 

• PRC 

– Specification published by Adobe in 2008 (PDF 1.7) 

– Released to ISO TC 171 for standardization in 2008 

– Currently managed by ISO DIS 14739 under TC 171 SC 2 

– Establishes 3D standard to be referenced by PDF (ISO 

32000) and others 

2012 MBE Summit 

Why 3D PDF Matters 

1. Access 

– through Acrobat Reader 

2. Multi-type 

– 3D, 2D, image, text, audio, video, enterprise

data 

3. Infrastructure 

– existing systems already support PDF 

4. Neutrality 

– Investment protection 

5. Value 

– Low investment threshold with high payback 
© 2012. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

 – 

 – 

 

 

 Siemens Product Lifecycle Management Software Inc. All rights reserved

 

em ns ro Pduct ecycl ment Softw re I nc All rights rese ed

e s ft

en

2012 MBE Summit 

What is the 3D PDF Consortium? 

• A community dedicated to driving adoption of 3D 

PDF enabled solutions through: 

– Defining industry needs and priorities 

– Creating reference implementations and other resources 

– Providing input to the standards process 

– Raising awareness 

• A worldwide, non-profit, member organization 

• Open to all companies 

2012 MBE Summit 

Organization Details 

• Law firm – Gesmer, Updegrove LLP 

• Incorporated in Delaware, U.S. January 3, 2012 

• Form of organization – 501(c)6 Trade Organization

under IRS Tax code 

• Filed with National Cooperative Research and

Production Act (NCRPA) for anti-trust protection 

• Bylaws, Articles of Incorporation, and incorporation

certificate available 

• Introduced in Japan (Feb) and Germany (June) 

• All back office functions outsourced 

• Managed by an Executive Director 

2012 MBE Summit 

What is the Consortium structure? 

Industry Committee 

- Define industry needs 

and priorities 

- Develop process-based 

use cases 

- Assign priorities to 

technical committee 

work 

Technical 

Committee 

- Project goals and 

objectives 

- Project plans, 

participation, funding 

- Implementers forum 

- ISO technical 

submissions 

Communications 

Committee 

- Web site 

- Publications 

- Solicit and propose 

case studies 

- Presentations 

- Blog/article 

submissions 

Executive Committee • mission, vision, strategic direction 

Board of Directors 

• governance, recruiting 

2012 MBE Summit 

Why is the Consortium important? 

• Define priorities according to member needs 

• Speak for the industry with a unified voice 

• Source of subject matter expertise 

• Illustrate market demand and availability 

• Provide technical input to standards process 

• Offer vendor-neutral advice to end user and ISV 

members on implementation strategies 

• Resources such as reference implementations, 

implementer forum, white papers, templates, 

Javascript, libraries 

© 2012. Siemens P od r s Poduc Lt i ucLt ifecycle Management So f wtare n I re n I enc. All rights re s r eserved 

Sieme ns PL M Software 

JT 

Powering the World of PLM 

Dennis Keating Federal Sales 

John Cunneen Federal Business Development 

nist mbe conference 2012 

Utilizing Lightweight Geometry 

in 

Down Stream Applications 

JT Presentation Topics 

Presentation Material 

00:00 – 00:05 1. Siemens PLM 

00:05 – 00:20 

JT 

1. What is JT 

2. JT Open 

3. Applications utilizing JT 

© 2009. Siemens Produ s Produ ct Life ct Life cycle M anageme nt Soft nt Soft ware In ware Inc All. rights reserved 

Page 2 Siemens PLM Software 
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© 2012. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

8 Software Inc. All rights

Page 3 

© 2009. S emens Produc Li ecyc e Management Sof ware nc A rights reserved 

Siemens PLM Software 

Siemens Product Lifecycle Management 

Siemens PLM 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

© 2012 Siemens Product Lifecycle Management Software Inc All rights reserved 

What is JT ? 

Page 5 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Some Details 

• JT is a binary format whose data model 

supports various representations of CAD 

geometry 

• The representations can be stored in a 

JT file individually or together 

• In addition to geometry, JT can display 

product structure, attributes, and product 

manufacturing information (PMI) like 

tolerances, dimensioning and surface 

properties. 

ct 

Page 6 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Geometry in a JT file 

Geometry Primitives: 

At one of the lowest levels, simple regular geometry such as 

cuboids, cylinders and pyramids are located in what is 

referred to as the bounding box. 

BREP (Boundary Representation): 

Offers the highest level of precision. BREP data is 

compressed using different algorithms and stored without 

loss. Two BREP representations are permitted: the 

traditional JT-BREP representation and XT-BREP, which is 

based on the Parasolid boundary representation. 

Page 7 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Geometry Continued... 

Tessellated Geometry: 

Representation of solids and surfaces as facets. Different 

levels of detail (LOD) can be defined within a JT file. A low 

LOD means a lower level of precision but a smaller volume 

of data, while a very high LOD means an almost exact 

geometry but a large volume of data. The JT file format is 

capable of storing an arbitrary number of faceted 

representations with varying LODs. 

ULP (Ultra-Lightweight Precise): 

The ULP format enables a lightweight, semi-precise 

representation of the 3D geometry. The level of precision 

that ULP offers is significantly higher than for tessellated 

geometry while the file size is significantly smaller (almost 

one hundredth the size of the original data). The ULP format 

makes it easier to share data across low bandwidth 

connections. 

Additional JT File Content Summary 

Scenegraph 

Facet information (Triangles) with Advanced 

Geometry Compression 

Lighting models 

Material data 

Texture Maps 

Supports a variety of representation 

configurations and delivery methods including 

asynchronous streaming of content 

Precise Surface Geometry (BREP) 

Product Manufacturing Information (PMI) 

Precise and imprecise wire frame 

Product Structure (BOM) 

Discrete purpose-built Levels of Detail 

Extensible data paging architecture 

CAE results visualization 

Wire harness information 

PointSets and ImplicitPrimSets 

Layers 

Pixel/Vertex Shaders (Cg and OGLSL) 

General and CAD specific Metadata 

ment S fotware In ar e In ec. A ll c. A l c l. cA l .l A ri h gt ri h gt ri h gt r i hgts reserved 

Siemens PL M S oftware 

8 are 

Page 8 

© 2012. Siemens Product Lifecycle Managem
 Siemens Product Lifecycle Management Soft Inc. All rights reserved

s PLM Software

d

 

 

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-

 

 

 l i 

 oduct Lifecycle Management Software Inc. All rights reserv

Siemens PLM Softw

t Lifecycl e Management Software Inc A r ghts r e l i 

 

 

 

l i l i 

ri ht g s reserve

t

s

fe cl s 

Page 9 

© 2010. ware 

Siemen 

Facets 

Attributes 

BREP 

CAD 

PMI 

Constraints 

History 

JT Extends CAD Data to Non-CAD Users 

Master Design Definition 

 Design Intent 

 Feature Creation History 

 Embedded Design Knowledge 

 Intellectual Property 

Inc. All rights r es s r s e s r s e s r e s rs er e d erve d rve d 

emens PLM Soft Software 

Lightweight 

1 

2 

... 

Level Of 

Details 

(LODs) 

Attributes 

Precise BREP 

JT 

PMI 

Synchronized Collaboration 

 Common, Multi-Purpose File 

 Only What’s Required from CAD 

 Supports All Major CAD Systems 

 Puts 3D in the Hands of Non-CAD Users 

Synchronized 

D 

ms 

AD Users

Tolerance and Mfg data in 3D context 

Loaded on demand 

Eliminate the need for 2D drawings 

Keep Mfg in sync with Design 

Optional exact surface geometry 

Loaded on demand 

Same precision as CAD 100% 

Enables exact spatial analysis 

Report CAD Parameters and Attributes 

Extract PDM Metadata 

Fast Load / Hi performance 

Extremely Large Assemblies 

Reduced N/W Bandwidth 

Reduced H/W Requirements 

Purpose Specific LODs 

Supports Streaming Page 10 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Example of file size benefits of JT 

© 2012. Siemens Pr ed 

are 

JT Open Program 

oduct L cy e Management Software In c. Allright reserve 

Siemens PLM Softwa Page 12 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

JT Open Program 

Objectives 

Purpose, Mission, Vision 

 Maintain a community of software 

vendors, users and interested parties 

to share JT knowledge and influence 

the direction of JT technology 

 Encourage widespread adoption of 

JT for 3D visualization, collaboration, 

interoperability and data archiving 

 Provide open access to a JT-based 

visualization pipeline 

 Establish JT as an open standard 

Page 13 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

JT Open Program 

Membership Types 

Corporate 

 Companies that use JT as the platform-ofchoice for visualization and data sharing 

Vendor 

 software vendors that provide JT-enabled 

applications 

Advocate 

 Hardware, software and service suppliers 

that want to actively support the goals of 

the JT Open community without directly 

making use of JT technology 

Academic 

 Educational institutions that use the JT 

Open Toolkit for research and teaching. 

Page 14 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

JT Open Program 

Community Interaction 

Management Review Board (MRB) 

 Represents the business and 

management interests of the JT Open 

member community 

 Manages the JT Open program 

 Elected Chairperson 

 All corporate member offered option to sit 

on the board 

 Limited number of Vendor Members 

elected by the MRB 

 Meets once per year with phone 

discussions as needed 

Chairperson 

Corporate MRB members 

Vendor MRB members 
l i 

 

l i 

© 2012. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

© 2012. Siemens Product Lifecycle Management Software Inc. All rights r

 

l i 

 

© 2012. Siemens Product Life cle Mana ent Software Inc. All ri rved

Page 15 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

JT Open Program 

Community Interaction 

Technical Review Board (TRB) 

 Represents the technical interests of 

the JT Open member community 

 Elected Chairperson 

 All corporate and vendor member 

offered option to sit on the board 

 Meets twice per year 

 Monthly phone discussions 

 Create and manager technical 

working groups 

Current working groups 

• CAE 

• Advanced Materials 

• JT Validation 

• Role based retrieval / JT repurpose 

• Long Term Data Retention 

• JT Best practices 

Page 16 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

JT Open Program 

Growing Community of over 100 members 

JT as open, 3D format 

 No cost viewer, JT2Go 

 Published file format (free to download) 

 Developer toolkit available to all via JT 

Open program 

JT as common language for PLM 

 Visualization 

 Interoperability 

 Long term archiving 

JT ISO Standard Status 

© 2012. Siemen s Prod uct Li f lecyc e Mana gement S ftow are Inc All. c All right s rese rved 

Siemens PLM Software Page 18 

eserved 

Siemens PLM Software 

Technical Committees (TC) have Subcommittees 

(SC) that actually do the work. 

Sub Committee 4 is where JT is being proposed 

There are 236 Technical Committees (TC) in ISO 

The TC of interest for JT is 

TC 184 Industrial automation systems and integration 

ISO JT ... where JT fits in ISO 

Page 19 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

JT Conformance with ISO TC 184 / SC 4 Standards 

TC 184/SC 4 manages several standards 

© Siemens AG 2012. All Rights Reserved. 

Page 20 Siemens PLM Software

Bringing JT through the ISO process 

Siemens PLM Software and ProSTEP iViP are working hand in hand to bring the 

JT Format through the ISO IS process 

• ProSTEP iViP was instrumental in achieving ISO PAS 14306 

• ProSTEP iViP sponsored the New Work Item Proposal that was accepted to 

deliver the JT specification as an International Standard 

© Siem en 
 

 

 

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Siemens PLM Software

Process Anim Pr

As

 

outputs

V sual zation

 

Page 26

© 2012. Siemens Product Lifecycle Management Software Inc. All rights reserved

Siemens PLM Software

© Siemens AG 2012. All Rights Reserved. 

Page 21 Siemens PLM Software

ISO JT PAS 

JT is currently a PAS not an IS 

The ISO JT PAS number is 14306 

PAS 14306 is the JT file format reference for 

Version 8.1 JT 

Siemens still owns JT 

PAS 14306 includes the XT B-Rep format 

reference 

Page 22 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

ISO / JT Status 

Final Draft International Standard (FDIS) ballot agreed to in 

Sweden meetings, June 2012 

• Resolution of ballot comments completed, agreement from 

national delegates to approve V1.0 ISO JT 

• Contains the V9.5 JT format definition 

• New ballot has been initiated 

• 2 month ballot will conclude December 2012 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Examples, Benefits of using JT 

Page 24 

© 2012. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

The JT Pipeline 

Breadth & Depth to Support All Lifecycle Processes Breadth & Depth to Support All Lifecycle Processes 

Number of Users (Proliferation) 

Data & Process Complexity

Supplier 

Viewing 

Styling Review 

Virtual Functional Build 

Virtual Factory 

Ergonomics 

Spatial Digital Validation 

CAE Results 

Common 

“Visualization pipeline” 

throughout the 

extended enterprise 

Quality Validation 

Technical Publishing 

2D/3D View & Markup 

Assembly Validation 

PLM Workflows 

Formal Design Review 

Immersive Design Review 

Drawingless Models - PMI 

Interoperable 

Design 

Page 25 

Multi-Source Solution 

Enables Data Neutral Environment Regardless of Native Source 

Mfg Execution • Production Mgt 

• Order Mgt 

• Material Mgt 

• KPI’s 

• Plant Performance 

• OEE 

• Reporting & Scheduling 

• Quality Assurance 

Visualization 

• Instant Collaboration 

• Product Mockup 

• Plant Simulation 

• ation 

Mfg Planning • CAM 

• Simulation 

• Process Plans 

• Work Instructions 

• BoM Mgt 

CATIA / Solid Works 

Pro/E 

AutoCAD / Inventor 

oduct Structures 

semblies 

Electronics 

Mentor, CADENCE, 

ZUKEN 

CE, 

PMI Information 

2d Dwgs 

Plant Layouts 

Mfg Dwgs 

Produc 

Ass 

Common Information 

Backbone 

Vault 

Teamcenter • Product Structure 

• Change Mgt 

• Workflow & Signoff 

• eBoM / mBoM / BoP Mgt 

• Documents / Content Mgt 

• Native CAD Files Mgt 

• Resources Mgt 

• Project Plans & Routings 

mce 

Multiple 

PLM 

XML 

i i 

Process

Mfg Execution System 

LMP Integrations 

Structure 

Geometry 

Example of Leveraging JT data in Shipbuilding 
 i 

Page 30



2012 MBE Summit 

 

- 

Page 27 

© 2010. Siemens Product Lifecycle Management Software Inc. All r ghts reserved 

Siemens PLM Software 

JT enabling multi-CAD assembly and integration 

Any size assembly for whole product context 

Siemens PLM Software 

© 2012. Siemens Product Lifecycle Management Software Inc. All Rights Reserved. 

JT enabling Multi-CAD for complex CAE analysis 

© Siemens AG 2012. All Rights Reserved. 

Page 29 Siemens PLM Software

JT enabling complex machining simulation 

3D models courtesy of Mori Seiki © Siemens AG 2012. All Rights Reserved. 

Siemens PLM Software 

JT enabling immersive environments 

GME975 Insignia Opel 2010 5-Door Subsystem Body 

Program Control Validation Concerns

Studies 

  

2012 Model Based 

Enterprise Summit 

The Digit l Futur Today The Digita el Future Today 

Turning Light Weight Graphics 

into Meaningful 3D Experiences 

Garth Coleman 

VP Products & Strategy, 3DVIA 

UNCLASSIFIED FOR PUBLIC RELEASE 1
2012 MBE Summit 

The Thr

UNCLASSIFIED - FOR PUBLIC RELEASE 9 

e

U

es 

-

2012 MBE Summit 

UNCLASSIFIED - FOR PUBLIC RELEASE 3 

sell

2012 MBE Summit 

UNCLASSIFIED - FOR PUBLIC RELEASE 4 

Extend, enrich, and augment the 3D MBE data 

into delivering real experiences about real 

products and how they work in the real world. 

2012 MBE Summit 

2012 MBE Summit 

3DVIA: The 3D Communication Brand 

2012 MBE Summit 

The T hree P’s 

roducts 

UNCLASSIFIED FOR PUBLIC 

rocedur 

C RELEASE 

ures 

9 

laces 
The Thr

UNCLASSIFIED - FOR PUBLIC RELEASE U 12 

es 

The Thr

UNCLASSIFIED - FOR PUBLIC RELEASE U 14 

es 

-

-

2012 MBE Summit JEITA 3D Experience 

• JEITA 

– Japan Electronics and Information Technology Industries Association 

• Member Companies 

– Omron, Canon, Konika-Minolta, Seiko Epson, Sony, Toshiba, Nikon, 

Panasonic, Hitachi, Fuji Xerox, Mitsubishi Electronics, and Ricoh 

• Defining guidelines to promote 3D annotated models 

– Importance for effective communication about design requirements 

for downstream, non-CAD users 

– Precise communication without ambiguity or confusion 

UNCLASSIFIED - FOR PUBLIC RELEASE 10 

2012 MBE Summit 

The T hree P’s 

roducts 

UNCLASSIFIED FOR PUBLIC 

rocedur 

C RELEASE 

ures 

12 

laces 

2012 MBE Summit Virtual Training 3D Experience 

UNCLASSIFIED - FOR PUBLIC RELEASE 13 

2012 MBE Summit 

The T hree P’s 

roducts 

UNCLASSIFIED FOR PUBLIC 

rocedur 

C RELEASE 

ures 

14 

laces 

2012 MBE Summit Orientation 3D Experience 

UNCLASSIFIED - FOR PUBLIC RELEASE 15 

2012 MBE Summit A bigger picture... 

UNCLASSIFIED - FOR PUBLIC RELEASE 16 
2012 MBE Summit 2012 MBE Sum mit 
2012 MBE Summit 

2012 MBE Summit 

“It’s Not Safe” 

“Not for Enterprise” 

“B2C, not B2B” 

Miscommunications about the Cloud 

Truth about the Cloud 

Safe & Secure 

Great for Small Business 

Enterprise use is growing 

fast! 

Employees will use anyway 

2012 MBE Summit Enterprise Business & The Cloud 2012 MBE Summit 

Content Sharing is Moving to the Cloud 

email usb 

Cloud 

Hosting 

TODAY 

“TOMORROW” 

(actually today!) 
3DVIA Web Interface,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2012 MBE Summit

3DVIA Cloud Workflow 

HOSTING 

One platform & content format for both 

CAD and DCC (everything in 3DXML) 

Developer APIs 

SHARING 

Ubiquitous, Fast, Simple Access – 

desktop, web, mobile apps 

Web Interface, nterface 

Share 

PUBLISHING 

3D content into 3DXML format - for 

reuse by 3DVIA consumer apps 

Composer 

3DVIA Studio Pro 

3DVIA Store 

3DVIA Virtual Training 

3DVIA Composer 3DVIA Composer 

Publish 

3DS WEB 

APPS 

3DS MOBILE 

APPS 

Web & 

Mobile 

3rd PARTY 

APPS 

M 

Sketchup 

ADSK 

PTC 

Other 

3DXML 

(NOT – MASTER DATA) 

2012 MBE Summit 

Then: Now: Next: 

Access Experience 

Host 

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

MEP: Connecting and Assisting 

U.S. Manufacturers 

with MBE-Based Approaches 

to Defense Business 

Opportunities 

David Stieren 

Manager, Technology Acceleration 

and Technical Principal, Supplier Development and Scouting 

National Institute of Standards and Technology (NIST) 

Manufacturing Extension Partnership (MEP) 

david.stieren@nist.gov 

NIST MEP 1 

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

THE MEP PROGRAM 

 MISSION – “To act as a strategic advisor to promote business growth and connect 

manufacturers to public and private resources essential for increased competitiveness 

and profitability. “ 

 60 centers with >370 field locations 

- 501 c3 non-profits, univ-based, embedded in state gov agencies 

- System wide, Non-Federal staff is > 1,300 

- Contract with over 2,300 third party service providers 

 MEP System budget ~ $300M – Federal / State / Industry 

- 1/3 Federal ($128.4M FY12), 2/3 State and Industry (fees for services) 

 MEP Program and Center performance measured per impact 

of services on client firms. 

- ~34,000 manufacturers served, >10,000 projects conducted annually * 

- Aggregate impacts include $8.2B increased/retained sales; $1.9B new client investment; 

$1.3B cost savings; 60,497 jobs created/retained * 

*Based on Client Reported Data in 2011 

www.nist.gov/mep 

– or – 

800-MEP-4MFG 

D. Stieren – MBE Summit, December 2012 NIST MEP 2

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

 Increasing manufacturers’ capacity for innovation, resulting in profitable 

sales growth is MEP’s overarching strategy. 

 Assistance framework capitalizes on cost-reduction strategies – historically MEP’s 

core services – to enhance productivity, free up capacity for business growth. 

 Innovation is stressed as the basis of business growth. 

 Business growth focuses on new sales, new markets, and/or new products. 

 5 key MEP strategies for increasing manufacturers’ profitability: 

Continuous Improvement 

Technology Acceleration 

Supplier Development 

Sustainability 

Workforce 

MEP Strategies 

D. Stieren – MBE Summit, December 2012 NIST MEP 3

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

 FOCUS: Supply chain development for current or 

new market spaces to capitalize on opportunities to 

differentiate companies using tech-based approaches 

 Example areas of emphasis 

• Integration of new processing techniques / technologies (tooling, capital 

equipment, metrology/sensors) into factory systems 

• Implementation of automation technologies / approaches into operations 

• Implementation of advanced engineering practices / integration of engineering 

with production & other manufacturing execution functions 

 Working with DOD to implement model-based enterprise (MBE) approaches 

throughout supply base 

 Including access to high-performance computing/modeling and simulation resources 

Technology-Based Supplier Development 

D. Stieren – MBE Summit, December 2012 NIST MEP 4
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

Level 4 

1% 

Level 3 

35% 

Level 2 

32% Level 1 

Complete 

17% 

Level 1 

Incomplete 

15% 

Level 1 

32% 

More information on this assessment can be found in its report, 

located at www.model-based-enterprise.com 

MBE Assessment Team: ARL, NIST MEP, 

BAE Systems, MEP Centers 

Capabilities assessment performed for 

445 military ground vehicle suppliers 

MBE Analysis Metric 

Analysis & Results: 2/3 of participating suppliers 

are ready to operate in an MBE environment 

NIST MEP 

White: 0 Suppliers 

Lt. Blue: < 5 Suppliers 

Med. Blue: 5-10 Suppliers 

Dk. Blue: >10 Suppliers 

5 

MEP Assistance to U.S. Manufacturers for DOD 

Supply Base Transition to MBE-Based Operations

2009 MBE Supplier

Capability Assessment 

D. Stieren – MBE Summit, December 2012 

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

Raising Supplier MBE Literacy: 

6 

MBE Education and Training Summits, 2010-2011 

• Raise awareness of MBE in suppliers and increase 

supplier confidence in MBE 

• Help current/existing DOD, and potential new DOD 

suppliers develop a business case for MBE 

implementation at their locations 

• Begin to establish advanced, MBE capable suppliers 

The MBE Website, Launched 2010 

www.model-based-enterprise.org

• Developed by partnership that included Army, NIST 

MEP, Catalyst Connection (SW PA MEP Center) 

• Designed to house info, resources to keep defense 

suppliers informed of MBE implementation efforts, 

development opportunities, events, guidance, etc. 

• Includes MBE Assessment tool for manufacturers to 

conduct self-assessment of MBE capabilities 

D. Stieren – MBE Summit, December 2012 NIST MEP 

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

2012 MEP Industrial Assessment of 

3D TDP Format, Tool 

D. Stieren – MBE Summit, December 2012 NIST MEP 7

• Connect w/supplier company reps responsible for receiving tech 

data and models, handling quotes/estimation, working w/models 

related to design/production 

• Drive target decision makers to view online demo/example of 3D TDP 

tool, video instructions to describe key features, usage of 3D TDP 

• Gather Feedback from ARDEC supplier base after review and demo 

of 3D TDP tool 

• Identify which features of 3D TDP are most useful, determine 

if anything important is missing that’s needed to make a part 

• Learn how 3D TDP will be used at supplier companies 

• Continue to prepare supplier base for roll-out of 3D TDP 

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

2012 3D TDP Assessment Results 

D. Stieren – MBE Summit, December 2012 NIST MEP 8

• Outreach to 309 contact targets in Army supply chain 

46 completed surveys - 15% response rate 

• All respondents reviewed 3D TDP prior to completing assessment 

• Nearly entire sample performs one or more of the following functions: 

Receiving technical data and models 

Handling quotes and estimation 

Working with models related to design 

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

2012 3D TDP Assessment Results 

D. Stieren – MBE Summit, December 2012 NIST MEP 9

• 89% of respondents said 3D TDP contains all info needed to make 

a part 

• The “most liked” feature of 3D TDP was 3D rotation and zoom 

• Imbedded CAD and .STP files (91%) and Fully-annotated 3D 

viewable (87%) were rated as 2 “most useful” features of the 3D TDP 

• 89% feel 3D TDP is better or much better than 2D drawings for conveying design intent. 

• 84% of respondents plan to use 3D TDP in their manufacturing planning 

• 76% of respondents plan to use 3D TDP to develop their CAM program 

• 74% of respondents plan to use 3D TDP as instrument to convey intent for shop floor 

M A N U F A C T U R I N G E X T E N S I O N P A R T N E R S H I P 

Next Steps for MEP and MBE 

D. Stieren – MBE Summit, December 2012 NIST MEP 10

MBE Becoming Real for U.S. Manufacturers 

- at the Point of Supplier Implementation 

2013 Upgrade to MBE Website www.model-based-enterprise.org

• Continue partnership among Army ARDEC, NIST MEP, Catalyst Connection 

• Include access to sample 3D TDP formats, tools, etc. 

• Continue to include MBE Assessment tools, other MBE resource info, including 

links/connections to nationwide MEP System as assistance resources 

• Provide access / links to MBE-related business opportunities – RFPs, BAAs, etc., 

that incorporate MBE-based approaches 

• Provide MBE success stories, business cases 

• News feeds, blogs, YouTube videos, social media apps and connections 

• Up-to-date MBE Calendar 

• NIST MEP Contacts: 

Dave Stieren or Jenna Giles, jenna.giles@nist.gov 
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“DISTRI “DISTR BUT ON STATEMENT Approved or publ c release; dis ribut on s unl m ed. Case Number 88ABW-2012-4974. TRIBUTION STATEMENT A . Approved for publi re c l ease; dis ri t but iion t iion su limn it Ced it C ed. ase u Nm as u e Nm ber 88A ber 88 ber 88ABW 2012 4974 ”.

CSI Update 

December – 

– 

Contract/Project Manager: PDES, Inc./ATI 

Technical Lead: International TechneGroup Incorporated (ITI) 

Industry Prime: Lockheed Martin 

Industry Suppliers: Rockwell Collins & Honeywell 

• LMCO – 1,000,000 translations / 

transmittals per year 

• HW – 340,000 file transmittals per year 

• Rockwell Collins – 1000 translations / 

transmittals per year 

Reality 

Automation 

s unl m ed. Case Number 88ABW-2012-4974. 

– 

more 

m 

sed 

d 

Draw-to-PM

(MBD Generator) 

Automation to 

associativ

GD&T into the 

and produce

associative 

Eliminate un producib 

features better qua 

• 

tow

oratively reso 

• Reduce 

design e 

• Elim 

tha 

rev 

Producibility 

Detects and resolves 

model issues in 

design for 

manufacturability 

• Im 

p 

ti 

re 

• Improv 

explici 

repres 

• Necessary step towa 

3D ECO 

Documentation 

Document model 

changes in a 3D 

format that greatly

improves 

communication in the 

MBE 

o 

ss 

uality 

nce 

tion issues 

rough automation of 

3D PMI Translation 

Translation of 

associative 3D 

models and 3D PMI 

between dissimilar 

CAD ironment 

MBE

CAD enviro nments

• 

s unl m ed. Case Number 88ABW-2012-4974. s unl m ed. Case Number 88ABW-2012-4974. 

– 

– 

– 
I I . f i t i i i it ” 

 

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I I . f i t i i i it ” I I . f i t i i i it ” 

 

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10 “DISTR BUT ON STATEMENT A Approved 

12 

Technology Commercialization 

11 “DISTR BUT ON STATEMENT A Approved 

large DoD Project over lifetime 

Cumulative estimated savings for a representative 

“DISTR BUT ON STATEMENT A Approved 

9 or publ c release; dis ribut on s unl m ed. Case Number 88ABW -2012-4974. 

Estimated overall program impact 

Applied findings on a representative large DoD program 

Merged findings from each partner 

ITI 

Savings in documentation generation, quotation and NC program change processes 

Determined processes almost identical and were both labor intensive and error prone 

Met with Progressive Machining and HM Dunn fabrication to discuss 3D ECO process 

Lockheed 

perspective and how much time is needed to correct problem) 

5 models selected to investigate in detail (is the problem significant from supplier 

12% found with producibility issues 

defense) using Producibility check 

Processed 300 recently released models from various programs (commercial and 

Rockwell Collins 

Recorded time to manually merge the 3D model and the 2D associative drawing 

Recorded time to manually refine the results 

Used automation to create MBD from 3D model and 2D associative drawing 

Honeywell 

Key activities performed to develop ROI 

“DISTR BUT ON STATEMENT A Approved 

MBE Interoperability Scenario - CSI Automation 

“DISTR BUT ON STATEMENT A Approved 

MBE Interoperability Scenario - Today 

“DISTR BUT ON STATEMENT A Approved 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW -2012-4974. 

drawings 

dimensioned 

minimally 

with 3D + 2D 

CSI Extensions 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW -2012-4974. 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW-2012-4974. or publ c release; dis ribut on s unl m ed. Case Number 88ABW-2012-4974. 

V5 model 

V5 

Drawing 

Manually 

Add PMI V5 MBD 

ECO 

change OK? 

OK? 

Build it! 

V5 MBD-Rn 

Partner 

Receives NX MBD 

Deliver 

Component to 

OEM 

Manufacturing Partner 

Prime Contractor 

Review Options with 

Prime / 

Communicate ECO 

Requirements 

yes 

yes 

no 

no 

Manually 

generated 

ECO 

documentation 

Manually 

create ECO 

Documentation 

and validate 

Translate to 

NX (BREP, 

FBT) 

Manually 

Add PMI to 

NX model 

Manually OK? generated 

report 

Send to 

Partner Translate 

w/o PMI 

Manually 

Inspect / 

Compare V5 

and NX 

MBD 

models 

Manually 

Inspect for 

Producibility 

Issues 

Manually 

generated 

report 

Visually 

compare 

models 

D 

N 

no 

yes 

X 9 

V5 model 

V5 

Drawing 

Generate 

V5 MBD V5 MBD 

ECO 

change 

ECO 

Documentation 

/ validation OK? 

Translate to NX with PMI 

Validate 

Send to Partner 

Check 

Producibility OK? 

Build it! 

V5 MBD-Rn 

OK? 3D Validate 

PDF 

3D PDF 

Partner 

Receives 

NX MBD 

Deliver 

Component to 

OEM Manufacturing Partner 

Prime Contractor 

Review Options with 

Prime / Communicate 

ECO Requirements 

no 

yes 

yes 

yes 

no 

no 

NX MBD 

NX MBD 

P 

Review 

ECO Doc 

vs Model 

(PDF) 3D ECO 

PDF 

3D ECO 

PDF 

3 

3 

c 

X 2 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW-2012-4974. 

– 

– 

– 

– 

– 

– 

– 

– 

– 

– 

– 

– 

Potential Estimated CSI Savings for Large DoD Project
	

Company 

Prime 

Design Partner 1 

Design Partner 2 

Design Partner 3 

Subsystem Supplier 1 

Subsystem Supplier 2 

Subsystem Supplier 3 

Manufacturing Supplier 1 

Manufacturing Supplier 2 

Manufacturing Supplier 3 

Relative task 

magnitude 

Recurring One-Time 

Day-to-day Future 

ECO Trans/Auto Producibility MBD Xlate Generate MBD 

100% $3,300,000 $500,000 $2,200,000 $8,200,000 $8,200,000 

75% $2,475,000 $375,000 $1,650,000 $6,150,000 $6,150,000 

65% $2,145,000 $325,000 $1,430,000 $5,330,000 $5,330,000 

50% $1,650,000 $250,000 $1,100,000 $4,100,000 $4,100,000 

25% $825,000 $125,000 $550,000 $2,050,000 $2,050,000 

10% $330,000 $50,000 $220,000 $820,000 $820,000 

10% $330,000 $50,000 $220,000 $820,000 $820,000 

1% $33,000 $5,000 $22,000 $82,000 $82,000 

0.2% $6,600 $1,000 $4,400 $16,400 $16,400 

0.1% $3,300 $500 $2,200 $8,200 $8,200 

Total 

$11,097,900 $1,681,500 $7,398,600 $27,576,600 $27,576,600 

Recurring annual savings - near term $20,178,000 

Recurring annual savings - near term plus future $47,754,600 

Non-recurring savings $27,576,600 

3D 

MBD 

CSI Original Scope 

CSI Extensions Scope 
I I . f i t i i i it ” 

 

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I I . f i t i i i it ” 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I I . f i t i i i it ” 

18 I I . f i t i i i it ” 

 

 

 

 

 

 

I I . f i t i i i it ” 

 

 

 

Complex >30 features 

Medium 11-30 features 

Simple 1-10 features 

Model Complexity: 

Y 

Y 

NA 15 hrs. NA NA 30 hrs. (20% first pass) NA

3 hrs. 

study overlay 

display options and pan/ 

Supplier uses colors, 

Models 

Complex 

Vericut 

using 

changes 

program 

NC 

validates 

Supplier 

program(s) 

NC 

modifies 

and 

change(s) 

identifies 

Supplier 

the 3D ECO 

as specified in 

in the model 

specific areas 

moves to 

ECO and 

opens 3D 

Supplier 

6 hrs. NA NA Models 

Complexity 

Medium 

Simple/ 

NA 20 hrs. NA NA 40 hrs. (20% first pass) NA

NA 4 hrs. 

study overlay 

display options and pan/ 

Supplier uses colors, 

Models 

Complex 

Vericut 

using 

changes 

program 

NC 

validates 

Supplier 

program(s) 

NC 

modifies 

and 

change(s) 

identifies 

Supplier 

study overlay 

functions to 

rotate 

pan/ zoom/ 

options and 

colors, display 

Supplier uses 

Simple/Medium: 8.8 hrs. labor / Complex: 28 hrs. labor 

8 hrs. NA. NA Models 

Complexity 

Medium 

Simple/ 

with CSI: 

Approach

CSI: 

without 

Approach

19 

program(s)” 

“Incorporate change into NC 

Process Step#3: 

Complex >30 features “DISTR BUT ON STATEMENT A Approved 

Medium 11-30 features 

Simple 1-10 features 

Model Complexity: 

NA NA NA 15 hrs. NA NA NA

NA NA NA NA NA

Complex Models 

the supplier 

and notifies 

the change 

dispositions 

LMCO 

of change 

finalize scope 

ECO to 

PDF and 3D 

reviews ECO 

changes and 

Supplier notes 

ECO 

and 3D 

ECO PDF 

model, 

downloads 

Supplier 

Simple/Medium: 1.7 hrs. labor / Complex: 15 hrs. labor 

Models 

Complexity 

Simple/ Medium 

to assembly 

revised model 

model and 

adds original 

assembly and 

creates 

Supplier 

supplier 

by 

received 

RFQ 

Complex Models NA NA NA 20 hrs. NA NA NA

NA NA NA

the supplier 

and notifies 

the change 

dispositions 

LMCO 

of change 

finalize scope 

PowerPoint to 

PDF and 

reviews ECO 

changes and 

Supplier notes 

study overlay 

functions to 

rotate 

pan/ zoom/ 

options and 

colors, display 

Supplier uses 

PowerPoint 

and 

ECO PDF 

model, 

downloads 

Supplier 

Simple/Medium: 2.1 hrs. labor / Complex: 20 hrs. labor 

NA 2.1 hrs. NA Models 

Complexity 

Simple/ Medium 

with CSI: 

Approach 

CSI: 

without 

Approach 

to assembly 

revised model 

model and 

adds original 

assembly and 

creates 

Supplier 

supplier 

by 

received 

RFQ 

“Quotation for ECO” 

Process Step#2: 

“DISTR BUT ON STATEMENT A Approved 

.02 hrs. labor 

Sample model results: NA .02 hrs. NA

.25 hrs. labor 

Sample model results: NA .25 hrs. NA

with CSI: 

Approach 

CSI: 

without 

Approach 

Point 

Powerpaste into 

shots and 

screen 

Capture 

17 

“Document change to 3D model” 

Process Step#1: 

16 “DISTR BUT ON STATEMENT A Approved 

Rockwell Collins – Producibility analysis savings 

“DISTR BUT ON STATEMENT A Approved 

15 

Typical program impact for 1000 parts 

“DISTR BUT ON STATEMENT A Approved 

.02 hrs. 

3.44 hrs. labor 

Sample model results: .02 hrs. 1.7 hrs. 1.7 hrs. 

20.1 hrs. labor 

Sample model results: 10 hrs. 10 hrs. 

up 

cleanManual 

up 

cleanManual 

MDB” 

“Translate 

Run 

with CSI: 

Approach 

CSI: 

without 

Approach 

system 

new CAD 

model in 

to 3D 

add PMI 

Manually 

system 

CAD 

source 

model in 

to 3D 

add PMI 

Manually 

14 

Honeywell – Comparing MBD scenario with and without CSI 

“DISTR BUT ON STATEMENT A Approved 

Simple/Medium: 6.6 hrs. labor / Complex: 21 hrs. labor 

for ECO 

Quotation 

3D model 

change to 

Document 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW -2012-4974. 

NA 

change to LMCO 

provide cost of 

check fixtures) to 

programs, and 

Tools, CCMM 

(NC programs, 

scope of change 

Supplier uses 

NA 

change to LMCO 

provide cost of 

check fixtures) to 

programs, and 

Tools, CCMM 

(NC programs, 

scope of change 

Supplier uses 

3D model 

change to 

Document 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW -2012-4974. 

change 

Release 

ECO” 

Run “3D 

model 

CATIA 

Update 

change 

Release 

model 

CATIA 

Update 

for ECO 

Quotation 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW -2012-4974. 

(in service) 

Customer 

(in assembly) 

Manufacturing Build 

(in fabrication) 

Supply Chain 

(in design) 

Product Development 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW-2012-4974. 

20.1 hrs – 3.44 hrs = 16.66 hours 

Current process hours – Proposed process hours 

Savings per change: 

.02 hrs + 1.7 hrs + .02 hrs + 1.7 hrs = 3.44 hours 

Time to generate MBD + Time to refine MBD + Time to translate MBD + Time to refine MBD 

Proposed process (with CSI): 

10 hrs + .1 hrs + 10 hrs = 20.1 hours 

Time to generate MBD + Time to translate/remaster MBD + Time to refine MBD 

Current process (without CSI): 

Annual savings: 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW -2012-4974. 

.1 hrs. 

Model(s) 

Target 

MBD” 

“Generate 

Run 

translator 

based 

feature 

using 

system 

to target 

Translate 

or publ c release; dis ribut on s unl m ed. Case Number 88ABW -2012-4974. 

Source 

Model(s) 

CPR used for producibility analysis 

during design process 

a) Designer identifies and 

eliminates issue or 

b) Checker identifies issue during 

release process 

W ithout CPR analysis – supplier 

determines there is issue and 

a) Adjusts model on own or 

b) Initiates change request (ECO 

required) 

W ithout CPR or Supplier initiated 

change – issue discovered during 

unit assembly or test and 

a) Requires TTR, ECO and 

material disposition 

Without CPR or Mfg initiated change 

– issue discovered by customer or in 

service and 

a) Requires TTR, ECO, material 

disposition and possibly a 

Service Bulletin 

b) Customer satisfaction, warranty, 

etc. affected 

• 1-2 hours to resolve finding 

when identified during in-process 

design 

• May require more time and 

possibly affect program schedule 

if identified during the release 

process 

Time to Resolve: 1-2 hours 

Relative Total Cost:$100’s 

• Hours or days to resolve finding 

when supplier engages 

Rockwell Collins 

• Part conformance risk (AS9102 

concern) 

• May affect delivery and build 

schedule 

• Possible no-bid from qualified 

supplier 

• Increased part cost – complex 

tooling / process of low-yield 

fabrication 

• Cost to complete ECO 

Time to Resolve: Hours/Days 

Relative Total Cost: $1K’s 

• Hours or days to resolve finding 

– possibly weeks if TTR required 

• Affects build schedule and may 

affect overall program schedule 

• Possible contract penalties for 

delivery misses 

• Increased production cost – 

TTR, scrap or rework, material 

disposition, etc. 

• Cost to complete ECO 

Time to Resolve: Days 

Relative Total Cost: $10K’s 

• Days or weeks to resolve finding – 

possibly months for warranty or 

service bulletin to be completed 

• May cause system failure/repair 

• Affects customer program 

• Possible contract penalties, 

warranty costs, SB costs, fleet 

costs, etc. 

• Increased repair cost – TTR, 

scrap and rework, material 

disposition, field service, fleet 

down-time, etc. 

• Cost to complete ECO / SB 

• Reduced customer satisfaction 

Time to Resolve: W eeks/Months 

Relative Total Cost: $100K’s 

based on when problem is first identified 

Document 

change to 

3D model 

Incorporate 

change 

into NC 

program(s) 

Quotation 

for ECO 

Incorporate 

change 

into NC 

program(s) 

21 h NA 

Supplier 

opens 3D 

ECO and 

moves to 

specific areas 

in the model 

as specified in 

the 3D ECO 

1.7 hrs. 

“D 

Incorporate 

change 

into NC 

program(s) 

8h NA NA 

Other 

changes 

? Supplier modifies tools, 

CCMM programs and 

check fixtures as req’d 

zoom/ rotate functions to 

(20% first pass) NA 

Change 

authorization 

received by 

supplier and 

downloads 

models, 

PDF’s and 

PowerPoint 

6 hrs NA NA 

Other 

changes 

? Supplier modifies tools, 

CCMM programs and 

check fixtures as req’d 

zoom/ rotate functions to 

(20% first pass) NA 

Change 

authorization 

received by 

supplier and 

downloads 

models, 

PDF’s and 

PowerPoint 

NA 

N 

N 
I I . f i t i i i it ” 

 

 

 

 

 

 

 

 

 

“DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Case Number 88ABW-2012-4974.” 

& Interoperability Solutions sbility Solutions  I I . f i t i i i it ” 

I I . f i t i i i it ” 

 

 

I I . f i t i i i it ” 

 

- - ” 

23 pprovedAATNEMETATSNOUTBRTS“DI e;easrelcpublor

enuerev2011* estimate

• globalNJn,owMorrist ecorporat headquart rse

• Nearly 000130, riescount100iningoperateesemploy

• $35-36 inbillion* revenues, 50% U.S.ofoutside

 oml.clewyneoH

Proprieta 22 WB88AberNumeCased.munlsonbutrisdi -2012-4974.

CSI Demonstrated Savings (ITI generated) (Original Scope)

pprovedAATNEMETATSNOUTBRTS“DI onbutrisdie;easrelcpublor

Complex Part: =hrs6.023–hrs48.25 shour3212.

=srh.328-srh5.111Part:tyilexpmoCiumde/MlepSim hours2.83

Current process roposedP–hours process hours

perngsiSav change:

=hrs6+hrs15+srh51+hrs2.0rt:PaxlepmoC shour2036.

Simple/Medium =hrs.6+hrs6+hrs1.7+hrs.02Part:ityComplex shour328.

+ngechaotequtoetim+ngechatnemcuodtoemiT sissueeresolvtoetim+geancheatorrpincotoetim

Proposed process CSI):ith(w

=hrs8+hrs20+srh02+hrs5.2rt:PaxlepmoC shour5248.

Simple/Medium =hrs.8+hrs8+hrs2.1+hrs.25Part:ityComplex shour51.11

+ngechaotequtoetim+ngechatnemcuodtoemiT sissueeresolvtoetim+geancheatorrpincotoetim

:)CSIhoutti(wocessprnterCur

20 

1000Per Parts

Lockheed program impact

pprovedAATNEMETATSNOUTBRTS“DI e;easrelcpublor

B*.2$10.8-11 B*.1$14.7-15 $4.3-4.5B* $5.0-5.2B*

stemsSy

ntatiorospanrT

Materials 

ltyiacSpe eacsperoA loContr SolutionstomationuA &

Honeywell’s Businesses

.ellwyenoHofnoissimpersesprexoutthwicopytonDoc.nIlaniotanternIellwyenoH2012© December 201213,

Karen Kontos

Gaithersberg MD,

Model Based Enterprise Summit NISTathosted

Thread 

The Sustainable Enterprise: Enabling Digitalthe

WB88AberNumeCased.munls -2012-4974.

on 

roperability Solut onsi buts WB88AberNumeCased.munlsonbutrisdi -2012-4974.

Open BTP 

PO's Part Complexity Hours saved per change 

Percentage of parts by 

complexity 

Labor hours saved per year based on expected change rate 

25% 50% 75% 100% 

1,000 Simple/Medium 2.83 95% 672 1,344 2,016 2,689 

Complex 12.23 5% 153 306 459 612 

Total hours saved based on expected change rate 825 1,650 2,475 3,300 

Estimated annual savings based on expected change rate and 

$100/hr labor rate $82,500 $165,000 $247,500 $330,000 

Annual savings: 

Document 

change to 

3D model 

Quotation 

for ECO 

Incorporate 

change 

into NC 

program(s) 

Model Complexity: 

Simple 1-10 features 

Medium 11-30 features 

Complex >30 features 

“DISTRIBUTION STAT 

Raising the Value of Your Product Data 

Product Data Integration ABW 2012 4974. ”s tion is u nlimited. Case Num erability Solut 

mber 88A 

tions TEMENT A . Approved for public releasntegration tegration & Intese; distri rope 21 “DISTR BUT ON STATEMENT A Approved or publ c release; dis ribut s unl m ed. Case Number 88ABW-2012-4974.

Savings based on functions developed in Phase 1, integrated into CSI platform and 

deployed throughout supply chain on a large DoD acquisition 

Savings Applied Across CSI Team Partners For A 

Typical Large Program 

CSI End User 

Company 

Active 

Mechanical CAD 

Models 

Generate MBD 

(non-recurring) 

Translate MBD 

(recurring) 

3D ECO 

(recurring) 

Producibility 

(recurring) 

Total 

(non-recurring) 

Total 

(recurring) 

Lockheed 10,000 $8,200,000 $8,200,000 $3,300,000 $8,800,000 $8,200,000 $20,300,000 

Honeywell 1,000 $820,000 $820,000 $330,000 $880,000 $820,000 $2,030,000 

Rockwell 

Collins 20 $16,400 $16,400 $6,600 $17,600 $16,400 $40,600 

Total $9,036,400 $9,036,400 $3,636,600 $9,697,600 $9,036,400 $22,370,600 

+Downstream +Downstream +Downstream +Downstream 

impact impact impact impact 
 

 

 

 

 

-

 © 2012 Honeywell nterna iona nc. Do no copy with 

Tech. Pubs.

(Interface with TDP)

Customer Support

MRO

Analysis/Simulation

Digital Design

nalysis/Sim ulation

Full Digital 

Validation

Model Based Mfg

on Supported

t Data Managem

© 2012 Honeywell Interna io

CM –

de

 

M

y opy th

–

onal Inc. Do not c wi

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com

Geographic Sales Mix 

Aerospace Overview 

Defense 

4.6% 

Commercial 

3.3% 

Defense 

5.6% 

Americas 

72.8% 

Asia 

8.9% 

Europe

Commercial 18.3%

13.7% 

Commercial 

30.1% 

Defense 

42.7% 

38,000 employees at 

nearly 100 manufacturing, engineering & 

service sites. 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com

Services 

12% 

Aerospace Revenue Breakdown 

Defense & 

Space 

51% 

Air 

Transport 

& Regional 

35% 

Business 

& General 

Aviation 

14% 

Aftermarket 

44% 

OEM 

44% Mechanical 

51% 

Electrical 

37% 

Services 

12% 

Revenue - $10.7B in 2010 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com

Freighters 

Wide Body Aircraft 

Air Transport & Regional Platform Breadth 

Regional Aircraft 

Narrow Body Aircraft 

Long Range Aircraft 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com

Business & General Aviation Platform Breadth 

Gulfstream Dassault 

Cessna Hawker 

Beechcraft 

Embraer Bombardier 

Pilatus 

Epic Aircraft Harbin 

Aircraft 

Viking 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com

DoD, Civil, and 

Commercial 

Space

30+ Platforms 

Human Space

10+ Platforms 

International 

20+ Platforms 

Army, Navy

and Air Force 

60+ Platforms 

D&S Products & Services Span ~300 Platforms 

Bomber 

Aircraft 

3 platforms 

Fighter/Attack/

Trainer Aircraft 

30+ platforms 

Special

Mission/ UAV 

Aircraft 

20+ platforms 

Mobility/Tanker

Aircraft 

40+ platforms 

Military

Helicopters

20+ platforms 

Surface/Soldier

Vehicles 

15+ platforms 

Commercial 

Helicopters

20+ platforms 

Naval 

Platforms 

10+ platforms 

Proud of Our Strong Position & Heritage in the D&S Industry 

I t l I t out express permission of Honeywell.

Honeywell.com

l I D t ith t

/Sil ti n

Engineering 

Manufacturing 

Quality 

Collaborati 

by Produc ent 

Requirement

Verify & Validate

Digital Thread Supports Honeywell’s Sustainable Enterprise 

ll I t ti

Customer Requirements 

Digital

dation 

NGPDM 

Visualization communicates 

sign intent & inspection 

criteria without requiring 

Native CAD/CAE. Created 

from a workflow and master 

model/master data in PLM 

platform. Validated and 

verified back to master 

model, and customer 

requirements. 

Model Based Inspection 

Closed loop of data -feeds back into 

design, supporting re-use and 

improving future designs 

CM

Vis 

de 

cri 

Na 

© 2 py ho Start the Development Cycle 
 

 

 

 

 

 

 

 

 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

The Honeywell Business Case for MBE and TDP 

• Complexity of Products and Communication of Design Intent 

– Design Collaboration across hundreds of design communities (internal and external) 

– Support Honeywell as the design integrator of complex mechanical & electrical 

assemblies 

– Support of ISC (eliminate the re-creation of design intent downstream) 

• Complexity of Aerospace Supply Chain 

– Complexity of Products 

– Product Lifecycle Support – long lifecycle, services is large portion of Honeywell 

business 

– Demands for Re-Use 

– Outsourced manufacturing for more than 50% of our products 

Communication and exchange processes associated with digital data 

must become more efficient and robust to support a sustainable business 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

MBE/Digital Data as a Honeywell Strategy 

• Quality parts, on time, at the best possible price – successful 

implementation of MBE can be a game changer for Honeywell 

–Quality 

• “Model is the master” is fundamental enabler that ensures quality parts that meet 

design intent, streamlined inspection processes 

–Development Cycle Time 

• Reduced opportunities for errors in design and manufacturing through early 

identification of manufacturing issues, facilitate MOT development/eliminate 

redundant efforts to re-create design intent 

–Reduced Costs 

• Reduced development cycle times and improved quality, also supports early analysis 

of manufacturing cost during design phase (DTC), and design for Manufacturability 

(DFM) 

MBE is a competitive advantage. In the longer term, it is a necessary 

means to sustain business and to meet customer requirements. 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

2012 Honeywell MBE Highlights 

• MBE Organization formally established as a part of Product 

Lifecycle Management/Engineering Operations in Aerospace 

• Honeywell internal MBE/TDP initiatives in VPDTM 

– Customer/Supplier Interoperability (CSI) project completed 

– TDP Strategy Defined, tools procured, process innovation and tool 

deployment in work 

– Model Based Engineering & Manufacturing Pilot Projects completed, 

supporting tool & process development, leadership support 

• Honeywell External/Industry Initiatives and Standards Support 

– Participation/support of many initiatives in PDES, LOTAR, AIA, and others 

– Technical Data Package /alignment with MIL STD 31000 

Support of key Aerospace standards is critical to achieving the 

sustainable enterprise. Opportunities for external funding help drive 

strategy development, timely execution, and critical vendor/tool alignment 

to meet customer requirements. © 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

Automated PLM Collaboration Template 

Advantages 

• Full collaborative 3D product data communication via a 

non-CAD system 

• Easy to use, user intuitive, graphical interface in the 

generally accepted PDF format and viewer. 

Revision history, EBOM, Notes, etc. embedded via automated workflows 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

Internal Use Case for Manufacturing – 

Work Instructions Generated from Master Model k Instructions Generated from Master Model 

• Web-based , directly accesses PLM system where Bill of Process and Master Models 

live 

• Shop and operators access system via web browser and have access to all required 

manufacturing documents 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

TDP Definition (Simplified) 

• Contains all artifacts 

described by MILSTD-31000A 

• Intended for bidirectional 

collaborative 

communication 

• Generated with 

automated workflows 
 

•

•

•

 

•

•

•

 

 

 

 

 

 

ad a a es

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

The TDP Container 

PDF Container - generally 

accepted as a business 

document type, viewer is 

highly available 

PDF has established security 

processes 

PDF enables bi-directional 

communication between 

customers and suppliers 

• TDP 

Container 

• 

• 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

The Manifest 

Includes list of artifacts, 

specifications, BOM

information, notes, key

characteristics and 

requirements 

AP239 / PLCS for Machine to

Machine / PLM to PLM 

communication 

MS Excel file supports human

consumption and downstream

extraction of data 

– Users know how to easily convert 

Excel files to other formats (i.e. 

XML, CSV, TXT, etc.) 

• 

• 

• 

Manifest 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

TDP Use Cases: Phase 1 Implementation 

• MCAD Piece Parts 

• Internal / External Suppliers 

• Specifications 

• 3D Representations of ECAD 

• BOx – Bills of Materials, Notes, Characteristics, Specifications, etc. 

• LOTAR Archival 

• MIL-STD-31000A Delivery 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

Enabling the Digital Thread: Examples of how MBE and the 

TDP Will Support Honeywell’s Sustainable Enterprise 

ECAD 3D PDF Example MCAD TDP Example 

© 2012 Honeywell International Inc. Do not copy without express permission of Honeywell.

Honeywell.com 

MBE/Technical Data Package Deployment Level and Timing 

Honeywell Aiming for Level 5 Deployment in 2013 

Creo View 

Madhavi Ramesh 

Product Management Director 

12 Dec 2012 
 

 

– 

2 

Model Based Enterprise 

3 

2D Drawings – primary deliverables... 

3 

4 

• Disconnected Data Sources 

– Information about the design in separate sources (Drawings, 

models, calculations, requirements, etc... – all with multiple 

versions) 

• Recreating data in 2D and 3D (duplicated efforts) 

– Drawings are time consuming to create and duplicated effort 

• 2D drawing are more prone to interpretation errors than 3D 

models 

– Drawings alone are not adequate to capture design 

innovations that engineers create 

– 30% - 40% of non-conformances are due to 2D drawings 

inaccuracies 

• Drawings are not well suited for wide-spread collaboration 

across geographical barriers 

– Using the 3D data, provides audiences with access to whatever information 

they may need 

Problem Statement 

Aberdeen report 

2D Drawings – the 

MASTER 

Drawings are Human Readable, Provides All Information... BUT... 

5 

Design– changes in real time 

© 2006 5 

6 

Design data Processes, workflows, standards in place to manage .... 

© 2006 6 7 

Users of design data– Upstream or downstream... 

© 2006 7 
 

 

I -

 

 

 

 

 

c c

8 

Collaboration– Review, feedback leads to product innovation 

© 2006 PTC 8 9 

Key enablers of MBE 

People Process Technology 

10 10

Building Model Based Enterprises 

11 

Model Based Enterprise 

© 2007 PTC 

Plan Concept Design Validate Produce Support

Manufacturing Service Management Sales & Mktg Engineering

PLM 

Op 

020 

Op 

010 

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Requirements 

Material 

Spec 

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Master Digital Dataset 

Master Digital Dataset Master Digital Dataset 

i i nufactu Ser ic e 

12 

Model Based Enteprise solution from PTC 

UNCLASSIF ED 

FOR PUBLIC 

Deliver Evaluate 

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Create 

Manage in Windchill 

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Based deliverables 

across the 

extended enterprise 

Evaluate 3D Design 

from various 

perspectives - Form, 

Fit, Functional, 

Environmental, 

Reliability, Quality, 

Assemblability, 

Manufacturability, 

Accessibility, etc. 

Create conceptual and detailed designs, analyze 

designs, create manufacturing tools and tool paths, 

perform engineering calculations, capture 

requirements 

Manage design and all its associated artifacts 

Build Model based Manufacturing Process plans, 

Inspection plans, Work Instructions, Tech 

Illustrations, NC deliverables, etc. 

13 

Computer-Aided Design (CAD) 

PTC Computer-Aided Design Capabilities 

Create conceptual and detailed designs, analyze designs, create manufacturing tools 

and tool paths, perform engineering calculations 

Engineering CAM Calculations 

CAID CAD CAE
 

Program 

M

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& 

Requirements

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15 

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System Model 

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Management Defect 

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Software 

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Supply Chain Management (SCM) 

Cost 

Management 

RFx Risk & 

Compliance

Management 

Supplier

Management

Component & Materials 

Management 

Service Lifecycle Management (SLM) 

Technical 

Illustrations 

Service 

Analytics 

Service 

Information 

Change & 

Config. Mgmt 

Collaboration Enterprise

Interoperability 

Workflow 

Warranty

Management 

sBOM 

Product Lifecycle Management (PLM) 

Program Portfolio 

Management 

Document 

Management 

Quality, Risk, &

Reliability Mgt. 

Hardware 

Management 

Software 

Management 

Visualization 

Enterprise 

Interoperability 

Variability Management 

& Digital Mockup 

eBOM mBOM sBOM Workflow 

Change & Configuration 

Management 

Manufacturing 

Process Management 

Business 

Reporting 

Collaboration 

Requirements 

Management 

Component 

Management 

Supplier 

Management 

Product Lifecycle Management (PLM) 

Portfolio 

anagement 

Document 

Management 

Quality, Risk, &

Reliability Mgt. 

Hardware 

Management 

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Management 

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© 2009 PTC2

 

 

 

 

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Load, Visualize, Navigate Massive assemblies 

Single source of Viewable truth Integrated cross discpline BOM

Visualize overloaded structure 

Analyse variants 

Exploded View Quarter cut

Review ECAD Design changes 

Access, View PMI, Combination States Ensure all critical dimensions are present

Print 3D Drawings 

Color coding based on 

“Lifecyclestate” 

PDF Collaboration ECAD-MCAD Collaboration 

Mate and Align 

Animation 

Interference Analysis 
parts with their carbon 

 

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Analyze cost information 

Identify parts based on 

regulations that are out of

compliance 

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print 

Associative EBOM-MBOM Manufacturing Work Inst ructions

Share product data with suppliers 

Access, Identify characteristics 

(Key, critical) 

Dynamically generate parts lists with 

callouts 

Create 2D illustrations 

Arbortext IETP Viewer for S1000D 

Access of MBD Information through 

custom applications 

Visualization in Program and 

Portfolio dashboards 

Immersive and Interactive evaluation of 

Digital Mockup 

Mobile access to Model based design 

data 

Op 

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i i nufactu Ser ic e 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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1 

Open Manufacturing 

Mr. Michael “Mick” Maher 

Briefing prepared for: NIST MBE/TDP Summit 

December 12, 2012 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

1.Need to Maintain Legacy Systems longer 

• Results in high mix, small quantities 

• In this environment often times the production processes originally approved for 

production are not appropriate for rapid response, small quantities 

2.Need to maintain a robust industrial base that is not dependent upon DoD but 

can be responsive when called upon 

• Defense Spending shrinking as % of GDP, Currently 4.7% 

• Defense supplier base is concerned 

3.Need more agile and rapid manufacturing capabilities 

• Fewer new systems with shrinking defense budgets 

• Need higher performance at reduced cost and weight 

• More prototype systems to keep performance innovation alive 

4.Need to establish confidence in these new processes 

• If risks are not known and controlled, non-traditional/innovative processes will not 

be implemented 

DoD Drivers for OM Going Forward 

2 Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

Open Manufacturing Vision 

3 

Enable Adoption of Additive Process and Bonded Structure for Defense 

Applications Using: 

Accelerate the Manufacturing Innovation Timeline 

Ensure Technology Acceptance and Adaptation 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

Specimen

Count 

Cost 

($M) 

Time 

(Yrs) 

2-3 100-125 4 

10-30 10-20 3 

25-50 10-35 3 

2000-5000 10-35 3 

5000-100,000 8-15 2 

Typical Aircraft Qualification/Certification Path 

•Range is determined by extent of new material, process and technology being introduced; and the 

amount of iterations 

•Rotor and UAV platform costs are lower, large transport 

costs can be higher 

New Manufacturing Technologies must undergo extensive 

qualification and certification testing 

Risk of unplanned cost and schedule impacts causes barrier to manufacturing innovation 

Fullscale 

article 

Components 

Sub-components 

Elements 

Coupons 

s 

Manufacturing Process (foundation)

e.g., autoclave process, casting, 

machining... 

Analysis 

validation 

Design-value 

development 

Material 

property 

evaluation 

4 Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

•Establish a thorough process understanding 

• Understand all potential process variables 

• Quantify effect of these variables on the end 

product 

•Modernize the toolsets the DoD manufacturing 

community implements to improve their products 

• The analysis community has successfully used 

modeling for years 

• Current aircraft are certified by analysis supported 

by testing 

•Enabled by development and use of: 

• Process modeling to understand the bounds 

• Infomatics to capture and analyze all the variables 

Open Manufacturing builds confidence for insertion of 

new manufacturing technology 

Finite element analysis provides high 

confidence predictions of structure 

properties for a given static load 

The manufacturing community 

relies on “make-and-break” testing 

to build allowables database 

Rapid Qualification 

Design and Analysis Robust Process Windows 

Probabilistic Process Models New Inspection Methodologies M&P Informatics B-Basis Test Data = 114 ksi 

B-B asi s Targe t= 120 k si 

Ti -6-4 E LI  -anneale d Plate est Sp mens 

Probability 

Tensile Strength 

5 Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

Certification 

Process 

Component 

Definition 

6 

Open Manufacturing fundamentally changes how 

manufacturing variability is captured and controlled 

• Variability from the factory floor 

• Propagate uncertainty throughout 

• Rigorous verification and validation 

• Probabilistically predict process and 

part performance 

Create a manufacturing framework that captures factory-floor variability and integrates 

robust computational tools, informatics systems, and rapid qualification approaches to build 

confidence in the process 

OM probabilistic design is a new paradigm for rapid qualification of manufacturing processes 

• Identify bounds of process window 

• Optimize and control processes 

• Build confidence and reduce testing 

• Reduced risk for new technology 

insertion 

Robust Computational Process and Design Tools 

Process 

Models 

μ-structure 

Models 

Probabilistic Design and Performance Lifing 

Optimization loop

Yield Strengt 

Property 

Models 

Verification 

and Validation 

Informatics Methodology 

Design of Experiments 

In Process Quality Assurance 

Parameterization 

t, T, P, ... 

Variability 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 
 

 t

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

t l 

i

t l

i

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Establish Manufacturing Demonstration Facilities (MDF) to capture 

technologies and disseminate knowledge 

7 

Bonded Composite Structures Metals Additive Manufacturing 

OM Demonstration Technologies 

Accelerate the manufacturing innovation timeline for these high impact processing technologies 

Demonstration technologies chosen to focus and validate value of program 

• Bonded Composite Structure: Holy grail for Composite community for last 30 years. 

• Additive manufacture: Emerging technology that is stuck at the demonstration phase. 

rastered 

laser beam bed of 

metal 

powder sintered metal 

consolidated In718 part 

• Direct Metal Laser Sintering (DMLS) 

• Electron Beam Direct Manufacturing (EBDM) 

substrate 

e-beam Ti wire 

feeder 

deposited Ti 

raster 

Ti par 

• Bonded Composite Structural Assemblies 

bonded Pi-joint 

Process Variability 

• Environmental 

• Surface prep 

• Cure 

• Metrology 

• Personnel 

Process variability 

• 10n welds 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

•Service affiliated repository of focused manufacturing knowledge and infrastructure 

•Independently demonstrate designs, manufacturing processes and manufactured 

products 

•Curate and independently assess and validate data and models 

•Build confidence for transition 

•Enable small and medium enterprise 

Current OM MDF’s 

Penn State University, Applied 

Research Lab (PSU-ARL) 

Army Research Laboratory, 

Aberdeen Proving Ground 

Air Force Research Lab, 

Kirtland Air Force Base 

Service 

Affiliation 

U.S. Navy U.S. Army U.S. Air Force 

Technology

Focus 

Additive Manufacturing Bonded Composites High Value/Low 

Volume Assembly 

Functional 

Focus 

Process Models and 

Qualification Schema 

Materials and Process 

Database 

Smart Manufacturing 

Framework 

Trusted agent and transition point for manufacturing technologies 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

9 

• Numerous sources of bond strength variability 

• The manufacturing process is not equipped to capture all of the variability 

• Therefore the certifiers and designers don’t have confidence that the 

process is well-controlled. 

• DoD Joint Service Specification Guide (SSG-2006) for Aircraft 

Structures, Part 3.10.5.d.: 

“Bonded structure shall be capable of sustaining residual strength

limit loads without a safety of flight failure with a complete bond line 

failure or disbond.” 

• Bolts are added after bonding 

Bonded Composite Exemplar 

Bonded Composite Pi Joint 

bolt 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 10 

Material and process informatics capture 

parameterized process conditions and 

variability 

Modeling quantitatively predicts the impact of

factory-floor process parameters on bond 

strength, defect generation, and defect 

distribution across structures in real time 

Metrology 

Laser bond inspection to quantify asmanufactured state of a bond line 

Reduced Process Variability 

Automated atmospheric plasma for surface 

cleaning and functionalization 

Lower risk by capturing the manufacturing process 

Improved process and quantitative prediction of as-manufactured state 

enable bonding without bolts 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

11 

Direct Metal Laser Sintering of Inconel 718+ (Ni-Cr superalloy) 

Take the process from laboratory to industry 

Additive Manufacturing Exemplar 

Rastered laser beam sinters/consolidates 

metal powder to create structural parts 

m sinters/consolidates ms 

laser 

beam bed of 

me a 

powder 

s ntered 

me a 

consol dated part 

• Physics-based models of the transient process, 

microstructural evolution, and resultant properties 

• Identify sources of variation using Design of 

Experiments (DoE) 

• Incorporate variation input at all levels of model 

hierarchy. 

• Incorporate In Process Quality Assurance into the 

manufacturing system for empirical feedback. 

Extend ICME concepts into integrated probabilistic design and lifing methodology

to serve as a new paradigm for rapid qualification. 

Laser beam normal 

to image scanning 

from left to right 

Transient, coupled thermalmechanical field is modeled 

for system 

Process Models 

ICME translates thermalmechanical fields into a 

microstructural description of 

manufactured component 

μ-structural Models 

Yield Strength (ksi) 175 

155 

165 

Property Models 

Performance is predicted 

from microstructural models 

and experimentally verified. 

DoE on small specimens 

conducted to determine 

relation between critical 

process parameters 

DoE 

Pyrometry of actual additive 

process captures thermal 

history and allows correlation 

to process models 

IPQA 

Integrated computational 

loop for optimization of 

process, design, material, 

and performance 

Probabilistic 

Design and Performance Lifing 

• Utilize Verification and Validation (V&V) methodology with integrated Uncertainty Quantification 

(UQ) – key to robust modeling. OM is first to implement V&V methods to ICME. 

• Implement Tool Maturity Level (TML) 

• Demonstrate on engine harness component. 

• MDF becomes repository for knowledge. 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

Open Manufacturing Impact 

12 

Establish open manufacturing tools that accelerate and encourage 

innovation through new manufacturing technology appropriate for the 

next 5 to 20 years by enabling rapid and affordable prototyping of 

new design concepts, and establish (process and materials models) for 

mitigating and addressing risks associated with these new approaches. 

Distribution authorized to U.S. Government Agencies and their contractors. Other requests for this document shall be 

referred to DARPA DSO. 

8 
Smart 

Manufacturing 

at NIST 

MBE Summit 

December 2012 

Simon Frechette 

National Institute of Standards 

and Technology 

U.S. Department of Commerce 

g 

Key Manufacturing Drivers 

• Increased rates of 

– Global competition 

– International trade 

– Technological change 

• Increased demand for: 

– Energy efficient and sustainable manufacturing 

– Better quality and innovative products 

– Higher productivity and lower cost 

ivers 

Key Challenges 

• Better methods and tools for 

diagnostic and prognostic 

• Balance life-cycle performance and 

minimum first-cost 

• Improved R&D support for new 

standards, codes, and regulations 

• Better ways to link pre-competitive 

R&D gaps with scale up 

What is Smart Manufacturing ? 

• Use high-fidelity models and intelligent software 

• Enable innovative production and products 

• Enhance economic/sustainability performance 

Smart Manufacturing Paradigm What is EL’s scope of SM activities? 

• Production systems at the equipment, factory, 

and network levels 

• Smart operating systems to monitor, control, 

and optimize performance 

• Systems engineering-based architectures and 

standards 

• Sensing, computing, communications, actuation, 

and control technologies 
What is EL’s role in SM? 

•		Measurement science 

•		Technical standards 

•		R&D testbeds 

Programs Supporting Smart 

Manufacturing
	

•		Smart Manufacturing Processes and Equipment 

•		Next-Generation Robotics and Automation 

•		Smart Manufacturing Control Systems 

•		Systems Integration for Manufacturing and 

Construction Applications 

•		Sustainable Manufacturing 

•		Manufacturing with Sustainable Materials 

Smart Manufacturing Processes and 

Equipment Program 

•		Geometric accuracy of axes of rotation
	

(ISO 230-7:2007)
	

•		Geometric accuracy of turning centers
	

(ISO 13041-2:2008 and ISO 13041-

3:2009)
	

•		Machine tool vibrations (ISO/TR 230-

8:2010)
	

•		Machine tool measuring capability (for onmachine measurements of parts) (ISO
	

230-10:2011)
	

Traceable Needs and Roadmaps 

Smart Manufacturing Processes and 

Equipment Program - Objective 

Rapid, cost-effective production of 

innovative, complex products using 

advanced manufacturing processes 

and equipment

90 0.003 

120 60 

 0.002

150 30 

 0.001

180 0 

210 330 

240 300 

270 

Next Generation Robotics and 

Automation Program - Objective
	

Safely increase the versatility, 

autonomy, and rapid retasking of intelligent robots 

and automation technologies 
–

 

 

–

–

–

Next Generation Robotics and 

Automation Program 

• Industrial Robotics Safety Standards 

–Critical technical contributions to 

OSHA-referenced Robotics Industries 

Association (RIA) and ISO robot safety 

standards. Standards support new robot 

capabilities that increase productivity 

and allow some forms of human-robot 

collaboration 

. 

• Automated Guided Vehicle (AGV) 

Safety Standards Testing results on 

non-contact sensors improved AGV 

safety standard developed by 

ANSI/ITSDF B56.5. 

Smart Manufacturing Control 

Systems Program - Objective 

Enable real-time monitoring, 

control, and performance 

optimization of smart 

manufacturing systems at 

the factory level 

Systems Integration for Manufacturing 

and Construction Applications Program 

- Objective 

Integration of engineering 

information systems used in 

complex manufacturing 

networks to improve product 

and process performance 

Systems Integration for Manufacturing 

and Constructions Applications Program 

• Data exchange 

– Over 68% of SMEs use STEP 

– U.S. aircraft manufacturers deliver 

digital-only aircraft design to FAA 

– Conformance tests for PMI 

• Systems Engineering 

– Systems engineering standards 

– Engineering requirements 

Sustainable Manufacturing Program 

Objective: To develop and deploy advances in measurement science to 

achieve sustainability across manufacturing processes enabling 

resource efficiency and production network resiliency 

• Sustainable Processes and Resources – 

enabling standards for characterizing and 

assessing sustainability performance (energy, 

materials, resiliency) 

Manufacturing with Sustainable 

Materials Program 

Objective: To develop and deploy measurement science, measurement 

standards and evaluated data needed to advance the identification, 

optimization and application of more sustainable materials for use 

in manufactured products 

• Identifying Alternative Sustainable Materials 

providing measurement science for identifying 

sustainable alternatives 

• Processing and Fabrication with Sustainable 

Materials providing measurement standards 

and protocols for assessing the quality of 

alternatives 

• Reliability of Sustainable Materials 

Replacements providing means to test the 

long-term reliability of sustainable materials 

replacements 



 

- i i 

l

B d li t

 

 

 

 

 

 

 

 

Partnering Strategies with Industry 

• Planning and Roadmapping 

Workshops 

• Testbeds, Facilities, and Tools 

• Standards Engagement 

• Cooperation Mechanisms 

• Other Tech Transfer 

Mechanisms 

• NIST Sponsored Events 

Summary 

• We are getting smarter 

– Technical Data Package and supply chain 

– MBE for design including PMI 

– Model validation 

– Model based inspection (M7) 

– Data exchange (AP242, 3DPDF, JT, etc) 

• We are not as smart as we could be 

– Systems engineering 

– Product lifecycle (both directions) 

– Predicting cost, controlling schedules 

– Modeling new materials and manufacturing processes 

(composites, additive, 

The Army’s Implementation of a 

Net-Centric 

Model Based Enterprise 

Paul Huang 

Army Research Laboratory 

Paul.huang@us.army.mil 

Sanjay Parimi 

Armament Research Development and Engineering Center (ARDEC) 

sanjay.u.parimi.civ@mail.mil 

Paul Villanova 

Armament Research Development and Engineering Center 

(ARDEC) 

paul.t.villanova.civ@mail.mil 

Net-Centric MBE to support the integrated weapon

system lifecycle 

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Major Capabilities: 

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Warfighter Operational Benefits: 

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Schedule & Cost 

FY11 FY12 FY13 FY14 

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MBE is an enabling capability that drives out 

acquisition costs 

Model Based Design 

& Reuse 

Product Def nit on 

Reuse 

Intelligent Mfg 

P anning & Execution 

Digital Product Realization 

 Development and implementation of fully-annotated CAD models 

± Modeling SOP has been adopted by the ARDEC enterprise and has been shared with TARDEC as well. 

± Fully Annotated modeling has been done for the M2A1 and several Spark II Mine Roller Interface brackets (Bradley & Max-Pro) 

 Establishment of a CAD validation capability 

± Validation ensures that CAD data can be used to drive manufacturing operations 

± Currently using the established processes to validate the M2A1 Quick Change Barrel 3DTDP 

 Creating a 3DTDP for PM-SW’s M2A1 Quick Change Barrel ± A modern and consistent product definition reduces manufacturing risk and cost 

± The final 3DTDP, to include manufacturing process data, will be used in the upcoming procurement action 

 Animated Digital Work Instructions for fielded systems 

± M153 Common Remote Weapon Station: Interactive Technical Repair Manual will be provided to Warfighters to reduce MTTR 

± TOW-GPK: Installation Manuals have been fielded to reduce War fighter assembly times 

± M2: Digital DMWR will reduce training times for new or cross-trained operators at ANAD 

± Max-Pro Dash Interface brackets: Documented assembly and weld processes reduced manufacturing risk for industry 

 Deployed a pilot Enterprise Product Data Management (ePDM) environment 

± Created a Windchill 10.1 instance at ARDEC’s PIF 

± Created areas for M24A1, Kiowa Helicopter and M2A1 products 

± Serving as a body of knowledge for AMC’s ePDM initiative. 

BLUF: 

Summary of Major Achievements 

BLUF: 

Major Activities in Process 

 Create and Deploy a Service Information System (SIS) to support logistics operations 

± The SIS will be an HTML portal where soldiers can access 3D, interactive logistics data 

± Reductions in assembly time, training and MTTR are feasible under this effort 

± TTA signed with PEO-AMMO 

 MIL-STD-31000: A new product data standard 

± Will help the acquisition community obtain 3D data from OEMs 

± Provides the basis for standardizing and modernizing the Army’s technical data 

± Helps to ensure that product data can be used to drive manufacturing during sustainment 

 Implementation of MBE capabilities at ANAD 

± Generation of an MBOM for the M2A1 using MPM-Link 

± Updating and modernizing shop-floor procedures for the M2A1 conversion process 

± Training ANAD Tech Pubs personnel on Digital Work Instruction software 

 Interactive Electronic Technical Manual for installing the SPARK II 

± Reduce operator training times 

± Reduce SPARK II installation times in theatre 

 Evaluate and implement reverse engineering technologies 

± Enables the Army to develop 3DTDPs from physical hardware 
 

 

 

TECHNICAL 

INFORMATION ON 

MBE 

CAPABILITIES 

Fully-Annotated CAD Modeling 

Proven Technology and Process: 

 Mature Fully-Annotated Modeling Standard Operating Procedure 

 Over 100 M2A1 models have been complete 

 2 major protection roller interface brackets are complete 

 Bradley Fighting Vehicle 

 Max-Pro Dash MRAP Vehicle. 

Bradley Protection Roller Interface Bracket 

Assembly 

M2A1 Feed Tray 

Cover 

Bradley Protection Roller Interface Bracket Component 

“Prototypical” 3D TDP 

Using the standard 3DPDF format 

Manufacturing 

Process Data Files 

Digital Work 

Instructions Interactive 

Design 

Documents 

Interactive 

Inspection 

Documents 

3D Technical Data Packages 3D Technical Data Packages: 

Industry Assessment y 

Objectives: 

1. Connect with individuals at supplier companies that are responsible for  receiving technical data and models 

 handling quotes/estimation 

 working with models related to design/production 

2. Drive target decision makers to view online demonstration/example of the 3D TDP tool and video 

instructions to describe key features and usage of 3D TDP 

3. Gather Feedback from the ARDEC supplier base 

Summary of Results: 

 89% of respondents feel that the 3D TDP is better or much better than 2D drawings for conveying 

design intent. 

 84.4% of respondents plan to use the 3D TDP in their manufacturing planning 

 76.1% of respondents plan to use the 3D TDP to develop their CAM program 

 73.9% of respondents plan to use the 3D TDP as an instrument to convey intent for shop floor 

Assessment conducted jointly between NIST, ARDEC and industry partners 

Project Objective: Provide validated, 3D 

product data that can be used to procure 

QCB kits 

Major Deliverables: 

1) Fully-Annotated PRO-E models 

2) Published nominal .STP files 

3) Published design 3DPDFs 

4) Validated CAD models and derivatives 

5) MPDFs for hard to source components 

6) Digital Work Instructions for assemblies 

Value Proposition: A modern Product Data package with supplementary manufacturing process data will: 

 Increase the number of bids from small manufacturers 

 Reduce cost, risk and lead times for system acquisition 

Creating the first 3DTDP: 

 M2A1 Quick Change Barrel acquisition 

Digital Work Instructions: 

Installation & Repair Manuals 

 Utilized manual and laser scanning 

techniques to reverse engineer model data 

 IETM will be immediately fielded when 

complete: summer, 2012 

 Single CD containing HTML based 

menu and multiple 3DPDF work 

instructions 

 Instructions have been fielded with 

each system. 
L

O

 Replace 2D paper instructions with a digital, interactive format that more 

effectively conveys each step 

Value Proposition: Work instructions can be rapidly updated and 

redistributed based on process & product changes. Reduces lead times and 

costs associated with training new operators 

Digital Work Instructions: 

Supporting ANAD shop floor operations 

RG-33 (NAV SEA) 

Pro E 

Design 

Mfg Review 

Windchill 

FEA 

Qualification 

Theater 

(first Q) 

R 

R&D Centers/ 

Depots/ Commercial 

Source 

Prototype 

Customer 

Requirements 

MAXPRO DASH STRYKER COUGAR A1 (NAV SEA) 

Manage different Spark II bracket configurations, provide producibility 

reviews and manage production operations for PM-CCS 

Data Management using Windchill: 

Supporting PM-CCS 

Service 

Information 

System 

Real-time 

Product & Configuration Data 

Product-centric 

Information 

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9 Service information is specific to the 

role of the user, their task and the 

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9 Service outcomes include a closed-loop 

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9 IT investments connect product 

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What is a Service Information System 

Implementing Digital 

Manufacturing Tools to connect 

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The Accelerated, Adaptive Army Fabrication 

Enterprise Vision 

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Results for Cable Box Optimization 

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Page 1 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

What is in NX Cam 

NIST 2012 Maryland. 

By: Sada Reddy Technical sales. 
l i l i 

 

l i 

 

l i 

 

l i s Product cle Management Sof l i served

Page 2 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

CAM Modules 

Milling 

Turning 

Wire EDM 

Feature Based Machining 

GMC ( Generic Motion Controller ) 

Postprocessors + Libraries + Shop Docs 

Simulation ( IS&V) + DNC 

Open Architecture & Automation 

Geometry 

Page 3 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

2.5 Axis Milling. 

Application: - Machinery and Electronics Components. 

Geometry: Points, Lines, Arcs, Splines, Sheet + Solid Bodies and Edges. 

Page 4 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

3-Axis Contour Machining. 

Application: Tool + Die, Aerospace, Medical and Consumer. 

Geometry: Points, Lines, Arcs, Splines, Sheet+ Solid Bodies And Edges. 

Page 5 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Multi-Axis Machining. 

Application: Aerospace and Medical. 

Geometry: Points, Lines, Arcs, Splines, Sheet + Solid Bodies And Edges. 

Page 6 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

2-Axis Turning. 

Page 7 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Mill-Turn Machining. 

Lifecy tware Inc All rights re 
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WEDM 2-Axis

l i 

13

© 2008. Siem 008. l i 

Page 8 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Sync. Mill-Turn 

Page 9 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

B-Axis Turning.. 

Page 10 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Interface 

Page 11 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Page 12 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

WEDM Multi-Axis 

Page 

ens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

NX/Open exit to access technology data at the 

operation level 

 Use API Exit to interface with machine specific technology tables 

 Have data accessible at the operation level, stored with the operation 

 Set operation parameters & UDSs through API 

 Simplifies the post 

Page 13 

© 2008 . Siemen 

API 
14

© 2008. Siem l i 

at on 

& UDSs through API

API

l i 

l i © 2008. Siemens Product Lifecycle Management Software Inc. All rights reserved

On Machine Probing.

l i 

 

l i 

Tool libraries i

i

Teamcenter 

l i

Teamcenter 

Page 

ens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

NX/Open exit to access technology data at the 

operation level 

 Use API Exit to interface with machine specific technology tables 

 Have data accessible the operati level, stored with the operation 

 Set operation parameters 

 Simplifies the post 

Page 14 

© 2008 . Siemen 

Page 15 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Color and Attribute Features (1/2) 

 Feature recognition based on color & attributes 

 Define feature types with corresponding color/attribute criteria 

through MKE (Machining Knowledge Editor) 

 Add face attributes & PMI to features 

 Targeted at complex feature geometry 

 Requires model “markup” for manufacturing 

Page 16 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

GMC. 

Page 17 Siemens PLM Software 

GMC – 

Page 18 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Shop Documentation. 

• Scope 

• All of Setup or Selected 

Program/Object 

• Mill/Drill/Turn/WEDM/Probe 

Operations 

• Replaces Post Versions 

• Template Customization 

• Use Excel to edit 

• Easy to create and modify 

• Requires no knowledge of TCL 

or MOM 

• Output 

• Page content length 

• Repeat title 

• Tool and Operation tables 

• Graphics 

• Part attributes 

• Over 1000 MOM variables Page 19 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Tooling Libraries 

Process 

planning 

CMM 

programm ng 

CAM Par odel 

preparation 

Tooling and 

f xture design 

CMM Process 

Planning 

P tar model T lioong and 

NX CAD/CAM 

NX CMM Teamcenter applications 

CMM inspect on 

execution 

Shop f oor data 

access 

Tool 

management 

Shop Floor DNC Program Validation CNC 

Shop floor d taa T loo CMM inspection

Production 

Teamcenter 
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Verification.

l i 

Simulation.

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© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Tool/Material Database. 

Page 21 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Page 22 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Tool-Path 

Page 23 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Machine Tool 

Page 24 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software Page 25 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 
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1 

3DS COM © Da au Sy ème Con iden ial Info ma ion 5 28 2013 ef.: 3DS_Do umen _2012 

Page 26 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software Page 27 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

DNC - Shop Floor Connect. 

Manages All Shop Floor Activities 

DNC 

Mfg. Resource Management ( Tools + Fixtures Etc..) 

Page 28 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

NX/Open Programs. 

 KBE. 

 User Function ( C, C++, VB, Java, Grip ) 

Page 29 

© 2008. Siemens Product Lifecyc e Management Software Inc. All r ghts reserved 

Siemens PLM Software 

Input Geometry: 

Standards: STEP IGES DXF DWG 

Cad Models: CATIA Pro-E S-works S-Edge SDRC 

Others: JT Parasolid STL CGM

 (JT is a Light weight Model for Collaboration.) 

. ss lt st s | f t r t | / / | r c t 3DS.COM © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012 

Extending the 3D Master to 

Manufacturing Information & Procedures 

Israel Flores 

13 December 2013 

MBE Summit, NIST 

3DS.COM/CATIA © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012 2 

DS 3D Experience : 3D Master (Eng Æ Mfg) 

Openness and Data Exchange (STEP) 

Manufacturing Data Archiving 

Agenda 
PAPER 

DOCUMENTS 

i

i

 

 

D M

s

FloorShoptoDeliveryandMaster3D 

De tionsarOpep FloorSho

_2012 tnmeucoDS_D3f.: re|201328/5/ionormatnfialt idenonfC|èmestsySaultsasD© COM.3DS

3DDS Experience Solution

tnetDe tionsarOpep Floor

_2012 tnmeucoDS_D3f.:er310282/5notamrfoInatnedfnoC|semètsSytuassaD©ACAT/MCO.3DS

FloorShoptoDeliveryandMaster3D 

De tionsarOpep FloorSho

_2012 tnmeucoDS_D3f.:er310282/5notamrfoInatnedfnoC|semètsSytuassaD©ACAT/MCO.3DS

with the shop floor and part ordering systems based entirely on a parame

Engineering Changes 

Configuration per tail number reflecting

with associated 3D Master information under

Executable workpreciseand, clear instructions

sign 

Simulation and Analysis

Design, Engineering 

6 

_2012 tnmeucoDS_D3f.: re|201328/5/ionormatnfialt idenonfC|èmestsySaultsasD© COM.3DS

2D only a presentation

3D single ereferenc

0% 3D10 definition

Digital Product Definition Æ

2102_tnmeucoDS_D3f.:er310/2825|iontamrfoInialtnidefnoCsemètsSytuassaD© COM.3DS

Legacy:Our from 3D-Design to 3DEXPERIENCE

2102_tnmeucoDS_D3f.:er310/2825|iontamrfoInialtnidefnoCsemètsSytuassaD© COM.3DS 3 l | / | 

4 l | / | 

3D Master 

3D Master Vision 

3D Design

3D Master 

Today 

3D Design

2D Master PAPER 

DOCUMENTS 

5 I | 

3D As Master End-to-End Process Coverage 

Customers Authorities rs Au 

Partners 

3D Work plan 

Definition 

3D Work Instruction 

Author ng 

Dedicated 

Pre-study tool 

3D Product 

definition 

Technical 

Publication 

Shop floor 

Review 

Assembly 

Tolerance 

Analysis 

Qual ty 

Inspection 

Technical 

Publication 

Native Data 

I | 

Work Instructions, 

Condition of Supply,

Technical Publications 

Engineering Manufacturing and Maintenance 

Planning Shop Floor In Service 

Communicate model-based Engineering Requirement (tolerances, standard parts, specifications, etc.)

terized 3D dataset 

I l i i l i | / | 7 

Design, Engineering

Simulation and 

Analysis 

Work Instructions, 

Condition of Supply,

Technical Publications 

sign 

From Engineering: 

Design annotations 

FT&A 

From Manufacturing: 

Manufacturing sequence / 

Routings 

Assembly validation 

Work instructions 

Manufacturing views 

Buy-off/Sign-off 

Data collection fields 

Quality checks 

Engineering 

Quality checks 

Manufacturing and 

Maintenance Planning Shop Floor In Service 

I l i i l i | / | 8 

Design, Engineering

Simulation and 

Analysis 

Planning, Offline 

Programming,

Simulation and 

Validation 

Work Instructions, 

Condition of Supply, 

Technical Publications 

sign In Sho

Data Management 

Engineering Manufacturing and 

Maintenance Planning Shop Floor In Service 
 

9 3DS.COM © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012

DS 3D Experience : 3D Master (Eng Æ Mfg) 

Openness and Data Exchange (STEP) 

Manufacturing Data Archiving 

Agenda 

3DS.COM/CATIA © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012 10 

STEP selected for LOng Term Data ARchiving 

STEP is the DS strategic format for Long Term Archiving and Interoperability 

STEP / ISO 10303 : dedicated standard for neutral Data exchange and Archiving 

STEP evolutions are driven by customer consortiums : ProSTEP, PDES inc, LOTAR 

DS has a long experience with STEP 

AP203 and AP214 available in V4, V5 and V6 

DS extends its support to STEP applicative data 

3DS.COM/CATIA © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012 11 

Solutions : DS working together with LOTAR 

PMI as polylines : Cost Reduction 

Simplest and Most Reliable way to Achieve PMI for 

human interpretation 

3DS.COM/CATIA © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012 12 

Solutions : DS working together with LOTAR 

Validation Properties : Improve Transfer Quality 

1. Cloud of Points on Surfaces and Edges 

2. PMI (Polylines) : Length, CoG, and Validation String 

3DS.COM/CATIA © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012 13 

Solutions : DS working together with LOTAR 

New Technologies: 

Composites 

Electrical 

Manufacturing Process 

14 3DS.COM © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012

DS 3D Experience : 3D Master (Eng Æ Mfg) 

Openness and Data Exchange (STEP) 

Manufacturing Data Archiving 

Agenda 
 

 

 

 

 

 

 

 

 

 

 

 

 

You need people.swf in the 

same dir as this ppt

15 3DS.COM © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012 

Archiving Manufacturing Data 

APT and CL files not useful for archiving 

CAM to CAM transfer means recreation of NC 

A step in the right direction - V6 stores and links all manufacturing info. 

A neutral format would be welcome but not easy to create 

Defining a standard could be the first step 

16 3DS.COM © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012 

Archiving Manufacturing Data 

How do we secure manufacturing data for long term archiving? 

STEP format? 

Must be an industry effort that drives the solution. 

17 3DS.COM © Dassault Systèmes | Confidential Information | 5/28/2013 | ref.: 3DS_Document_2012 

Engineering Data Exchange 

and the Manufacturing Supply Chain 

One Vendor’s View 

Hanan Fishman 

Director 

Delcam Plc 

Delcam’s History 

1960 & 70’s Initial research at Cambridge University 

Development taken over by Delta Group 

1980 Software sales start 

1990 Staff purchase company 

 New HQ, Birmingham, UK 

1997 Delcam floats on UK Market 

2002 10,000th customer 1st of 3 Queen’s Award 

2006 IMCS (PartMaker) joins Delcam 

2007 25,000th Customer 

End user sales exceed $100M 

2009 30,000th Customer 

Who Delcam are today 

Our People 

800 Staff 

325 Within Overseas Subsidiaries 

240 Within Joint Ventures 

227 Software Development Group 

What makes Us Unique 

In house manufacturing facility 

Nationwide/Worldwide training facilities 

Local support 

Delcam’s Ownership Structure 

Industrial Partners 

Our Success 

End user revenues over $100m 

30,000+ Customers 

60,000+ End users 

Local Events 

User Groups 

Software Release Meetings 

Technology Seminars 

Press Conference 

Regional Engineer Training Events 

Inward Missions 
 

 

 

 

 

 

 

 

 

Delcam offers services for Toolmakers and manufacturers. The experience gained contributes to: 

Development of a practical, efficient and cost effective software. 

Co-ordination between the software development team and tooling services. 

Provision of competitive contract services to our software customers. 

Validation of new software releases and new product development. 

Awarded ISO9000. 

Delcam Tooling Services 

Return to 

Delcam Today 

Proper training is essential to maximize the 

benefits of any CADCAM system. 

Delcam offers comprehensive training in all its 

software, either at your local support office or on 

site. 

PartMaker training offered across the country in 

Philadelphia, Chicago and Los Angeles 

All training is given by experienced Delcam 

engineers. 

Advanced courses are run for skilled users. 

Monthly webinars are offered free of cost 

Delcam Training Courses 

D 

s 

s 

P 

P 

A 

e 

A 

Return to 

Delcam Today 

Delcam offers online & phone support for both 

software to all customers on maintenance. 

All Philadelphia-based engineers have extensive 

CNC programming experience 

Support is expert, local and highly efficient with 

“one click email support” 

Experienced engineers can access and analyse 

problems on-line. 

Upgrades and patches available from 

http://updates.delcam.com 

Regular product release update seminars enable 

users to get to grips with new features rapidly. 

Delcam Support Services 

Return to 

Delcam Today 

Ownership 

• Delcam’s ownership is also a unique strength 

– Listed on the UK Stock Exchange providing oversight and 

discipline (DLC.L) 

– Renishaw is major external shareholder (20%) 

– Renishaw & Delcam’s management team control the majority 

of the shares, creating a stable position and ensuring a long 

term perspective 

Return to 

Delcam Today 

CAM Partners 

Return to 

Delcam Today 

Offices Worldwide 
How are the costs incurred? 

• Cost of data translation software 

• Cost of time needed to repair models 

• Cost of time to confirm repairs are correct 

• Cost of maintaining multiple CAD systems 

• Cost of hiring or training staff to operate multiple 

systems 

• Cost of translating files to return to customer 

 

 

 

Worldwide Support 

Over 300 local support offices 

world wide 

Manned by experienced 

engineers, local to you 

Supported by a network of 

resources around the world 

Select to find out more about Delcam in 

North America Europe Russia China 

Latin America Asia India Africa Return to Worldwide Locations 

Data Translation 

Problems Affecting 

Your Supply Chain The data translation problem 

Why is it getting worse? 

Modeling Basics 

Data Repair – Solid Doctor 

Direct Modeling 

Conclusions 

Data Translation 

• Data translation is the 

same as translating 

languages 

• Easy at the basic level 

• Very difficult for 

complex or intricate 

details 

What is football? – U.S. vs UK 

• Two nations 

separated by a 

common language 

• How do you spell 

mold (mould)? 

• True Irony: 

– U.S. - Modeling 

– U.K. - Modelling 

The cost of data translation 

• In 1999, NIST estimated the cost of data 

translation to the automotive industry as over $1 

billion 

• 2008 report in MoldMaking Technology claimed: 

– 90% of toolmakers receive less than half of models in 

their preferred format 

– 42% of toolmaking companies use four or more CAD 

systems each month 
CADCAM and the supply chain 

• Some promote the concept of a single system for 

the whole supply chain 

• This won’t work because: 

– OEMs and Contract Manufacturers use different 

systems 

– OEMs change the systems they use 

– New versions of “same” system aren’t compatible 

– Disappearing CAD systems, e.g. CADDS and SDRC 

The “best” software 

• No software is the “best” for everything 

• The needs of the OEM manufacturer are not the 

same as those of the contract manufacturer 

• Being the best at data management and product 

design does not make you the best at NC 

programming 

• OEMs can afford to pay more for software than 

smaller contract manufacturers 

The problem – Part complexity The problem - Productivity 

• All industries are looking to shorten product 

development times as faster new product 

introduction increases profitability 

• Companies that are second to market want to 

shorten the time gap 

• Time taken to solve data translation issues 

increases product development times 

The problem – Data reuse 

• Companies are looking to increase design 

productivity by modifying existing products 

• Data translation issues are a major problem 

according to Longview Advisors 

– Only 14% of designers receive their data in the 

required format, even in the same company 

– 8% never get their data in the required format 

The problem - Litigation 

• Buyers are more likely 

to sue suppliers 

• OEMs are more likely 

to pass the problem 

on to suppliers 
The problem - Longevity 

• Aircraft built 50 years 

ago are still flying 

• Aircraft built today 

will still need 

replacement parts for 

the rest of this 

century 

The problem - Traceability 

• OEMs, especially in areas like aerospace and 

medical applications, need to provide complete 

traceability on their parts 

• Data must be transferred back up the supply 

chain if any changes are made to the design 

– Fillets added or altered to improve flow in the mold 

– Draft angles changed to ease removal of the part 

from the mold 

Modeling Basics 

Wireframe 

• Lines 

• Arcs 

• Curves 

• Highly rigid and mechanical 

• Basically 2D 

Surfaces 

• Created with longitude, 

laterals, and trim 

boundaries using 

wireframe and curve 

geometry 

• Individual pieces 

• Highly malleable and 

flexible, but have no 

volume 

• Typical neutral formats 

IGES 

STP/STEP 

Solids 

• Groups of surfaces to 

create one piece 

• Contains history tree 

in native format 

• Have volume 
Solids 

What is a dumb model? 

Definition: A solid model without any “history” 

or perhaps one converted to a surface model 

such as IGES or STEP 

Why should you care? 

• Designers may not want to send outside 

manufacturers their actual native files for 

concern of IP piracy 

• Designers don’t want to send out more 

information than they have to get the part 

made 

• Designers often don’t know how a part will 

be made – i.e. machined, cast, molded, 

pressed etc. 

Standard formats 

• Standard formats are 

promoted, especially 

IGES, STEP and 

Parasolid 

• IGES is like ice cream, 

very nice but comes 

in many flavors 

Model Repair

• Solid Doctor

Data Repair Solution 

• Software (part of CAD and 

reverse engineering) that can 

read and repair CAD models 

• Converts CAD files into valid, 

high-precision Solid models 

• Typical problems solved are: 

– Gaps/overlaps 

– Duplicated/missing surfaces 

– Poor quality trimming 

• This requires solid and surface 

modeling options 

Stage 1 – Highlight the 

problems 

• Analyses the model 

and labels all the 

problems 

Stage 2 – Automatic repair 

• Automatic repair 

tools fix the simpler 

problems 

• Solid modeling tools 

used to match edges 

exactly 

• Labels are turned 

green as problems are 

fixed 
tend and

Modelling for 

manufacture 

edits

Stage 3 – Complex problems 

• Remaining problems 

keep red labels 

• Repair methods are 

suggested using 

surface modeling 

tools 

Stage 4 – Re-trimming 

• A common problem 

comes when surfaces 

aren’t trimmed 

correctly 

• This can be corrected 

by editing boundaries 

Stage 5 – Replace surfaces 

• For the most complex 

problems, surfaces 

must be deleted and 

replaced 

• Surface modeling can 

fill the area with a 

surface tangent to 

adjoining areas 

What is Direct Modeling? 

• Ability to make rapid, 

history free edits to solids 

• Surrounding faces 

automatically ex 

re-intersect 

• Maintains a closed 

solid 

xtend and 

sed 

What does Direct Modelling 

mean to Delcam? 

Import and 

Fixing 

Export to 

CAM 

Direct Modeling 

Edit draft

Edit 

• Move

• Rotate

• Offset

• Scale

• Copy

Edit faces

Remove & Heal

Edit features

• Holes

• Pockets

• Cuts &

bosses

• Fillets

s
 

-

D

 

 

 

 

 

 

 

 Slide 4 

 

 

 

 

Conclusions 

• Lack of CAD compatibility is a major problem for 

manufacturing industry 

• Using the same system along the supply chain is 

not the answer 

• A combination of solid and surface modeling 

tools provides a quick, easy way to work with 

models created from any CAD system through to 

manufacturing 

Martin Hardwick 

MBE Summit ‒ 2012-12-13 

STEP Tools, Inc. 

http://www.steptools.com 

Computer 

Aided Design 

Computer Aided 

Manufacturing 

Tool & Fixture 

Database 

Machine System 

Database 

Intelligent 

Control 

CAM to CAM Data Exchange 

STEP NC 

Technical 

Data Package 

n 

d 

D 

T 

M 

e 

ellige 

ISO 10303-238 

© Copyright 2012 — STEP Tools, Inc. Slide 2

Contracting for manufacturing assemblies 

• How to reduce costs by cooperating? 

1. If OEM owns the process (by owning the resources) then the 

solution is more expensive (traditional solution) 

2. If supplier owns the process then the solution is more time

consuming (recent aerospace solution) 

3. If OEM and supplier share the process then solution is less 

expensive and less time consuming (CAM Data Exchange

solution) 

Assembly

Requirements 

Manufacturing

Resources 

OEM Supplier 

+ Manufacturing

Process = 

Who? 

© Copyright 2012 — STEP Tools, Inc. Slide 3

• Visits to suppliers to explain models 

• Maintenance of additional machines 

• Repetitive, error prone data entry 

• Misunderstandings over drawing symbols 

• Incomplete simulations 

CAD CAM CNC IGES Gcode One machine 

One setup

One tooling 

Weak automation No interoperability 

Unnecessary costs 

OEM assembly 

constraints 

Repeat for every

Supplier 

One shop

solution 

© Copyright 2012 — STEP Tools, Inc. 

Desired solution – Science not Art 

Model Driven 

Manufacturing for 

Assembly 

Geometry with

associative 

tolerances from 

assembly 

Mode 

Adjustable

tools and 

fixtures 

Driven 

Slide 4 

Manufacturing 

accuracy

solution 

mbly 

Adjustable

manufacturing 

processes 

Asse 

© Copyright 2012 — STEP Tools, Inc. Slide 5

What is ISO 10303-238 STEP-NC? 

• STEP-NC describes “what” not “how” 

– Make this geometry from this stock 

– By removing these features 

– In this order 

– With these tolerances 

– And tools that meets these requirements 

• The old standard described “how” 

– Move tool to this location 

– Move tool to this location 

– And so on for millions of commands 

• New information to make 

machining faster and more 

accurate 

– Supply chain interoperability 

– On machine feed-speed/tool-wear optimization 

– On machine simulation and collision detection 

– Closed loop machining and measurement 

– Feature based 

– Platform independent 

– Full fidelity simulation 

– Plug and play with CAD and CAM systems 

STEP-NC AP238 

BC Table Tilt AB Tool Tilt 
 

 

 

 

 

 

-

 

 

 

 

 

5 May 2009 

September 2009 

June 2010 

October 2011 

June 2012 

Tool wear modeling 

Machine tool modeling 

Closed loop compensation 

Accuracy prediction 

Just in time 

tooling 

Phase Demonstration 

Dates 

Capabilities Shown Application 

1 November 2000 

February 2002 

January 2003 

June 2003 

Tool path generation from 

manufacturing features 

Cost estimate 

automation 

2 February 2005 CAM to CNC data exchange without 

post processors 

Interoperability 

3 May 2005 

June 2006 

July 2007 

Integration of machining and 

measurement 

On machine 

acceptance 

4 December 2007 

March 2008 

October 2008 

Cutting tool modeling 

Cutting cross section modeling 

Resource and 

performance 

optimization 

How do we know - 10 years of testing 

© Copyright 2012 — STEP Tools, Inc. Slide 6
	 © Copyright 2012 — STEP Tools, Inc. Slide 7

Projected Benefits* 

• 35% reduction in preparation costs for routine

machining 

• 50% reduction in costs for engineering changes 

• 50% reduction in inspection costs 

• 90% reduction in drawings 

• 20% increase in value of CAM solutions 

– New shop floor applications (e.g. adaptive fixturing) 

– Increased usage of advanced functionality (e.g.

feed/speed automation) 

– Access to a much larger database 

– Support for a long term archive data format 

*by Organization for Machine Automation and Control (OMAC) 

© Copyright 2012 — STEP Tools, Inc. Slide 8

Path to Deployment – Starting Jan 2013 

ISO 10303 

-238 

STEP NC 

STEP-NC 

Explorer 

View & Verify 

Operation CAM Writer

1st 6 months 

Boxy STEP-NC file 

(www.steptools.com) 

Operation 

Reader 

O CAM 

2nd 6 months 

Boxy part in 

aluminum or steel 

CAM to CAM data exchange for a 3 axis part 

© Copyright 2012 — STEP Tools, Inc. Slide 9

Summary 

• STEP-NC defines a technical data package for

manufacturing 

– Portability and Interoperability for manufacturing 

– Enable many new automation applications 

– Faster communication, fewer errors, more accurate 

simulations 

– Decade of testing, ready for deployment 

• Industry projects large process savings and

significant increased value for CAM systems 

• Join us! 

– Make a Boxy 

– Translate to STEP-NC 

– Participate in testing forum 

We make products for national security. 

Kansas City Kansas City Plant 

DOE/NNSA 

Model-Based Quality Metrology 

Enabled by Quality Information Framework Interoperability 

One of Two Key Technology Enablers Required for 

Smarter Manufacturing in MBE 

Curtis W. Brown, P.E. 

Principal Mechanical Engineer 

Model-Based Enterprise Summit 

December 11, 2012 

The Kansas City Plant is Operated by

Honeywell FM&T for the United States Department of Energy under Contract No. DE- NA0000622 

We make products for national security. 

Overview 

• Safety Message 

• What is the Kansas City Plant / Honeywell FM&T? 

• Model-Based Quality Metrology Requirements 

• Interoperability Standards enable MBE 

• Dimensional Metrology Standards Consortium 

• Quality Information Framework 

• Product Definition + PMI (GD&T) 

• Features Reduce Complexity 

• Smarter Model-Based PMI 

• Some Big Ideas and Request for Involvement 
 

We make products for national security.

 

We make products for national security. 

Kansas City Plant 

M&O Honeywell FM&T 

Established by DOE in 1949 with over 3.2 

million ft2, 2800+ people 

3⁄4 Classified Secured Facility 

 Managed and Operated by Honeywell

Federal Mfg. & Technology (FM&T) 

 Primary Mission: Build & Sustain NonNuclear Portions of the Nuclear Arsenal 

 Engineering & Manufacturing are

Primary Core Competency’s - very

diverse capabilities 

 Responsible to provide (make and/or

purchase) 100,000 + items for DOE 

 Mission includes partnering with 

3⁄4 Companies and Other Government Agencies 

3⁄4 Work for Others (WFO) Program; and/or 

3⁄4 Companies – Cooperative Research & 

Development Agreement (CRADA) 

Plant Relocation 

• Kansas City Plant for NNSA nonnuclear production is moving. 

• Honeywell proposed a multifaceted transformation in Dec, 2005. 

• Kansas City Plant transformation strategic thrust areas: 

• Reduce oversight 

• Strategic sourcing and sizing 

• Business process transformation 

• Creation of a new, modern, agile facility 

• Together these changes will: 

• Reduce footprint by at least 50% 

• Reduce costs by 25% ($100M annually) 

• Maintain current mission performance 

• Provide Flexibility for future mission needs 

• Provides an infrastructure that is more responsive to potential changes in technical 

capabilities and schedule demands. 

• Move Starts in Dec, 2012 from the Bannister Federal Complex, Kansas City, MO 

• Move Completed in May 2014 to the National Security Campus, Kansas City, MO 

We make products for national security. 

MBQM Critical Requirements 

• Fully Semantic Product Tolerance Representation 

• Domain Specific Shape Features 

• Digital Interoperability Standards

• Product Definition Plus PMI 

• Quality Information Framework

• Dimensional Metrology Standards Consortium 

• MBQM Workflow 

• Validation & Demonstration 

• Measurement Results 

• Dimensional 

• Attribute 

• Metrology Resources 

• Measurement Rules 

• Process Plans 

• Part Programs 

• Non-Dimensional 

• Real-Valued 

We make products for national security. 

Quality Information Framework 

What is it? 

High level view 

QIF is a standard integrated information model for the 

real-time exchange of data between software and 

equipment modules in quality measurement 

• Standard ֜ Open development, free-to-implement, free tools 

• Integrated ֜ No overlap, harmonized upstream 

• Information model ֜ XML Schema (W3C) 

• Application Data Files ֜ Conform to QIF data model 

• Actual interfaces ֜ Actual market use case 

• Software/equipment modules in the quality measurement process 

֜ Plan, Program, Execute, Analyze 

QIF developed within the Dimensional Metrology 

Standards Consortium (DMSC)e 

We make products for national security. 

• A non-for-profit, cooperative sponsorship organization with 

members Large and Small 

• Focused on or relating to Digital Dimensional Metrology 

• Dedicated to identifying, promoting, fostering, and 

encouraging the Development and Interoperability of 

Standards that benefit the dimensional metrology 

community. 

• An ANSI accredited Standards Making organization with 

ISO fast-track international presence 

• Brought you the DMIS ISO Standard, the most influential 

standard in the industry 

• Ensure that metrology standards fill gaps and do not overlap 

We make products for national security. 

• Response to 2006 Metrology Interoperabilty Roadmap 

• Introducing the Quality Information Framework (QIF) 

•A suite of integrated XML Schema-based standards 

• Enabling the seamless flow of information for digital 

quality measurement systems 

• Emerging as an American National Standard (CY2013) 

• Progress as an ISO fast tracked Standard 

• www.qifstandards.org 

• Preparing a complementary XML Schema-based Product 

Definition with Product Manufacturing Information (PMI) 

solution 

• Intent to submit for standardization 
We make products for national security.

We make products for national security.

We make products for national security.

QM

Rules 

Driving Technology and Innovation through Standards Wemake products for national security. 

(DMIS) 

Organization Structure 

We make products for national security. 

• DMSC Consortia Members 

• Working Groups 

• Open to all who have a Direct and Material Interest 

• Applied Automation 

Technologies 

• Capvidia 

• Deere & Company 

• Hexagon Metrology 

• Honeywell FM&T 

• Lockheed Martin 

• Origin International, Inc. 

• MetroSage 

• Metrology Integrators 

• Mitutoyo America Corp 

• Nikon Metrology 

• NIST 

• PAS Technology 

• Renishaw 

• Siemens PLM Software 

• Rolls Royce 

• Pratt Whitney 

• GE Aviation 

• Boeing 

• DISCUS Software 

• Zeiss 

• Renaissance 

Services 

We make products for national security. 

In Summary, the DMSC can: 

• Define Standard Interoperability Exchanges within a ModelBased Quality System 

• Provide the holistic mechanism to establish national and 

international standards. 

• Foster authorized groups (committees, work groups). 

– to promote and/or develop specifications into standards. 

– to maintain and/or enhance existing standards 

– to coordinate and harmonize related standards. 

• Encourage collaboration of efforts to achieve shared goals. 

• Increase profits for DM vendors & manufacturers! 

– Saves You and your QIF enabled vendors Time and Money 

Model-Based Quality Metrology 

Workflow 

Define 

Product 

Determine 

Measurement 

Requirements 

Define 

Measurement 

Process 

Execute 

Measurement 

Process 

Analyze & 

Report 

Quality Data 

Manufacturing 

Process 

Tolerance 

Standards 

Customer 

Requirements 

Design 

Specifications 

Product Design 

w/ Criticalities 

Measurement 

Criteria (whats) 

Inspection Plan 

(hows) 

Measurement 

Results 

Part Report & 

Analysis 

Metrology 

Knowledge 

Metrology 

Resources 

DME 

Work 

Activity 

Define 

Product 

Determine 

Measurement 

Requirements 

Define 

Measurement 

Process 

Execute 

Measurement 

Process 

Analyze & 

Report 

Quality Data 

Manufacturing 

Process 

Tolerance 

Standards 

Customer 

Requirements 

Design 

Specifications 

Product Design 

w/ Criticalities 

Measurement 

Criteria (whats) 

Inspection Plan 

(hows) 

Measurement 

Results 

Part Report & 

Analysis 

Work 

Activity 

Metrology 

Knowledge 

Metrology 

Resources 

QMResources 

QMRules 

QMPlans 

(whats) 

QMPlans 

(hows) 

QMResults 

QMStatistics 

DMSC Standard DMIS

PDPMI 

DME 

Model-Based Quality Metrology 

Workflow w/ QIF Components 

We make products for national security. 

FAI 

Model-Based 

Definition 

Statistics 

QMResults 

QM

Whats Hows 

DME 

QMPlans 

ts 

QM 

Rules 

QM

Execution 

(DMIS) 

cs 

ats Hows 

QM 

Execu 

QM 

Wha 

QIF 

Library 

QM 

Resources 

DMSC’s QIF LifeSaver Slide 

XML Schema 
e make products for national security.

FAI

Model-Based

Definition

QM

Statistics 

QMResults

QM

Rules 

Whats Hows 

DME

QMPlans 

QM

Execution 

(DMIS)

ry Resources 

XML Schema

QM

H

P

 

 n 

s

ans

 

 

-

We make products for national security. 

XML Schema 

Why XML Schema Files are Used 

• XML Schema (.xsd) has adequate expressive 

power: types, derived types, built-in data types, 

constraints, inclusion, etc. are provided. 

• There is a default data file format (XML) for data 

files governed by XML Schemas. 

• XML Schema is a widely accepted language, and its 

data file format is even more widely accepted. 

• Tools for processing XML schemas and XML data 

files governed by schemas are available free or at a 

moderate price. 

• Lower cost investment for application implementers. 

W

QIF

Libra 

QM 

QIF Model Suite 

e make products for national security. 

FAI 

Model Based 

Definition 

Statistic 

QMResult 

ats Hows 

DME 

QMP lans

ts 

QM 

Rules 

M 

ution 

(DMIS) 

cs 

ats Hows 

QM 

Execu 

QM 

Wha 

QIF 

Library 

QM 

Resources

QIF Library Models XML Schema

Eleven Schema Models 

QIF Application Schema Models (uses the QIF Library) 

• QMPlans v1.0 (whats) 

• QMResults 

• QMResources 

• QMRules 

• QMPlans v2.0 (hows) 

• QMStatistics 

• QMExecution (NG-DMIS) 

Product Definition w/PMI 

• PDPMI 

We make products for national security. 

• Common Quality Data Framework 

• Ensuring Interoperability betwee Standards 

• XSD Schemas Files for 

• Characteristic Aspects Type

• Characteristic Types 

• Constructed Feature Types 

• Feature Types 

• Measurement Devices 

• Part Types 

• Primitive Types 

• QIF Types 

• Traceability 

• Transforms 

• Units 

• Support QIF Application Models 

• Benefits 

• Avoid Multiple Definitions 

• Avoid Conflicting Definitions 

• Eliminate Point-to-Point Harmonization and Mapping with other specs. 

QIF Library 

en Standards 

es 

CAT CT CFT FT 

MD Prt PmT QIF Trcb 

Trns Unt 

QIF 

Library 

Metrology Requires Features 

QIF Feature Types 

QIF Feature DMIS Equivalent QIF Feature DMIS Equivalent 

Arc ARC (format 1) Line LINE 

Attribute OBJECT (possibly) Pattern PATERN 

Circle CIRCLE Plane PLANE 

Composite PointDefinedCurve GCURVE 

Compound COMPOUND Point POINT 

Cone CONE PointDefinedSurface GSURF 

ConicalSegment CONRADSEGMNT Slot2D CPARLN 

ExtrudedCrossSection no equivalent Slot3D PARPLN 

Cuboid RCTNGL Slot3DWithDraft SYMPLN 

Cylinder CYLNDR Sphere SPHERE 

CylindricalSegment CYLRADSEGMNT SphericalSegment SPHRADSEGMNT 

EdgePoint EDGEPT SurfaceOfRevolution REVSURF 

Ellipse ELLIPS ToroidalSegment TORRADSEGMNT 

ElongatedCylinder ELONGCYL Torus TORUS 

We make products for national security. 

We make products for national security. 

Tolerances are Characteristics 

QIF Characteristics 

CharacteristicBaseType 

CharacteristicAspectBaseType 

DimensionalCharacteristicAspectBaseType 

AngleCharacteristicAspectBaseType 

AngularCharacteristicAspectBaseType 

LengthCharacteristicAspectBaseType 

LinearCharacteristicAspectBaseType 

GeometricCharacteristicAspectBaseType 

FormCharacteristicAspectBaseType 

LocationCharacteristicAspectBaseType 

OrientationCharacteristicAspectBaseType 

ProfileCharacteristicAspectBaseType 

RunoutCharacteristicAspectBaseType 

UserDefinedAttributeCharacteristicAspectType 

UserDefinedVariableCharacteristicAspectType 

We make products for national security. 

Quality Measurement Pl 

• XML Schema File 

• Standard format for Defining Measurement Requirements (i.e., the 

“whats” that need to be inspected) 

• Identify Measurement Features 

• Their Characteristics (e.g., Tolerances) 

• Criticality 

• Measuring Sequence 

• Scalable 

• Extensible 

Plans 

QMPlans 

Actions 

Whats 

ing Measurement Re 

QIF 

Library 

QMPlans 
 

 

 

 

 

 

We make products for national security.

 

 

We make products for national security.

We make products for national security. 

Quality Measurement Results 

• XML Schema File 

• Standard format for Representing Measurement Results 

• Dimensional 

• Non-Dimensional 

• Point data 

• Fit Features to data 

• Feature Actuals 

• Characteristic Actuals

• Pass/Fails 

QMResults 

s 

QIF 

Library 

QMResults 

We make products for national security. 

Whats 

QMResults 

QIF 

Library 

First Phase of Standardization 

QIF V1.0 

QMPlans 

QIF V1.0 Deliverables 

• QIF Common Library 

• Eleven Schema Files 

• Application Models 

• QMPlans.xsd 

• QMResults.xsd 

• XML Schema (.xsd) files 

• Data Structures & Semantics 

• April, 2013 Completion 

• ANSI Standardization Ballot 

• Future ISO Fast Track 

QIF Standard Parts for ANSI 

QIF Part 1: Overview and 

Fundamental Principles of QIF 

QIF Part 2: Library Data Model, 

Data Structures and Semantics 

QIF Part 3: QMPlans Application 

Data Model, Data Structures 

and Semantics 

QIF Part 4: QMResults 

Application Data Model, Data 

Structures and Semantics 

Validation thru Demonstrations 

Use Case #1 

We make products for national security. 

FAI 

Whats 

QMResults 

IMTS 2012 QIF Demonstration 

QMPlans & QMResults 

Model-Based QMPlans

Definition 

DME 

ts 

DMIS 

ats 

DM 

QIF 

Library 

Measurement 

Results from the DME 

Key Characteristics 

“whats” from the 

Plan to the FAI 

Execution Program to drive 

the CMM DME to validate the 

“whats” from the Plan 

Plan the Measurement Criteria 

“whats” from the Model 

Definition’s Part Tolerances 

as Key Characteristics 

Wha 

Results Match 

with the Plan 

We make products for national security. 

QIF Use Case #1 Demo 

IMTS 2012 Participants 

• Honeywell FM&T 

• PAS Technology 

• Mitutoyo America 

• DISCUS Software 

• Renishaw 

• IPI Technology 

• with 

• MTConnect Institute 

• NIST 

• Lockheed Martin 
 

 

 

We make products for national security. 

Multivendor Interoperability

Output and Input of QMPlans 

Mitutoyo 

America 

Honeywell 

FM&T 

Mitutoyo 

America 

PAS 

CMM 

IPI 

Solutions 

IPI 

Solutions 

QMPlans XML format 

MTConnect 

Institute 

Origin 

Internat’l 

We make products for national security. 

QMPlans from KCP’s FBTol 

We make products for national security. 

Multivendor Interoperability 

Output and Input of QMResults 

Mitutoyo 

America 

Renishaw Mitutoyo 

America 

IPI 

Solutions 

PAS 

Technology 

QMResults XML format 

MTConnect 

Institute 

Origin 

Internat’l 

DISCUS 

Software 

IPI 

Solutions 

We make products for national security. 

Press Release 

Quality Community Impressed with QIF Interoperability 

Demonstration at IMTS 2012. 

At the IMTS 2012 Show, the DMSC, Inc. successfully 

demonstrated the generation and population of an 

AS9102 First Article Inspection form as their first use case 

for the exchange of quality data via the emerging Quality 

Information Framework (QIF) national standard. 

We make products for national security. 

QMResources 

QIF 

Library 

QM 

Resources 

Quality Measurement Resources 

• XML Schema File 

• Standard format for Defining Measurement Resources 

• Supports QMPlans w/Methods 

• Measuring Equipment 

• Sensors 

• Rotary Tables 

• Work Centers 

We make products for national security. 

QM 

Rules 

QMRules 

QIF 

Library 

Quality Measurement Rules 

• XML Schema File 

• Standard format for Defining Measurement Rules 

• Supports QMPlans w/Methods 

• Point Measures 

• Resource Selections 

• Sampling Techniques 

• Algorithms 
 

 

s 

 

Pr

 

 

 

 

 

 

 

 

s

We make products for national security. 

Quality Measurement Plans 

•XML Schema File 

•Standard format for 

Defining Measurement Process (i.e., the “hows” it to be inspected) 

•Assigns Resources 

•Applies Rules 

•Measuring Sequence 

•Dimensional & Non-Dimensional 

•Setup 

•Algorithms 

QMPlans 

Methods 

Whats 

QMPlans 

How 

QM 

Rules 

Hows 

QM 

Resources 

t P (i th “ 

Whats Hows 

Res 

QIF 

Library 

We make products for national security. 

QMStatistics 

QM 

Statistics 

QMResults 

cs 

QIF 

Library 

Quality Measurement Results 

• XML Schema 

• Standard format for 

Analyzing Multiple Part Inspections 

• Quality Control 

• Identify Trends 

• Assess Performance 

• Judge Quality and 

• Efficiency of Processes 

• Trace Anomalies 

• Provide Feedback 

• Improve Production 

We make products for national security. 

MBQM Critical Requirements 

• Fully Semantic Product Tolerance Representation 

• Domain Specific Shape Features 

• Digital Interoperability Standards 

• Product Definition Plus PMI 

• Quality Information Framework 

• Dimensional Metrology Standards Consortium 

• MBQM Workflow 

• Validation & Demonstration 

• Measurement Results 

• Dimensional 

• Attribute 

• Metrology Resources 

• Measurement Rules 

• Process Plans 

• Part Programs 

• Non-Dimensional 

• Real-Valued 

We make products for national security. 

oduct Definition w/ Product Manufacturing Information 

• Native CAD + PMI 

• STEP AP242 

PDPMI 

Pro 

Model-Based 

Definition 

QIF 

Library 

• XML Schema Files (via Newly Proposed DMSC/Capvidia MoU) 

• Standard format for Exchange of Product Definition w/ PMI (PDPMI) 

• Product Definition (e.g., Solid Model) 

• Various Conformance Levels of Semantic PMI (GD&T) 

• Easier Use and Implementation 

• Satisfy CAD to Model-Based Metrology Use Case and more.... 

• Satisfy STEP to Model-Based Metrology Use Case and more.... 

We make products for national security. 

Issue Statement 

Quality is a customer requirement and it is not optional. 

Unfortunately, even with the successful emergence of modelbased definition, our Metrology Community has not 

realized the benefits promised by this investment. 

Two primary contributions: 

• Standard digital interoperability needs of the community 

as being addressed by the QIF. 

• Successful exchange of model-based product definition 

along with PMI data in a cost effective standard-based 

manner, as being addressed by proposed MoU. 

• CAD Data via XML 

• STEP AP242 via XML 

We make products for national security. 

Statement of Intent 

• Pursue a Memorandum of Understanding (MoU) for collaborative 

development work. 

• DMSC – a not-for-profit standards developing consortium 

• Capvidia – a private engineering software developing company 

• Capvidia will donate a set of XML Schemas from their CAP.XML data 

format, which pertains to the rich, mature, and multiple representation of 

3D Model Based Definition with PMI. 

• DMSC Working Group will: 

• Harmonize Contribution with its QIF 

• Progress and Prepare for ANSI Standardization 

• Expected Outcome is an XML-based exchange solution for Product 

Definition plus PMI (PDPMI) that satisfies the Industrial use cases: 

• CAD to Metrology as well as CAD to Manufacturing 

• STEP to Metrology as well as STEP to Manufacturing 
QM

Rules 

Q

s

We make products for national security. 

FAI 

Model-Based 

Definition 

Statistics 

QMResults 

QM

Whats Hows 

DME 

QMPlans 

ts 

QM 

Rules 

QM 

Execution 

(DMIS) 

cs 

ats Hows 

QM 

Execu 

QM 

Wha 

QIF 

Library 

QM 

Resources 

DMSC’s QIF LifeSaver Slide 

XML Schema 

E-3327 IMTS 2012 

Presented by: Ronald Branch, Product Manager 

Model Based Inspection: Leveraging Model Based 

Definition for Quality Assurance 

Definition of MBD 

Model Based Definition(MBD) also known as digital product 

definition (DPD), is the practice of using 3D digital data (such as 

solid models and associated metadata) within 3D CAD software 

to provide specifications for individual components and product 

assemblies. The types of information included are geometric 

dimensioning and tolerancing (GD&T), component level 

materials, assembly level bills of materials, engineering 

configurations, design intent, etc. By contrast, other 

methodologies have historically required accompanying use of 

2D drawings to provide such details. 

Origins of MBD 

MBD has developed from the globalization of aircraft 

manufacturing and extended product lifecycle of aircraft. In the 

past aircraft companies were vertically integrated and 

manufactured most the aircraft components. Most had large 

machining centers and stretch forming plants, some even had 

their own foundries. 

Origins of MBD 

Today major OEM’s are reshaping their business models 

to be that of airframe assemblers and are outsourcing 

part and sub-assembly manufacture across a global 

supply chain. OEM’s realize they need a process that 

will reduce time-to-market and improve product quality 

while communicating all the required design intent. 

OEM 

Tier 1 

Tier 2 Tier 2 

Tier 1 

Tier 2 Tier 2 

NIST - Simon Frechette 

“The central concept embodied in MBD is that 

the 3D product model is the vehicle for delivery 

of all the detailed product information 

necessary for all aspects of the product life 

cycle.” 
Terrence McGowan Boeing Corp. 

• “The 3D model should contain everything 

needed from design to manufacturing, in 

particular, GD&T.” 

• “The use of a 3D (spatial) process and product 

definition that represents and communicates 

‘purposed’ design intent in 3D form to any 

downstream production and/or consumer 

utilization.” 

Boeing D6-51991 MBD 

A Boeing dataset containing the exact solid, its 

associated 3D geometry and 3D annotation of the 

product’s dimensions and tolerances to specify a 

complete product definition. This dataset does not 

contain a conventional 2D drawing. 

Model Based Definition provides a single-source of 

definition, and it reduces conflict between CAD and 

paper drawings 

MBD Implementation Levels Value of MBD 

• With authority bestowed on the model, MBD will: 

– Eliminate errors that result from referencing an incorrect 

source. 

– Make processes more efficient—no more searching to 

determine correct revision levels. 

– Eliminate outdated drawings floating around the 

manufacturing floor. 

– Eliminate discrepancy between the CAD model and 2D 

documentation. 

Courtesy of Model Based Enterprise 

Goals of MBD Companies Less Profitable using 2D Drawings. 

• Accelerate time-to-market ( Reduce the 

Manufacturing lead times.) 

• Decrease time and expense ( Reduction 

in wasted manpower, more certainty on 

the shop floor, reduction of scrap and 

less time waiting for answers.) 

process. 

• Improve quality ( Better and Quicker 

answers and more involvement 

throughout the whole manufacturing 
s

 

Lean concept for Six Sigma Inspection 

• TIMWOOD – The 7 Wastes 

• Transportation – Are you moving parts to/from inspection? 

• Inventory – Is your inspection work in progress high? 

• Motion – Do inspection people and equipment move

efficiently? 

• Waiting – How much lag time is there between inspection 

steps? 

• Overproduction – Are inspections taking to long? 

• Over-processing – Do you inspecting too many times or 

inefficiently? 

• Defects – Are you making inspection mistakes and are you

catching mistakes? 

Lean Inspection Practices 

• Eliminate drawing waste with Adoption of 

Model Based Inspection Methods 

– Drawing creation (2-6 hours) 

– Drawing paper and printing (1-4 Hours) 

– Drawing based inspection (2-10 Hours) 

– Ambiguity or Uncertainty waste (1-100 hours) 

Lean Inspection Practices 

• Eliminate setup and alignment waste by inspecting parts they 

are still in their fixtures (Currently Most Manufacturing Plants 

have Inspection on side of the plant and everyone has to go 

back and forth 30 machines -150 hours/week) 

• Eliminate waste of final inspection dependency (Integrate in 

process inspection into daily activities. Catch possible 

production problem before they get out of hand ????) 

Model Based Definition Broken with 2D Drawings 

Design 

3D Modeling 

Engineering 

3D Simulation 

Manufacturing 

3D Tool Paths 

ng 

Model Based Definition 

• 3D Solid Models 

• CAD Intelligence Utilized 

• Automated Digital Processes 

Model Based Definition Broken 

•Productivity Barrier 

•Quality Data Loop Broken 

•Statistical Improvement Impeded 

Drawing Based Definition 

• 2D Drawings 

• CAD Intelligence Lost 

• Manual Analog Hand Tools 

Inspection Process 2D Verses 3D 

• Traditional Inspection Drawings 

– 2D drafting & blueprint reading 

– Non-Lean, large batch, isolated CMM’s, serial 

processes 

– Stationary CMM inspection technology 

– 100% inspection 

• Modern Inspection MBI 

– 3D Model based definition & inspection 

– Lean inspection processes 

– Affordable portable inspection technology 

– Key characteristics inspection 

Benefits of Model-Based Measurement and 

Inspection 

• No 2D Drawings 

– Cost and time eliminated 

– Contradictions removed 

• Automated inspection planning 

• Automated report formatting 

• Accuracy 

– All features included in plan 

– No interpretation errors 

– GD&T rule checking 

– No data entry errors 

• Prompted inspection procedures 

• Live, graphical measurement 

display 

• Automated reporting 

– No data entry 

– No manual calculations 

• Only basic skills needed 

• Eliminate CMM overhead (PCMM) 

– No fixtures 

– No part set-up 

– No programming 

– No manual data recording 
 

Companies More Profitable with 3D MBD 

Design 

3D Modeling 

Engineering 

3D Simulation 

Manufacturing 

3D Tool Paths 

Inspection 

3D Profile 

3D Statistical Quality Improvement 

Model Based Definition 

• 3D Solid Models 

• CAD Intelligence Utilized 

• Automated Digital Processes 

Model Based Definition Extended 

•Productivity Improved 

•No 2D Drawing Waste 

•3D Quality Data Loop Closed 

Model Based Inspection 

• 3D Profile with Tolerances 

• CAD Intelligence Utilized 

• Automated Digital Process 

Model Based Definition Extended 

MBI Software Needed Capabilities 

• Intuitive 3D CAD/CAM interface 

• Import and inspect to any 3D CAD model 

• Import or define MBD and GD&T 

• Colorful graphical results display 

• Concise inspection reports 

• Repeatable automated inspection plans automation 

MBI using MBD (3D GD&T) 

• Import MBD 

• Create MBD 

• Align to MBD 

• Inspect to MBD 

• Report to MBD 

MBI Software Interpretability 

• CATIA – Dassault 

• UG - Siemens 

• Pro/ENGINEER - PTC 

• SolidWorks - Dassault 

• Inventor - Autodesk 

• SolidEdge - Siemens 

MBI Graphics Display 
MBI Inspection Process (3 Steps) 

1 

2 3 

MBI Types Of Inspections 

• On Machine 

• In Process 

• First Article 

• Incoming 

• Final 

MBI Inspection On The Machine 

• Check Set-ups 

• Maintain Alignments 

• Fast First Articles 

Leveraging Model Based 

Inspection for QA. 

PEOPLE 

3 COMPONENTS TO LEVERAGE MODEL 

BASED INSPECTION 

PROCESS TECHNOLOGY 

People 

• Aging Workforce 

• Developing New Talent 

• Diminishing Supply of Manufacturing Skilling 

• Personnel is key to remaining competitive 

• Keeping workforce current with Rapidly Changing Technology 

Process 

• Requirements for daily operations 

• Assures Constancy, Predictable and Traceability 

• Frequently an Auditable Requirement 
 

 

Technology 

• Non Contact (Laser Scanning, White Light, etc..) 

• PCMM Improved Accuracy and Capabilities 

• Imbedded 3D GD&T(MBD) 

• Rapidly Changing Technology 

Predictions 

• 3D Global Supply Chains 

• Elimination of 2D Drawings 

• STEP AP242 Will Enhance Interoperability 

• Increased Noncontact Inspection & 3D 

Scanning 

• Cloud Based Inspection Databases 

• SPC of Key Characteristics 

SpaceX – MBI Company 

“Verisurf metrology software is doing its part in maintaining 

precision in the shop and on the launch pad. We use it for 

everything from tooling fabrication to pre-launch preparation” - 

Larry Mosse, Tooling Operations Manager 

Coast Composites – MBI 

“Verisurf and the laser tracker has allowed us to perform all the QA tasks 

we need to make our customers happy. The model tells you where it wants 

a hole or a part to be assembled and works perfectly to help us locate 

points on the mold to set details brackets, holes, you name it“ – Steve 

Anthony 

Vought – MBI 

“With Verisurf, we set up our laser trackers, take our 

measurements and get on the spot analysis comparing the real 

product against the solid model. This gives us an instant and 

graphical error report”. “We evaluated several software packages, 

and decided Verisurf was best suited for our needs” - Angel Diaz 

AIT – MBI 

“ To say AIT utilizes Verisurf X metrology software would be an 

understatement; AIT relies on Verisurf for virtually every aspect of our 

development and production workflow,” Kempen, Quality Manufacturing 

Systems Manager, AIT. 
 

2012 MBE Summit 

US Navy – MBI 

“We’re trying to efficiently and effectively implement 3D MBI into the Navy 

system and Verisurf has been very helpful to us in that effort. Our goal is to 

keep US Navy F-18’s flying, and Verisurf is a big help.” Gabe Draguicevich, 

Engineering Technologist NAVAIR Advanced Measurement Systems and 

Reverse Engineering Lab 

Devices used for MBI 

Questions & Next Steps 

1. Contact Ron Branch 

1. Phone: 714-970-1683 ext. 136 

2. Email: ron.branch@verisurf.com 

2. Learn about Verisurf www.verisurf.com 

3. Visit our Booth E-3327 

Verisurf Corporate Overview 

• Verisurf Software, Inc. is a software development company 

located in Anaheim California 

• Industries Served - Aerospace, Defense, Energy, Automotive, 

Heavy Equipment, Biomedical 

• Applications - Manufacturing Inspection, Tooling Fabrication, 

Mold Making, Reverse Engineering 

• Worldwide distribution through Mastercam Resellers 

Born in Aerospace but Diversified Well Beyond 

2012 Model Based 

Enterprise Summit 

The Digital Future Today 

1 

Using open CAD formats 

to bridge the gap between 

today’s and tomorrow’s 

standards 

CAPVIDIA 

Tomasz Luniewski 
 

Geometry Topology PMI (GD&T, FT&A) Attributes

Model Based Enterprise (MBE)

• Multi-CAD/CAM/CMM environment

• Standards

 

 

 

• Founded in 1994 (Belgium, Russia, USA, China, Japan) 

• Development of engineering software applications 

• CAD data translation and CFD services 

• 80 programmers & engineers (20% PhD) 

• Name reflects company activities 

Cap – capturing 

Vidia – knowledge (Sanskrit) 

Applications Areas: 

• 3D CAD data translation, validation, quality assessment 

• CFD simulations - FlowVision 

CAPVIDIA Model Based Definition (MBD) 

Standards 

Realization 

Formats 

Standards Today 

CAD System 

• DIN 

• JSO 

• ASME Y14.5 

• Etc. 

• Kernels ( Manifold, Non-Manifold) 

• Entity Definitions (Analytical, NURBS, Bezier) 

• Tolerance (Absolute, Relative) STEP, IGES, Native 

Methods: Free Surface, Solid BREP 

Standards 

Realization 

Formats 

Standards 

Realization 

Formats 

CAD A CAD B 

CAD systems cmpability 

How to 

bridge this 

gap? 

Interoperability Today 

3D CAD visualization 

• 3DXML 

• 3DPDF 

• JT 

• STL, VRML, etc. 

3D CAD data exchange (native CAD formats, STEP, IGES) 

• IGES, STEP - 3D Geometry/Metadata non semantic 

Work in progress 

• STEP AP242 - 3D Geometry/Metadata semantic and non semantic 

• STEP P28 - Data in xml format 

MBE Challenges 

Exchanging 3D geometry with metadata keeping semantic relations 

as they are defined in native CAD system 

Provide open/standard based data exchange mechanisms for 

mainstream and downstream applications, production processes 

and long term archiving 
How to 

bridge this 

gap?

 

 

 

 

 

 

 

 

 

 

 

 

Solution 

Standard 

Realization 

Formats 

Standard 

Realization 

Formats 

CAD A CAD B 

CAP 

XML 

Entity List 

Capvidia 

Kernel 

PRO/E 

KERNEL 

Entity List 

CATIA V5 

KERNEL 

Entity List 

PARASOLID 

How we handle different native CAD data 

• Based on Capvidia’s Geometry Kernel 

• Design to capture data structures from all 

CAD systems 

• Maintains Original Data Entity Definition 

for each Kernel 

CAP XML 

CAP XML Structure/Schemas 

NAS6606D27.CADPart 

(Native Format) 

CAP XML schemas 

CAP XML Structure/Schemas 

NAS6606D27.CADPart 

(Native Format) 

CAP XML format 

CAP XML Structure/Schemas 

CAP XML format - Topology 

CAP XML Structure/Schemas 

CAP XML format - Geometry 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

Face 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Parametric Parametric

 – 

CAP XML Structure/Schemas 

CAP XML format - Attributes 

In addition to the standard attributes a third part application can specify an arbitrary "custom" 

attribute (AttributeUser). 

CAP XML Structure/Schemas 

CAP XML schemas - Constrains 

Using constrains in the xsd-schemas allows to specify certain 

restrictions on the values of the element (or attribute) and to 

establish a correct relationship between elements. 

• BlockRoot – Layer 

• BlockRoot, Block, Subfigure – Block, Subfigure, 

SubfigureInstance, Brep 

• Brep – Shell, Face, Loop, Edge, Vertex 

• Shell – Face 

• Face – Loop, Surface 

• Loop – Edge, Curve12 

Face 

Surface 

Loop 

CAP XML Structure/Schemas 

CAP XML schemas - validation example 

Face must be connected with surface: 

Face/Surface/Id -> SurfaceSet/*/@id 

Error: Face 175 is connected with an entity 

1162 which is not presented in the 

SurfaceSet 

Surface

Loop 

1162? 

Surface 

CAP XML format - PMI Metadata 

• Roughness – roughness 

• GTol – geometric tolerance 

• Text – text annotation 

• FlagNote – flag note 

• Datum - datum 

• DatumTarget – datum target 

• Dimensions: 

• DimAng - angular dimension 

• DimLin – linear dimension 

• DimRad – radial dimension 

• PartNote – part notes and standard notes 

CAP XML Data Format 

<DirectRefs Number="1"> 

<Face id="5569"/> 

</DirectRefs> 

<BackRefs Number="2">5737 5738 

</BackRefs> 

References/Semantics in CAP XML 

<Model> 

<Header> 

</Header> 

<Scene> 

Topology objects 

Geometry objects 

• Points 

• Curves 2d 

• Curves 3d 

• Surfaces 

• Transformation 

Auxiliary objects 

Relations 

Features 

Metadata 

• Text – text annotation 

• FlagNote – flag note 

• Roughness – roughness 

• Datum - datum 

• DatumTarget – datum target 

• GTol – geometric tolerance 

• DimAng - angular dimension 

• DimLin – linear dimension 

• DimRad – radial dimension 

Triangulation 

Wire-Frame 

CMM 

</Scene> 

<Brep id=”123” ...> 

<Shells> 

<Shell ...> ... </Shell> 

</Shells> 

<Faces> 

<Face id=”34”/> 

</Faces> 

</Brep> 

<Face id=”10” ...> 

<DirectRefs ...> 

<Nurbs23 id=”100”... > 

<BackRefs Number=”2”>1012 

</BackRefs>

 </Nurbs23> 

</DirectRefs> 

</Face> 

<Face id=”12” ...> 

<DirectRefs ...> 

<Nurbs23 id=”100”/> 

</DirectRefs> 

</Face> 

Triangulation 

Wire-Frame 

CMM Points 

Metadata 

<Points "> 

30612.634628846 -1269.21177250052 6666.02342780258 

30612.6119637385 -1269.21823690379 6665.35717922205 

30612.5892986309 -1269.22470130706 6664.69093064152 

30612.5666335234 -1269.23116571033 6664.02468206099 

</Points> 

CAP XML support of mixed model definition 
 – 

 

 

 

 

 

CATIA V5 

CATIA V4 

UGS 

SIEMENS NX 

PRO/E 

PRO/E Creo 

CAPVIDIA XML 

3D TransVidia 

CAP XML support of mixed model definition Integration with CMM software 

Benefits CAP XML: 

• Open XML format 

• Human and machine readable 

• Flexible and easy to extended 

• Used for over 10 years in Capvidia applications 

• Covers well all CAD systems structures 

• Compact 

• Bi-directional compatibility with STEP 242 

Summary DMSC, Inc. 

Model-Based Predictive Technologies for 

Dimensional Measurement 

Jon M. Baldwin 

Managing Partner 

MetroSage LLC 

©Copyright 2012 by MetroSage LLC 

Outline 

• What current model-based measurement 

planning (MBMP) does well. 

• What current model-based measurement 

planning sometimes does. 

• What model-based measurement planning 

could do well if it applied some existing 

technologies. 

©Copyright 2012 by MetroSage LLC 
What MBMP Does Well 

• Enables partial concurrent measurement 

process planning. 

• Enables “reasonable” measurement 

sequencing. 

• Generates collision-free probe path. 

• Facilitates sensor orientation selection. 

• Somewhat automates probing point 

placement. 

©Copyright 2012 by MetroSage LLC 

What MBMP Sometimes Does 

• Provides input and attachment of non-shape 

information (GD&T). 

• Performance is extremely variable. 

– Dependent on user skill. 

– GD&T rules are often not well-enforced (if at all). 

– Measurement features are often not well defined. 

– GD&T attachment is often not robust. 

– Transfer between modeling systems can be 

problematic 

. 

©Copyright 2012 by MetroSage LLC 

What MBMP Does Not Do 

• Validate GD&T (complete, syntactically & 

semantically correct, non-redundant). 

• Produce a measurement plan that is 

guaranteed to demonstrate traceability. 

• Produce a measurement plan that is in 

any respect proven to be optimal. 

©Copyright 2012 by MetroSage LLC 

Tools to Alleviate These Issues 

• Tolerance Scheme Validation 

• Measurement Uncertainty Evaluation 

• Cost of Measurement & Product 

Profitability Estimation 

• Measurement Plan Optimization 

©Copyright 2012 by MetroSage LLC 

GD&T Validation 

©Copyright 2012 by MetroSage LLC 

Measurement Uncertainty Evaluation 

In addition, GD&T parameters measured on a CMM are often highly correlated 

and exhibit non-normal distributions. 

©Copyright 2012 by MetroSage LLC 
 

 

 

 

 

 

 

Motivations for Knowing 

Measurement Uncertainty 

©Copyright 2012 by MetroSage LLC 

Strengths of Model-based 

Simulation Methods 

• Can be applied to any part for which we have a 

model. 

• Can simultaneously evaluate many GD&T 

parameters in one “experiment”. 

• Does not require knowledge of measureand 

interactions. 

• Detects both measurement bias & variability. 

• Predictive 

• Economical 

©Copyright 2012 by MetroSage LLC 

Example: Choosing the Right CMM 

©Copyright 2012 by MetroSage LLC 

Example: Choosing the Right CMM 

B89.4.1 Performance Test Data from Manufacturer’s Data Sheets 

©Copyright 2012 by MetroSage LLC 

Example: Choosing the Right CMM 

Conclusions: 

None of the CMMs meet the 

10:1 Rule for the 

measurement task of 

interest. 

Based on the 4:1 Rule: 

CMM D is clearly inadequate 

CMMs B & C are questionable 

CMM A meets requirements 

4:1 Rule 

Results 

©Copyright 2012 by MetroSage LLC 

Measurement Risks and Costs 

• There are two kinds of risk, each with an 

associated cost, associated with measurement 

errors. 

– There is a risk, D, and an associated cost of 

incorrectly classifying a good part as bad on the basis 

of a measurement error (Type I error). 

– There is a corresponding risk, E, and cost of 

incorrectly classifying a bad part as good on the basis 

of a measurement error (Type II error). 

©Copyright 2012 by MetroSage LLC 
 

 

 

 

 

 

0.002 0.004 0.006 0.008 0.01 

Measurement Error Costs 

 Cost of a Type I error: 

– Cost of processing the item 

– Costs of reworking or discarding the item 

– Cost of un-needed process corrections 

 Cost of a Type II error: 

– Cost of correction if discovered later in process 

– Costs if shipped to customer 

 Replacement cost 

 Cost of warranty pool 

 Loss of reputation or good will 

 Lawsuits 

©Copyright 2012 by MetroSage LLC 

Production & Measurement 

LOSS 

LOSS LOSS 

PROFIT 

©Copyright 2012 by MetroSage LLC 

Economics of Measurement 

Factors for Consideration: 

• Production Process Capability 

• Measurement Process Capability 

• Cost of Production 

• Cost of Measurement 

• Cost of Rejecting a Good Part (Type I Error) 

• Cost of Accepting a Bad Part (Type II Error) 

• Selling Price 

• Loss Function 

©Copyright 2012 by MetroSage LLC 

Economics of Measurement 

Optimized Guardband 

Depends on Loss Ratio of 

Type II/Type I Errors 

I More stringent acceptance More relaxed acceptanceJ

Risks of Type I & Type II 

Errors Depend on Cp, Cm & 

Guardbands 

Table data for 1000 

units 

©Copyright 2012 by MetroSage LLC 

Truly Optimized Measurement 

Processes – Production Bias 

150 

160 

170 

180 

190 

200 

210 

220 

230 

240 

0 0.002 0.004 0.006 0.008 0.01 0.012 

Profit 

Bias - Hole Diameter 

©Copyright 2012 by MetroSage LLC 

Profit 200 

150 

100 

50 

0 

0 

-50 

-100 Guardband 

Truly Optimized Measurement 

Processes - Guardbanding
	

0.012 

©Copyright 2012 by MetroSage LLC 
product lifecycle management (PLM) is the 

process of managing the entire lifecycle of a 

product from its conception, through design 

and manufacture, to to 

service and disposal. PLM integrates people, 

data, processes and business systems and 

provides a higher product quality , cost 

reduction and expedited delivery time for 

companies and their extended enterprise. 

QA is integral part of PLM 

 

 

 

 

, 

quality assurance,

Model Based Definition 

Enables 

Inspection Lifecycle Management 

Sam Golan 

President & CEO 

PAS TECHNOLOGY 

November 2012 

DMIS Compliant QIF Compliant PLM – product lifecycle management 

product lifecycle management (PLM) is the 

process of managing the entire lifecycle of a 

product from its conception, through design and 

manufacture, to service and disposal. PLM 

integrates people, data, processes and business 

systems and provides a product information 

backbone for companies and their extended 

enterprise. 

product lifecycle management (PLM) is the 

process of managing the entire lifecycle of a 

product from its conception, through design 

and manufacture, to service and disposal. PLM 

integrates people, data, processes and business 

systems and provides a product information 

backbone for companies and their extended 

enterprise. 

PLM – the “how” 

product lifecycle management (PLM) is the 

process of managing the entire lifecycle of a 

product from its conception, through design 

and manufacture, to service and disposal. PLM 

integrates people, data, processes and business 

systems and provides a product information 

backbone for companies and their extended 

enterprise. 

PLM – the “results” 

product lifecycle management (PLM) is the 

process of managing the entire lifecycle of a 

product from its conception, through design 

and manufacture, to service and disposal. PLM 

integrates people, data, processes and business 

systems and provides a higher product quality 

cost reduction and expedited delivery time for 

companies and their extended enterprise. 

PLM – the practical “Backbone” 

(A non “IT definition”) 
 

quality assurance,

 

 

The 787 outsourcing challenge for QA 787 Dreamliner 

quality cost 

“Boeing outsourced production around the world, 

but that caused quality problems and delays that 

sent the $5 billion development costs soaring - by 

some estimates to more than $30 billion. 

The first plane was delivered three years late, and 

those delays cost Boeing 160 orders. 

"There's no question you lose credibility with your 

customers," said Randy Tinseth, vice president of 

marketing for Boeing commercial airplanes. 

product lifecycle management (PLM) is the 

process of managing the entire lifecycle of a 

product from its conception, through design 

and manufacture, to to 

service and disposal. PLM integrates people, 

data, processes and business systems and 

provides a higher product quality , cost 

reduction and expedited delivery time for 

companies and their extended enterprise. 

A real integral part of PLM? 

The inspection challenges 

How long it takes to generate a CNC program 

for this part in the PLM world? 

3-5 hours to 

How long it takes to generate a CMM program 

for this part ? 

18-25 hours 
 

Why CMM program takes 5 time 

longer than CNC program? 

Because it is not part of PLM? 

Can it be? 

Can this process “integrates”? 

1. Inspection starts with translated model (IGES\STEP) with blue print 

2. Manual ballooning on drawing or PDF 

3. Model & Drawing requires Interpretation for inspection program 

4. Inspected feature’s selection 

5. Annotations (dimensions, tolerance, datum, construction) 

6. Parameters 

7. Manual collision detection & prevention 

8. Engineering change control 

9. Non standard communication to CMM machines 

10. Manual reporting (FAI) with home grown excel (for the most part) 

11. Trusted results 

Root cause samples 

• The process requires vertical (machine\software) CMM

programming expert (non standardization) 

• Programming and reporting is time consuming associated

with manual labor intensive, interpretation and potential

human errors (Delivery time, cost and quality) 

• Lack of completeness and integrity due to “broken links” in

the process (integrated) 

• The industry in general is missing quality assurance data

exchange standardization (translation, interpretation, 

delivery time, cost...) 

A quote from aerospace supplier 

“As companies receive more and more MBD (model 

based definition) and the parts get physically bigger, 

the task of both inspecting the parts and controlling the 

manufacturing process grow by at least an order of 

magnitude. Programming the CMM in xxxxxxx no 

longer takes a day, now it takes a week, and then it 

takes another week to prove out and understand the 

part results. Then how do you guarantee that you have 

checked all the features when you programmed 

manually?” 

ILM – Inspection Lifecycle management 

as an integral part of PLM 

 From any native CAD model to trusted 

inspection results with no translation, no 

interpretation and no data entry once 

entered 

ILM process example – model & drawing stage 
Automated ballooning and part inspection requirements 

analysis 

(eliminating user inspection interpretation) 

CAD model validation having all needed inspection 

information 

CAD model converted with all required inspection 

information including views and balloons Creating inspection planning “package” electronically 

Part inspection completed in minutes as all required 

information converted from the CAD model 

Inspection planning & results directly from the CAD model 

and from any CMM machine or other inspection tools. 
 

 

 

 



ȋȌ-



, 2012 December 12th

MBE Summit – NIST Gaithersburg, MD 

Presented at: 

Phone: (256) 655-6703 

Email: paul.gilll@nasa.gov 

Paul Gill 

ILM can be an integral part of the PLM 

inspection results 

than hours ...or days with trusted 

(including FAI) in minutes rather 

Inspection program & reporting 

First Article Inspection report in one click.. 

suns 

dark matter, planets around other 

holes, the big bang, dark energy, 

• Astrophysics: Stars, Galaxies, black 

Solar System, Small Bodies 

• Planets: Inner Solar System, Outer 

Environment 

magnetospheres, Space 

• Heliophysics: Heliosphere, 

Composition 

Surface & Interior, Atmospheric 

Climate Variability & Change, Earth 

Ecosystems, Water & Energy Cycles, 

• Earth: Weather, Carbon Cycle & 

and space exploration for society 

discovery; and reaps the benefits of Earth 

universe beyond; charts the best route of 

Explores the Earth, solar system and 

Science 

managing traffic congestion) 

System (increasing safety and 

• Next Generation Air Transportation 

• Green aviation 

have practical applications on Earth 

that improve our ability to explore and which 

Pioneers and proves new flight technologies 

Aeronautics 

Century Ground Operations 3

st • 21

• Space Launch System 

• Multi-Purpose Crewed Vehicle (Orion) 

• International Space Station 

low Earth orbit 

operations and human exploration beyond 

Focuses on International Space Station 

Human Exploration and Operations 

2 

inspection results. 

manufacturing to inspection to trusted 

quality assurance process from design to 

automates and manages the entire integrated 

Inspection lifecycle management (ILM)
 

 

 

Typical capabilities that were explored in each of these areas 

Benchmarking: 

 ȋȌ

• JSC Engineering

• JPL

• And two internal 

• Pratt &Whitney Rocketdyne – Canoga Park, California 

• Lockheed Martin –Space Systems Company – Littleton, Colorado 

• Lockheed Martin Joint Strike Fighter – Fort Worth, Texas 

• Ford Motor Company – Detroit, Michigan 

• Whirlpool Corporation – Benton Harbor, Michigan 

• ATK – Brigham City, Utah 

• Benchmarking-- The following companies were benchmarked : 

architecture 

• Improve product quality and success through use of a model-centric 

• Inform/train invigorate workforce on model-centric architecture 

architecture 

centers and external partners through use of a model-centric 

• Achieve interoperability within and among programs/projects, 

• Increase affordability through use of a model-centric architecture 

-

• Configuration Management for Complex Hybrid Products 

• Acquisition and Contracting Practices 

• Records Retention and Archiving 

Areas Needing More Attention 

practice 

• Moving away from Document-Centric engineering 

• Parsing the Modeling & Simulation Territory 

release exchange 

• Cross-mapping of model maturity states to support preAreas We Are Looking At 

• Product Data Management & Interchange 

• NASA Integrated Model-centric Architecture (NIMA) 



• Reuse of design data for new products 

operational environment are more significant) 

• Lifecycle cost optimization due to product design (special purpose needs and 

• hŶŝƚĐŽƐƚƌĞĚƵĐƚŝŽŶ;ƚLJƉŝĐĂůůLJŵĂŬĞчϯŽĨĂĚĞƐŝŐŶͿ

• Manufacturing or Supply Chain Coordination (due to low rates) 

What Does NOT Drive NASA’s MBE Work 

Modeling & Simulation, CAD Interoperability, PDLM) 

• Discipline-focused Working Groups converging on similar issues (e.g., MBSE, 

(e.g., from Ares) 

• New insights into the flow of data within Engineering and downstream activities 

issues 

• Columbia Accident Investigation Board Report specifically pointed to product data 

• NASA has pioneered several specialized engineering technology advances (e.g., FEA) 

• Past Experience 

• Systems Integration 

• Systems Engineering 

• Conceptual Engineering 

• Very low volumes of complex products 

• Nature of work is dominated by Developmental Engineering 

ǯ

• Vehicle Acceptance (e.g., SRBs arrive at KSC) 

• Systems Integrations (e.g., science payload on ISS) 

and production) 

• Insight & Oversight (e.g., for fully-outsourced development 

• Prime Contractor Interfaces 

• Concept Development & Proposal Reviews 

External Activities Related to MBE 

Anomalies) 

• Post Event Analysis and Review (e.g., CAIB, In Flight 

• Some Prototyping and Test Article production 

• Flight Operations 

• Vehicle Systems Integration 

• Verification & Validation 

• Systems Modeling & Simulation 

• Developmental Engineering 

Internal Activities Related to MBE 



years ago) 

common approach( e.g., 3D CAD did not exist for Voyager 37 

• Difficult to coordinate change due to timing to converge on any 

• Long product development and operational life cycles 

• Every project negotiates own contracts 

• Extensive dependence on prime contractors 

Interactions between centers tend to be project-specific 

• Different missions but all include engineering of some kind 

• Composed of independent Centers 

ǯƬ

MBSE 

CoP Capabilities/topics explored 

6/19/2013 

Goals: 

6/19/2013 

Associated with Two Initiatives 

6/19/2013 

What Drives NASA’s MBE work? 

6/19/2013 6/19/2013 

6/19/2013 

4 5 

6 7 

8 

-

9 

Motivations/Business Case 

MBSE Vision 

Infusion Strategy & lessons learned 

Implementation 

System Model and Linkages 

Model Data Exchange 

Tools and Standards 

Methodology/framework 

Metrics 

PDLM Managing the product configuration 

Criticality of PDLM to your business 

Use of models for 3D model visualization 

Integration with manufacturing systems 

Ensuring appropriate revision of data 

CAD Electrical and mechanical design tools 

Enabling data exchange 

Use of 2D and 3D 

Tool selection criteria 

Return on investment for tools 

How analysis and simulations can be improved using CAD 

M&S Applications used 

Model reuse 

Simulation environments 

Linking models together 

Visualization 

General Organization layout 

Definition of MBSE, PDLM, CAD, M&S 

Overall process 

use of standards 

How funded 

Tool selection 

Benefits 

Training 
 

 

 

 

 

 

 

 

 

 

 

 

- 

 

 

 

 

Acquisition & Exchange 

Getting Specific: CAD Interoperability Insights for Project Data 

 ǡ ȋǯȌ

(Engine Outer Mold Line Models ) 

Only one (#7) met by NIST 2011 TDP 

Interestingly #2 reflects a bi-directional flow to/from contractor 

#1 corresponds to new MSFC Handbook 

Capturing insights from recent projects like Constellation’s /Ares (next chart) 

design) 

Example -- JPL Collaborative Engineering facility using SE models (concept/preliminary 

MBSE adoption can be found at every Center on different scales/life cycle stages, e.g., 

 ǡ ȋǯȌ

derived from Ares experiences 

• Builds on a pending CAD Interoperability Standard 

and vehicle 

sources together to support vehicle integration 

• Bringing envelope models from multiple design 

for Launch Vehicle Integration “ 

• MSFC Handbook 2644, “Design Product Package 

exchange 

• Building new practices for pre-release CAD data 

Variable progress seen at different scales 

centric changes 

• Funding by project (vs. organization) diffuses leverage to make organizationengineering IT 

• Ongoing disconnect between CIO and Center & Project Engineering on 

• PLM tools “owned” by individual Centers 

New policy impact can be hard to see 

• Needs guidance for acquisition, internal flows of engineering info, etc. 

• PDLM Handbook approval expected <30 days 

• Does not replace Center-standards 

management tools 

• Does NOT expect or encourage projects to provide own separate model 

PDLM NPR is project-focused 

yet) 

• So far, only applied at beginning of projects (e.g., few PDLM plan updates as 

• Basically requires a PDLM plan for significant space flight projects 

• Comes from recognition of major risk on Constellation 

 ǡ 

• Practice is driven by Center-level policies, procedures, handbooks 

“drawing ” 

• For example, may substitute “model” wherever they had 

models 

• Project and Systems engineering policies inconsistent on topic of 

• Projects have a lot of authority to choose their engineering tools 

• Detail design work often outsourced or handled by prime 

• Inconsistent experience with 3D CAD 

• NASA cannot dictate what primes use 

programs like Constellation 

• Tool and architecture selected before 3D CAD and prior to large 

• Ten+ PLM systems at NASA 

progress 

Proliferation of silos and differential learning but some notable 

Ƭ

mapping (More later) 

• Pre-release product data state crossTraining Needs 

• Assessing Workforce Awareness & 

pilots across agency 

• Assembling information on various 

• Developing Concepts of Operations 

Major On-going NIMA Activities 

-ȋcont’d)

• “MBE has many keys to breaking the spiral of cost and schedule overruns” 

• “Leadership must make a solid commitment” 

• “MBE must be used early and often as possible to see the benefits” 

trying to do too much at one time” 

• “Have seen a lot of positive benefits, when there were failures it was due to 

leverage this technology" 

• "You can't afford to do business like you did before. You can't afford NOT to 

seeing positive trends” 

better roadmap to program/project managers for how to cost. We are 

table. Trades were made much easier by having data available. It gives a 

development time by 2/3. It increased reliability without changing the costing 

• “We did a full study alongside an existing study and found it reduced 

Selected Quotes from companies: 

-ȋȌ

6/19/2013 

10 

6/19/2013 

11 

6/19/2013 

12 

- -

6/19/2013 

13 

Agency-level Product Data and Life cycle Management (PDLM) Policy (NPR 7120.9) 

6/19/2013 

14 

- -

6/19/2013 

15 

If we want to: Likely we would need CAD specified like this: 

1. Do design integrations Specific pre-release models to defined (high) accuracy based on negotiated agreement between 

provider and user (e.g., per NASA-STD-0007 or MFSC HDBK 2644) 

2. Sub contract part of 

design work 

To send contractor skeleton files, start parts, approved parts lists....AND receive back from them 

design files, component models, and other elements of product definition package 

3. Take over design 

change authority 

Full design history and 3D CAD models for a given vehicle block, including skeletons, standard parts, 

start parts, drawings, configuration settings, model checking criteria 

4. Conduct design review 3D “viewable” of released models or external alternative representations that support annotations 

5. Do derivative designs 

such as GSE 

Pre-release CAD models from source at defined maturity level treated as “released” by users within 

their own environment with associated metadata 

6. Do modeling and 

simulations 

Pre-release alternative representations with full definition of items significant for modeling and 

simulation and with settings to support conversion to VRML, etc. 

7. Re-bid production Released CAD models, drawings, material specs, manufacturing processes, installation models, etc. 

8. Do physical integration 

& verification (e.g., at 

VAB) 

Released alternative representations or source CAD with appropriate alternative representations 

substitutions with full definition of items at integration point (but lacking internal detail) 

9. Acceptance Data 

Package for physical 

delivery 

CAD need based on defining requirements–who/what/when/how models will be used–to assure that 

they are right lifecycle/maturity state, format, and contain needed content 

- -
 

 

 

 

 

 

Initiative 

Integrated Manufacturing Technology 

Richard Neal 

Model-Based Products 

Some Imperatives for Realizing 

outcomes. 

* Multifinal is defined as the potential for similar initiating factors to result in diverse 

Conclusion: This is an “multifinal” case* with more than one acceptable solution 

action 

Observation: NASA’s very long development and operational cycles shift incentives for 

Conclusion: Engineering and IS need to collaborate to build adaptable “data supply chains” 

• Exchange of engineering models is increasingly a driver for project timing and cost 

solutions 

• Multiple disciplines involved who are accustomed to pursuing their own technology 

Observation: Everybody’s a data supplier and a data customer 

production 

Conclusion: NASA driven more by engineering developmental phases than hand-off to 

• If you are making <3 of something, you can bend some rules 

• Many highly technical domains producing and keeping large data volumes 

• NASA’s project-orientation is an independent source of diversity 

Being complex project-centric with extremely low volumes matters 



ȋǯȌ

• Multiple design and verification cycles 

ignoring huge volumes of engineering data 

• Current focus on “end-of-pipe” design product 

product definition 

• Does not reflect advances in technology of 

centric approaches 

• Moving beyond CM based on document or file-

(HW/SW) Products 

Configuration Management for Complex Hybrid 

not even exist when contract signed 

• Technology to be used for some engineering work undetermined or may 

• Large cost and time impacts associated with contract changes 

• Much data that will be exchanged is not anticipated when contract written 

policies 

• Can NO LONGER rely on referencing exisiting data management and CM 

denominator” formats (e.g. PDF, native CAD, etc.) 

• Few understand the consequences of defaulting to “least common 

• Knowledge gap between technical data users and PM/contracts people 

• Contract language often inappropriately reused 

Acquisition & Contracting Practices 

Webb telescope 

• No universal format or storage medium covering Voyager, Shuttle, and James 

formats originating across decades of development and operation 

• NASA simultaneously (currently 90 active science programs) producing records in 

Records Retention and Archiving 



Center DDMS States Neutral States Supplier States 

State-ȋȌ



• For confidence in Decisions and Reviews 

oversight 

• Significant need for engineering analyzes and 

• Traceability and understanding of changes 

(interoperability – open standards based) 

• Seeking PLM tool independence 

• Many reasons for differences in maturity states 

development 

• Driven by need to exchange models during 

NIMA) 

support pre-release exchange (moving under 

Cross-mapping of model maturity states to 

at:

6/19/2013 

Observation: 

6/19/2013 

Release 

Pending 

Approval 

Workgroup 

Release 

Approval 

Pending 

Design 

Under Review 

In Work 

6/19/2013 

16 

Release for 

Production 

Peer Share 

Group 

Approved 

In Work In Work 

Preliminary 

Under 

Review 

Release 

Pending 

Release 

18 19 

20 
impacts of 

M

 

-

–

–

SOME Imperatives for Realizing ModelBased Products 

• Systems compatible and Resilient 

• Totally Connected and Integrated across the 

product lifecyle 

• Optimized early with clear definition of costs and 

risks 

• Model-based and knowledge rich 

• Collaborative and Secure 

• Drives downstream applications and enables and 

delivers a complete Technical Data Package 

Systems Engineering and Design and 

Manufacturing – Just Personal Observations 

• Systems engineering focuses on how products should be designed 

and managed across their lifecycle. Some discriminators include: 

– Broader view of the acquisition process 

– Driving the emphasis on lifecycle issues, logistics 

– Deals with the complexities of systems – especially large systems 

– Focused on risk, uncertainty, etc 

• A systems view enables optimization across domains, disciplines, 

subsystems, perspectives . . . 

• Obviously, “design and manufacturing” is changing dramatically! 

“Boeing has Learned that Every Design or 

Manufacturing Engineer, No Matter What the 

Discipline, Must Be a Systems Engineer” 

Systems Representation and Modeling 

– Physical, logical structure, behavior, interactions, interoperability... 

Engineered Resilient Systems Key Technical Areas 

Characterizing Changing 

Operational Contexts 

– Deep understanding of warfighter needs, 

alternative designs 

Cross-Domain Coupling 

– odel interchange & composition 

across scales, disciplines 

Data-driven Tradespace

Exploration and Analysis 

– Multi-dimensional 

generation/evaluation of 

alternative designs 

Collaborative Design and Decision Support 

– Enabling well-informed, low-overhead discussion, 

analysis, and assessment among engineers and 

decision-makers 

Domain Coupling 

Operational Co 

Deep understa 

impacts of alte 

Cross 

Mod 

acro 

n Tradespace 

Cross 

From Presentation by Phil Zimmerman 

Totally Connected and Integrated 

across the product lifecyle 

Totally Connected and Integrated 

across the product lifecyle 

• There is nothing new about “moving manufacturing 

forward” 

• We have sought for two decades to drive a concept 

of a totally integrated view of the design and 

manufacturing lifecycle 

• These concepts might provide great historical context 

for moving toward Engineered Resilient Systems 

A Look at Attempts to Communicate this Basic 

Concept Might be Fun – and Instructive? 

The Enterprise 
The TEAM Product Realization model 

Concept Optimization 

Design Optimization Execute 

Workflow models 

Hierarchical simulation 

environment 

Coupled design/manufacturing tools 

Requirements capture 

Parametric tradeoffs 

Visual representation 

of inspection data 

Open-architecture controllers / APIs 

Multi-platform 

Metrology microplanner 

Conventions Manual 

Feature based 

The Integrated Material Removal Demonstration 

Emphasized Internet Based Interoperability--

Characteristics of the NAMII Integrated 

Technology Plan 
–

Enough: What’s the Point? 

• The model-based enterprise must be an 

implementation of a totally connected, integrated 

system of much more than models 

• Everyone is on to the same big ideas, and the 

emerging strategies are similar 

– NNSA – PRIDE 

– ManTech – Advanced Manufacturing Enterprise 

– Systems Engineering – Engineered Resilient Systems . . . 

Concept to Manufacturing and Lifecycle Support is a 

System and Must be Totally Connected and Integrated 

Optimized early with clear 

definition of costs and risks
 

Optimized early with clear definition of 

costs and risks 

• Everyone knows the horrors of cost escalation and time extension 

• Key reasons: 

– Deployment of immature technologies 

– Failure to understand cost and risk early 

• The process starts with what is needed (in DoD terms) and what will sell 

(in commercial terms) 

– Understand the “heart and soul of the user” 

– Understand what could be 

– Understand what is required 

– Break the string of minor variants 

A Rich Assessment and Optimization Environment 

Enables the Unbounded Exploration of the Possible to 

Find the Best Total Value Solutions 

An Example of an Emerging 

Methodology 

The pilot system: 

• Accepts all inputs 

– Requirements 

– Historical costs 

– Lessons learned 

– Rule sets . . . 

• Assesses the risk of cost escalation in a hierarchical structure 

• Leads the user through a cost optimization and risk mitigation 

process 

In Many Cases, Detailed Cost Analysis is not Performed 

Until Detailed Designs are Delivered. The Cost and Risk 

Assessment and Trades Should be Pushed to the Front! 

Select Rotor Assembly 

High Risk of Cost 

Escalation 

Specify Radical 

Changes 

(Material from 

Steel to Ti) 

Conduct 

Research on 

Titanium 

Compressors 

and Turbines 
 – 

Conduct an 

Assessment of Each 

Perspective Defining 

Cost Impacts 

Dispaly 

Rulesets 

Responses 

Automatically 

Build Queries 

Knowledge View Gives the User 

Customizable Reports of Various 

Perspectives Document View Provides 

Hierarchical Access to 

Needed Information 

The Evaluation Process 

• The exclamation icon shows rule sets; the book icon launches 

intelligent search 

• Every perspective is evaluated and cost escalators and deescalators are assigned 

• The costs are rolled up and risks are reassessed with each 

evaluation 

• A hierarchical control structure enables collaboration and 

control of systems, subsystems, and components 

An Evaluation and Optimization of Sub-systems and 

Components that Pose a Significant Risk of Cost 

Escalation with Optimization and Risk Mitigation -

Lower Cost and Assured Affordability 

Model-based and 

knowledge Rich
 
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D 

Product Flow 

Deformation 

Model

Based 

el 

Based 

Enterprise 

ry 

Kinematics 

Con ol 

Physics 

Planning System Models 

D 

Fit 

Machine Motion 

KanBan Trigger Models 

Tolerance 

Interference 

Product Flow 

Deflection, Vibration Analysis 

Auto Data Capture 

Feature Recognition 

Process Optimization Models 

Resource Loading 

Auto Micro Planning 

Auto Macro Planning 

Process Advisors 

Diagnostics 

Prognostics 

Advisors 

Discrete Event Simulation 

Casting Solidification 

Forging Deformation 

Material Removal 

H/T Distortion 

Residual Stress Material Mechanistic Models 

Unified Process Models 

Intelligent Machine 

Performance Models 

Predictive Models 

Decision Advisors 

Algorithms 

Adaptive Control and Learning 

Machine Optimization Models 

Machine Condition Model 

Sensor Data Learning Models 

Non-Geometric Attributes 

Seamless File Exchange 

Closed Loop Sensing Models 

Real Time Dimension Analysis 

Microstructural Models 

Data Storage, Retrieval, & Exchange 

Model

Based 

el 

Based 

Enterprise 

Customer Preferences r Preferen es Captur nces

ms 

Master Product Models & Scripts 

Databases & Knowledge Repository 

Life Cycle

Support 

cle 

rt 

Inspection & sp

Acceptance 

& 

Analysis & ce

Simulation 

Design 

Manufacturi g

& Assembly 

ing 

ly 

Cost Savings, Resiliency, Capability Assurance, 

Time Compression . . . 
 

Not For Public Release

Collaborative and Secure 

Today’s Realities 

• Secure information comes in many views from 

totally open to highly classified. Resiliency 

demands ready and secure access to exactly what 

is needed 

• Individual projects, programs, and organizations 

each have their own IT strategies 

• Unifying information access, project and program 

management in a secure environment will pay 

great dividends 

We Need a Comprehensive Infrastructure for Managing 

the Delivery of Critical Solutions 

Manufacturing Innovation Network (MIN): Cluster 

Manufacturing And Hub Enterprise Concepts Enable Acquisition 

Innovation. 

• MIN is a member-driven, self-forming network and must be 

administered federally to maintain system security and integrity. 

• MIN is the “Enabling Technology” that maximizes collaboration and 

innovation by: 

– eliminating “government and industry silos” 

– establishing the highest level of information security and 

– providing comprehensive connectivity among MIN partners. 

N ot For Public Release 

MIN Pilot Features 

• Provides a platform for acquisition management 

• Provides access to needed systems 

• Assures management of all levels of information

security 

• Places the program manager or designee in the

control position – with broad visibility 

• Enables negotiation and agreement concerning 

access 

• Leverages a national asset in “Your Cloud” 

• Manages supply networks for best results 

Drives downstream 

applications and enables 

and delivers a complete 

Technical Data Package 

Data Input One Time and Growing in Detail and Value 

Conceptual 

TDP 

Manufacturing 

TDP + 
, 

, 

i 

, ,

 

l 

t i l , 

t t

, 

i

, 

, 

 

 

 

Configuration & Change Management 

STEP Modular Architecture (STEPmod) 

Configuration 

Maintained 

MTBF MTTR 

Records, 

Maintenance 

Upgrades 

Spares

Support 

Operations & 

Orders 

Schedules, 

T mes, 

Buffers, Lead 

Network 

Supply Chain: 

Fac ory Layou 

Utilization, 

Quality,

Ma er a s 

Factory:

One-time Data Entry and Growing to 

Support What is Needed 

• Begins with many possibilities/requirements 

• Evaluation is rapid for fast failure, easy recovery, and 

automated/augmented optimization 

• Concepts convey elementary design data which is taken to 

appropriate fidelity (goes away?) 

• Design data supports all planning functions and spawns 

operational and sustainment models 

• The resulting model set is so complete that it becomes the 

product and process controller for assured product delivery 

As Conceived, as Designed, as Planned, as Built, as 

Used, as Supported in One Data and Model Set 

Conclusion 

• There is strong consensus about the goals and the 

strategies 

• Model-based product delivery is mature to the point of 

getting it done! 

• Needed tools and methods are maturing that enable the 

realization of the vision 

• It is time for unified programs that deliver the 

implementation of the vision 

The MBE/TDP DEDMWG Activity Provides 

A Great Success Model 

Model standards interoperability 

across domains, the life cycle, and 

the supply chain 

Charlie Stirk 

stirk@costvision.com 

303-539-9312 

Dec. 13, 2012 

My perspective ... 

Data Across Functional Domains & Life Cycle Stages 

Security 

Concept 

Requirements 

Volume 

Budget,

Schedule 

Architecture 

Functional 

Design 

Systems 

structure & 

interfaces 

Function & 

State 

Behaviors 

Packaging,

Test Plans 

System

Preliminary

Design 

BOM 

Architecture 

Layout, 

Physical 

Interfaces 

Assembly

Sequence,

Logistics & 

Maintenance 

Plans 

Product/Process 

Preliminary

Design 

Solid Model, 

Kinematics 

Fabrication 

Processes, 

Factory

Layout, 

Ergonomics 

Detailed Design 

CAD w th 

GD&T,Tooling,

CAE 

RFx ECx 

CAM, Process 

Plans, DFX 

Ru es, Tech 

Manuals 

Manufacturing 

• Cost models need to interoperate with other models 

• Requirements, Arch., Project, CAD, Assembly, Mfg., O&S 

• Standards Involvement 

• PDES Manufacturing & Systems Engineering Teams 

• INCOSE MBSE, Tool Integration and Interoperability 

•		OMG Model Interchange Working Group 

•		CAX Implementor Forum 

•		PLCS Implementor Forum 

•		AIA/ASD Long Term Archiving and Retrieval (LOTAR) 

– Product Data Management & Metadata Teams 

• AIA/ASD Integrated Logistics Support (ILS S-series) 

– Data Modeling and Exchange Working Group 

• Use of other technologies 

• OAGIS, Acrobat/3D PDF, COLLADA, CAD/PLM API’s 

• Modular Application Protocol (AP) Benefits 

– STEP Module and Resource Library (HTML on CD) for CHF 352 

•		Faster revision process (months rather than years) 

–		Interoperability of implementations through module & code reuse 

•		requirements, assembly structure, geometry, PMI etc. 

• Two implementation levels 

•		ARM domain-specific entities map to MIM entities from integrated 

resources 

• Modular STEP AP Domains 

–		AP209 CAE (FEA and CFD) 

–		AP210 EDA/MCAD (electrical and mechanical assemblies) 

–		AP233 Systems Engineering 

–		AP239 Product Life Cycle Support (PLCS) 

–		AP242 Mechanical CAD (parts & assemblies) 
 

Program and Project Management 

• Earned Value Management (EVM) 

• UNCEFACT based XML Schemas for Cost and Schedule 

• Cost classification by Work Breakdown Structure 

– MIL-STD-881 for systems (but hybrid breakdown) 

– Operations & Support WBS (functional breakdown) 

• DoD requiring on all large programs for EVM baseline and 

reporting to Central Repository 

• NATO Guidance on Life Cycle Costing (ALCCP-1) 

• Recommends use of PLCS for data collection 

• Recommends standard Cost Breakdown Structure 

• Recommends standard activity and resource classification 

• Collaborative Project Management (CPM) 

• Usage Guide, Data Exchange Model, Implementation Guide 

• By ProSTEP iViP with German auto industry 

• XML schemas and WSDL transport 

Systems Engineering Model Standards 

• SysML = Systems Modeling Language 

• Diagram language based on UML/OMG MOF 

• XMI = XML Model Interchange format 

– Written specification for OMG MOF (interpreted!) 

– Canonical XMI is restricted specification (NIST Validator) 

– OMG MIWG testing conformance, but not interchange yet 

– Need UID for diagram/data management 

– Without diagram exchange, limited to libraries or manual 

model re-building 

• Partial mapping with AP233 needs completion 

• ReqIF = Requirements Interchange Format 

• XML schema for spec hierarchy, data types, attributes 

• Several versions in use 

• Vendor implementations not interoperable 

• ProSTEP iViP setting up an implementers forum 

• Early version mapping with AP233 needs updating/validation 

SysML/AP233 Data Overlaps 

AP233 SysML 

Issue Management 

Risk Management 

State Machines 

Function Models 

V & V 

System Structures/Blocks 

Schedule Text-based Requirements 

Organizations Activities 

Property & Units 

Classification 

Approvals, Security, Status 

Change Management 

Interfaces/Ports & Flows 

Model Organization 

Eng Config Mgmt 

Lifecycle Stages 

Parametrics 

Views and Viewpoints 

Allocations 

Diagrams 

Property-based Requirements 

Requirements Management 

Model Transformation Technologies 

• XSLT (Extensible Stylesheet Language Transformations)

• Between XML documents, HTML, PDF, relational databases, ... 

• Many proprietary and open source implementations 

• E.g. STEPmod publishing system for STEP AP’s 

• EXPRESS-X (ISO 10303-14) 

• Data between EXPRESS schemas 

• NIST Expresso open source and commercial tools 

• E.g. implement STEP ARM to MIM/AIM mapping 

• Meta Object Facility (OMG MOF) 

• Typically between UML derived languages and models 

• Ecore variant in Eclipse Modeling Framework commonly used 

• Transformation languages: QVT, ATL, VIATRA 

• E.g. ReqIF to SysML Requirements 

Use of AP233/239 in Systems Engineering 

• Early version of AP233 used for 

• Data Migration between Slate and TeamCenter SE 

• Mapping of CADM 1.5 format for DoDAF 

• AP233 and AP239 Convergence 

• AP239ed2 contains all but 233’s Issue and Behavior Models 

(State Machines and Enhanced Functional Flow Block 

Diagrams) 

– Roll them into modules or reference data 

• AP239 PLCS used to manage mapped objects 

• PLCS supports relationships & configuration management 

– Like earlier work with CADM, IFC, SysML 

– Add ReqIF, UPDM, EVM, CPM, etc. 

• PLCS provides links to other domains (PDM, LSA, 

provisioning, scheduled maintenance, tech pubs, field data .. 

PDES Systems Engineering Projects 

• Requirements Traceability 

• Decomposition from Capabilities to Specifications 

• Across supply chain 

• Across tools (DOORS, ReqIF, SysML, etc.) 

• To verification & validation artifacts 

• Engineering change processes 

• Systems Model Interoperability 

• Architecture, Behavior, ... 

• Across lifecycle (Architecture, Systems, Design, Test, etc.) 

• Across languages (UPDM, SysML, UML, AADL, domain 

specific, ...) 

• Sharing info with ProSTEP iViP Smart Systems Eng. 

• Initial focus on Modelica Functional Mockup Interface (FMI) 

• Have advantages over Matlab/Simulink S-Functions 
 

 

 

 

 

 

 

 

 

 

Convergence of AP203 (Aero) and AP214 (Auto) New Functionality for AP242ed1 

•		 Create single superset standard for MCAD 

–		203 x 214 = 242 and upwardly compatible 

–		Modularization for interoperability across domains 

–		Already harmonized for geometry (translators handle both) 

•		 214 adds the following capabilities 

–		Manufacturing process planning 

•		Relate plans, operations, tools, raw/in-process/finished, 

projects, other activities, etc. 

–		Kinematics 

–		Machining Features 

–		OMG PLM Services (web services API) for PDM and
	

Engineering Change
	

•		 Enable association with 203 unique capabilities 

–		Catalog, Composites, Construction History, Requirements 

• Business Object Model (BOM) 

•		AP214 ARM was higher level than STEPmod ARMs 

•		Upward compatibility for AP214 ARM based implementations 

•		Harmonization ongoing with AP239 for PDM 

•		Mapping from BOM to ARM 

– Enables higher level API 

– Composites then PDM and other areas 

– Eventually kinematics and mfg. process for visualization 

• Shape Data Quality 

• Access Rights Management 

• Expanded Kinematics Simulation 

• Improved PMI 

• External Element Reference (eg. for Assembly PMI) 

• Tessellated Geometry 

• EXPRESS schemas and draft recommended practices 

available for testing 

•		 3D parametric / geometric constraints design 

•		 3D kinematics assembly 

•		 3D GD&T at assembly level 

•		 Sustainability information 

•		 Software / mechatronics 

•		 3D electrical harness 

•		 3D piping 

•		Mapping of screw threads standards to AIC522/AM machining_feature 

•		Welding standards (ISO 2553, AWS A2.4) 

•		PMI for ISO assembly documentation, assembly technology, assembly 

joint 

•		Support of adhesive standards (ASTM D7447) 

•		ISO 1101 FDAM1 - Tolerances of form, orientation, location and run-out 

•		Surface texture (ISO 1306, etc. and ASME B46.1) 

•		Other items that had been categories as out of scope for PMI-1 e.g. spotface 

•		Update for new editions of ASME Y14.41 and ISO 16792 

•		Individual results covered by

non-disclosure 

•		Publish only aggregate

results 

• Test Suites 

•		Instructions on building test

models •		Test, production models in

file repository (STEP & native) 

• Draft Recommended Practices 

•		Model Styling & Organization •		User Defined Attributes •		External References •		PMI •		Tessellation •		STEP File Compression 

•		LOTAR provides requirements

and test models 

• 3D PDF Generator 

Proposed Functionality for AP 242ed2 AP242 PMI Subgroup work deferred for lack of funding 

CAx-Implementor Forum CAX-IF Benefits 

• Joint testing effort of PDES Inc. &

ProSTEP iViP 

•		 Participants: AutoDesk, Capvidia, CT

Core Technology, Dassault Systemes,

DataKit, ITI TranscenData, Kubotek,

LKsoft, PTC, Siemens, TechSoft 3D,

Theorem Solutions, Vistagy 

•		 JT, 3DPDF, 3DXML, CAP-XML sponsors 

are active members 

•		 Bi-annual rounds of testing of CAD data

exchange 

– Cooperate on implementing STEP 

–		 Feedback to STEP developers 

–		 Accelerate translator development 

–		 Promote interoperability 3D Tessellated Geometry 

Synthetic Test Model –		 Scope is AP203, AP214, AP242 Semantic PMI Representation –		 Capability & Validation Test Model 
 

 

 

CAX-IF Implementation Coverage Matrix 

• Purpose is to coordinate vendor testing 

• Organized by major sections of Recommended Practices 

• Self-reported Vendor Status 

• Categories: Production, Customer Tests, Development, Future 

Plans, Not Supported 

(Only Production status made public) 

• Can compare implementations 

• Total of 6 Vendors testing 242 implementations 

• Sufficient to have schema and recommended practices 

Public Implementation Coverage Example (CATIA V6) 

Composites AP209ed2 Multidisciplinary Analysis and Design 

•		 Composite meta-data 

•		 Ply orientation angle and thickness 

•		 Material specification 

•		 Shape 

•		 2 1⁄2 D wireframe and surfaces 

•		 Explicit solids 

• New tessellated geometry 

• Going forward in AP242 and 

Publicly sharable 

Finite Element Model 

for testing AP209 Composite Plies & 

Core Structure 

Simulation Data Management (SDM) Behavioural Digital Aircraft (BDA) Model 

•		 Combines CAD, CAE, PDM 

capabilities 

–		 Superset of AP203ed2 

–		 Finite Element Analysis (FEA) 

–		 Computational Fluid Dynamics 

(CFD) 

–		 General numerical analysis 

–		 Shares base analysis models with 

AP233 Systems Engineering 

•		 Developing binary format 

–		 Based on open source HDF5 toolkit 

–		 New ISO 10303-26 (part26) 

•		 New API specification 

• BOM to ARM to AIM mapping 

• Web services implementation 

• SimPDM project of ProSTEP iViP 

•		Business process diagrams 

•		Business process between SDM, Multi-Body, FEM, CFD, PDM 

• Not an interchange data format, it is a metadata model 

• CAE Services project of ProSTEP iViP 

• Successor to Collaborative CAD/CAE Integration (C3I) 

– Successor to SimPDM 

– XML schemas and WSDL 

– Mapping to AP209 entities 

• SimDM project of PDES Inc. 

•		Uses AP209ed2 and 242-style Business Object Model 

• CRESCENDO project of EU 

•		Based on EU VIVACE, AP233/239 and PLCSlib 

•		Behavioural Digital Aircraft (BDA) Model ... 

 BDA Business Object Model defines common

language exposed as web services based on 233/239 

 BDA PLCSlib DEX’s to be publicly released soon 

 Many base PLCS templates already available as OASIS

templates 

 Not specific to aircraft, can be used for other types of

products 

 Web services to create, update, read and search data 

 WSDL interfaces implemented against 

 Share-a-space collaboration hub 

 Clients: MSC SimManager/SimXpert, Siemens

TeamCenter/NX, Scilab, Proosis, Dassault

CATIA/Enovia/iSight/Dymola, Altair/Optistruct 
 

 

 

 

 

 

 

Benefits of PLCSlib 

• New DEX development environment 

• Recommended by OASIS PLCS Technical Committee on all new DEX 

development 

• Replaces DEXlib and based on AP239ed2 International Standard (IS) 

• Generate DEX XML schema from SysML model 

• Reference data in semantic web technology (OWL2 DL) 

• Uses new templates (due to AP239ed2 and other lessons learned) 

• Benefits 

• Can transform data for legacy DEX to new DEX’s (no DEX transform) 

• Re-use DEXlib business information requirements/entity mapping 

• Faster DEX development (SysML IDE & encapsulation/abstraction) 

• SysML integration to Enterprise Architecture and Systems 

Engineering 

• Smaller file sizes and schemas 

• Better re-use and fewer base templates 

• Better quality due to built-in object and type checking 

• Software code and Web service generation 

Business Object Model : BDA Dataset coverage 

Rich model designed to 

enable traceability from 

customer expectations 

through to certification 

AP239 ed2 PLCS Concept Model 

Business Objects 

Model 

PLCS PSM XSD 

maps 

Templates 

Transformed Tr ansformed

maps 

PLCS PSM 

Organization A 

Exchange process specifies

System model System model

s 

bjects 

Ref. Data 

uses 

specializes 

Translator Translator 

System A System B 

Data Exchange Specification (DEX) 

maps maps

References 

SysML Block Definition Diagram of PLCS Requirements A CRESCENDO example (simplified) 

A typical example case in CRESCENDO: 

• Airbus (France and UK) start to 

develop a new plane based on an 

analysis of customer expectations 

leading to requirements 

• Cranfield (UK) are asked by Airbus to 

develop engine properties to match 

the requirements 

• DLR analyse power off-takes 

• The requirements and engine 

properties are passed by Airbus to 

Rolls Royce (D and UK) to propose a 

type of engine with more properties 

and requirements for which RR then 

simulate 

• The results of the simulation are 

passed to NLR (Netherlands) who 

produce a “surrogate model” which 

is passed back to RR and then made 

available to Airbus 

• Iterate taking into account thermal, 

noise, pylon structures,... 
 

Multiple Visualization Formats 3D CAD in a Web Browser 

• New LOTAR visualization team 

•		Provide requirements to other consortiums 

• Interoperability testing with 3D tessellation in STEP 

• JT and 3D PDF working on PMI 

• COLLADA from Khronos Group 

•		Harvesting by ISO TC184/SC4 like JT 

•		XML schema with an extension method 

•		Open source toolkits available 

•		Used in Digital Content Creation industry 

– CGI, gaming, training ... 

• New version includes BREP, kinematics (little support yet) 

• Khronos also provides WebGL (3D model in browser) 

• Open source for COLLADA to WebGL (three.js, scene.js) 

• WebGL in HTML5 

•		Embedded in most browsers, or plug-in to Internet Explorer 

•		Runs on desktop and Android, RIM mobile browsers (not iOS) 

•		Uses GPU for 3D acceleration 

• Examples using WebGL 

•		PythonOCC – STEP through OpenCascade to browser 

•		Sketchfab – publishing system from CAD to web pages 

•		Tinkercad – parametric 3D CAD in browser and STL interface 

•		3DTin – modeller with STL, OBJ, DAE (COLLADA) export 

• ShapeSmith – parametric NURBS open source 

•		Sunglass.io – collab. viewer, parts/assemblies, CAD formats 

and plug-ins 

• X3D plug-in for browsers 

•		Collaborating with COLLADA and WebGL teams 

PLCS and Logistics 

EXP 

EXP 

IMP 

Tessellated Geometry Interoperability Testing 

CAD authoring 

application STEP Converters 

STEP 3D tessel. 

to VRML 

STEP 3D tessel. 

Catia V5-R21 to STL 

STEP 

3D tessellated 

geometry 

IMP 

NX V7 

Creation of prototypes 

by stereolithography 

STEP 3D tessel. 

to PDF 3D 

STEP 3D tessel. 

to Deep Vision 

Adobe 

Acrobat 3D 

Deep Vision 

3D viewer 

STEP file checker 

IMP 

VRML browser 

Right Hemisphere 

Adobe 

Convergence on Maintenance Feedback Transglobal Secure Collaboration Program (TSCP) 

• ASD/AIA Integrated Logistics Support S-series 

• SX000i Guide for Use of S-series: writing chapters 

•		S2000M Material Management: issue 5.0 on May 3 

•		S3000L Logistics Support Analysis: issue 1.1 Q1 2013 

•		S4000M Scheduled Maintenance: working on issue 1.0 

•		S5000F Operational & Maintenance Feedback: early draft 

handbook, data 

•		S6000T Training Needs Analysis, TBD 

•		S9000D Dictionary: issue 1.0 under development 

• GEIA-0007 Logistics Product Data 

•		Some DEXlib DEX’s developed 

•		Handbook Rev B Ballot Draft released August 20 

•		Draft MIL-HDBK-502A Acquisition Logistics on Oct. 1 

• Other MODs developing PLCSlib DEXs 

•		France, Norway, Sweden, UK, USMC/NATO 

• Spec 2000 from Airlines for America (A4A)

(A4A formerly known as Air Transport Association (ATA)) 

•		E-business Specification for Material Management 

•		For Maintenance, Repair, Operation (MRO) of civil aircraft 

•		Strongly recommended by airframers in procurement 

•		Chapter 11 Reliability Data Collection/Exchange 

– Eg. LRU Unscheduled Removal Record 

•		Chapter 13 Performance Metrics Standards 

– Eg. To compute MTBF 

• ASD Strategic Standarization Group (SSG) Plan 

•		Analyze Spec 2000 and prepare adjustment proposals to A4A 

to fit with ASD S5000F requirements 

• Challenge: Input to ASD indicates that A4A is not open 

to adoption of AIA/ASD S-series standards 

• Members: MoD’s, DoD, and A&D contractors 

• Secure E-mail Specification v1 (SE v1) 

•		Check sender/receiver for EAR and ITAR rules 

•		PKI certificates for digital signature and encryption 

•		Certificate Authority and cross-certification 

• Identity Federation v1 Assertion Profile (IdF v1) 

•		Security Assertion Mark-up Language (SAML ) profile for A&D 

•		Attributes also passed through WS-Fed Protocol 

• Communicating with OASIS PLCS TC on Information 

Rights Management 
 1

 

Standards Radar Chart by ASD STEPcode Open Source 

• Based on legacy NIST STEP Class Library 

• BRL-CAD Open Source Reference Implementation 

• BRL-CAD used Coverity for static code analysis to find and 

fix defects and security vulnerabilities 

• Current STEPcode functions 

• Generates p22 SDAI class library in p23 C++ binding 

• Compiles p21read/write executable 

• Works on major EXPRESS schemas and p21 files 

• www.stepcode.org 

• scl-dev Google group discussions on STEP 

• Used by SCView: EXPRESS-G, tree & text viewer 

• Github: Notepad++ plug-in for EXPRESS schemas 

Conclusions 

• Many complementary interoperability standards for 

models across domains and the life cycle 

• Need to define interfaces (map overlaps and fill gaps) 

• Need to portfolio manage collections (like LOTAR & ASD SSG) 

• Technology is available, but needs investment 

• Standards development infrastructure (eg. STEPmod) 

• Share implementer forum resources and best practices 

• Tighten implement/test/feedback/modify cycle like CAX-IF 

• Need open source reference implementations 

• Sharing best practices (Validation, UIDs, Testing ...) 

Evolving Lockheed Martin’s Engineering 

Practices Through the Creation 

of a Model-centric Digital Tapestry 

Tom Hannon 

Advanced Engineering Practices 

Lockheed Martin Corporation 

© Copyright 2012 Lockheed Martin Corporation 

2 

The New Reality – Affordability and Resilience 

Systems 2020 Vision 

• Adversary can use commercial

technologies and new tactics to

rapidly alter the threat to US 

forces 

• DoD engineering, and business 

processes not structured for 

adaptability 

• New research, tools, pilot efforts 

needed to determine best methods 

for building adaptable defense systems 

• Need faster delivery of adaptable

systems that are trusted, assured, 

reliable and interoperable 

Existing Gaps and Critical Needs 

• Gap: Lack of a Conceptual Design 

Environment 

• Gap: Lack of tools to integrate system 

modeling capabilities across domains 

• Gap: Lack of open, virtual and realistic 

environment for validation and 

producibility analysis 

• Need an integrated (i.e. cross discipline) 

framework for concept, design and 

analysis of systems based on standards, 

open architecture and existing COTS 

tool sets 

© Copyright 2012 Lockheed Martin Corporation 3 

Model-Centric Digital Tapestry: 

Lockheed Martin Model-Based Enterprise 

© Copyright 2012 Lockheed Martin Corporation 

Requirements 

Planning 

Concept 

Engineering 

Product 

Engineering 

Sourcing 

Manufacturing 

Engineering 

Manufacturing 

& Production 

Deployment 

Sustainment 

Decommission 

& Recycling 

Product Test 

& Verification 
Support for 

Customer Decisi

DM

34.00%

PROG

0.92%

SA

14.82% INT 0.92%

LCWF 10.92%

PROD

8.94%

REQMTS 7.03%

REPT 5.73%

ENV

5.04%

DOC

4.13%

CHG

3.82%

MISC

2.37%

SEA

1.38%

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

6/1/20018/1/2001

10/1/200112/1/2001

2/1/20024/1/20026/1/20028/1/2002

10/1/200212/1/2002

2/1/20034/1/20036/1/20038/1/2003

10/1/200312/1/2003

-

0.50

1.00

1.50

2.00

2.50

3.00

3.50

Test

Deploy

Av g

0

50

100

150

200

250

Jul-01 Oct-01 Jan-02 Apr-02 Jul-02 Oct-02 Jan-03 Apr-03 Jul-03 Oct-03

ent

p ate

4 

Model Centric Digital Tapestry 

• An aligning vision, framework and strategy 

for integrated business, engineering and 

manufacturing supported largely by Model 

Based Systems Development. 

• Focused on linking the architectural 

framework with the Model-based 

integrations of design, analysis, cost 

prediction, technology management and 

production methods 

• Enables Performance Prediction with 

Execution Prediction and O&S Prediction 

• An enabler to meet the challenge of the 

Systems 2020 vision and Resilient Systems 

for adaptability, affordability and rapid 

design. 

© Copyright 2012 Lockheed Martin Corporation 

Digital 

Tapestry 

MBE 

Product 

Development 

Analysis of 

Architectures 

Enterprise 

Governance 

M&SA 

Operations & 

Sustainment 

© Copyright 2012 Lockheed Martin Corporation 5

Product 

Integration 

Enabling our Engineers 

• Expertise Utilizing Model Based 

Practices And Integrated Tool 

Suites Allows More Variables And 

Trade Permutations To Optimize A 

Design And Find The Best Value 

Solution Faster 

ons 

DM 34.00% 

PROG 0.92% SA 14.82% INT 0.92% 

LCWF 10.92% 

PROD 8.94% 

REQMTS 7.03% 

REPT 5.73% 

ENV 5.04% 

DOC 4.13% 

CHG 3.82% 

MISC 2.37% 

SEA 1.38% 

0 

0.5 

1 

1.5 

2 

2.5 

3 

3.5 

4 

4.5 

6/1/20018/1/2001

10/1/200112/1/2001

2/1/20024/1/20026/1/20028/1/2002

10/1/200212/1/2002

2/1/20034/1/20036/1/20038/1/2003

10/1/200312/1/2003 

-

0.50 

1.00 

1.50 

2.00 

2.50 

3.00 

3.50 

Test 

Deploy 

Av g 

0 

50 

100 

150 

200 

250 

Jul-01 Oct-01 Jan-02 Apr-02 Jul-02 Oct-02 Jan-03 Apr-03 Jul-03 Oct-03 

Series1 Series2 

Se ries1 Se ries2 

Enhanced Trade 

Space Exploration 

Technical 

Approach Validation 

Domain Specific 

Model Development 

& Integration 

Enterprise Modeling 

System Modeling 

Component Modeling 

HW Modeling SW Modeling V&V Modeling

HW Impl. SW Impl. 

6 

Existing Modeling Activities 

• Most engineers leverage focused modeling activities across 

various disciplines. 

• Capability to support integration across discipline lines tends 

to be limited or missing. 

• Existing integrations tend to be “point to point” 

© Copyright 2012 Lockheed Martin Corporation 

Architecture Cost CAD Performance Manufacturing 

7 

SysML: An Enabler for the Digital Tapestry 

• A well defined System 

Architecture Model (SAM) is the 

underlying structure connecting

threads of digital information 

together. 

• The SAM helps link requirements 

to logical and behavioral design. 

• Requirements can be fed into 

increasingly detailed levels of 

domain specific modeling. 

• By viewing the SAM as the hub of 

the digital tapestry, an integration 

pattern emerges enabling crossdomain connectivity with a 

minimal set of required 

integrations. 

© Copyright 2012 Lockheed Martin Corporation 

8 

Shaping Concept Refinement Pursuit/Capture Tech Development E&MD Sourcing Production Sustainm 

BD 

OA 

PM 

SE 

SW 

EEP 

ME 

MFG 

TEST 

L&S

Undesrtanding In Process Future

Lockheed Martin Model Based Portfolio Level of Detail

Today’s Hard Problems are System Level 

Problems. Therefore Lockheed Martin’s 

Model Based Effort is Grounded with a 

Solid Model-based Systems Engineering 

and Architecture Portfolio 

LM’s Model-based 

Strategy is Focused on 

Pulling Model-based 

Digital Threads from 

Concept Development 

through Design to Test, 

Production and 

Sustainment 

Partitioned Across Multiple 

Programs and Pilots 

© Copyright 2012 Lockheed Martin Corporation 

nment 

9 

Expand, Acceler and Validate Trades Accelerate an 

Mission 

Interactions 

Customer Business Climate Demands More 

Levels and Complexity of Trades to build 

Compatible Affordable Useable Solutions 

VS 

Calls for and Integrated Digital Analysis Thread for 

Performance, Cost, Usability and Compatibility 

Accelerates Trade Analysis 

Model Based 

Standards Based 

Integrated / Compatible Tools 

Technical Progress Validation 

Mission Performance and 

Force Compatibility 

Customer Inclusion 

© Copyright 2012 Lockheed Martin Corporation 
10

Key Components for Enhanced Trades

• Leveraging system architecture models and integrated domain models to

trace requirements to product design

• Integrating analysis models and tools into a common model-driven 

framework to drive performance, cost, and schedule analyses

• Integrated visualization and dashboards to track performance, 

completeness and customer value of the solution space

• Utilize subject matter expertise to develop standardized distributed 

analyses

Providing Glue Between Architecture, Cost, Performance Analysis

and Overall Value Assessment

© Copyright 2012 Lockheed Martin Corporation 11

Integrated DRM Process

Use Cases

Sequence Diagrams

Activity Diagrams

Parametric Diagrams

Define Mission

Generate Timeline

Perform Simulations/Scenarios

Generate Outputs

EPS Models 

Comm Models 

Thermal Models

Prop Models 

Avionics Models 

GNC Models 

Sun Vector, 

Power States

Gnd Vector

Sun/Earth Vector, 

Power States

Maneuvers

Data Flows

Orbits/Attitude

Power Collect, 

Storage

Link Margins

Thermal Balance, 

Heater Usage

dV, duty cycles

Data Storage

Pointing Control, 

Actuator Usage

Analysis Outputs 

Feedback to 

Mission Scenario

User Models 

(Simulink, Excel, etc)

Rhapsody/SysML models 

operations dynamically linked 

to analysis tools and models

© Copyright 2012 Lockheed Martin Corporation 

12

Integrated Analytical Models

Component 

Analysis Models

TLR Validation, Derived SLR’s, 

System-Level Characteristics

Optimized Component 

Characteristics

Component 

Requirements

Optimized Component 

Characteristics Component 

Requirements

d

System 

Analysis Models

Sy

-110 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0 1500

1510

1520

1530

1540

1550

1560

1570

1580

1590

1600

East/West(ft)

North/South (ft)

Vehicle Architecture &

Mission CONOPs

Vehicle

«block»

hull 1

Hull

«block»

nrg 1

Energy

«block»

con 1

Control

«block»

Flotation

«block»

flot 1

vb 1

Variable Ballast

«block»

sens 1

Sensors

«block»

prop 1

Propulsion

«block»

1

*

«block»

strct 1

Structure

«block»

Reference 

Architectural Diagrams

AVCDU

1 « Co n s tra in tPro p

{[VehicleLength VehicleWeight VehicleVolume] = rhapsody_interface(HullType, DiameterOption, Fixed, CrossSectionAspectRatio, HotelLoad, PressureVesselMaterial, GlobalPacking, 1, PayloadInternal, EnergyType, EnergyMargin, PowerMargin, BatteryType, BatteryAspectRatio, DieselFuelMargin, HydrogenMargin, FinNumber, HasPylon, PylonFairing, PylonWidth, PylonLength, PylonHeight, SnorkelRetractable, 1, VerticalThrustersNumber+LateralThrustersNumber, LateralThrustersNumber, 1, FirstDepth, FirstDistance, FirstDuration, FirstRecharge, FirstSpeed, FirstPayloadPower, FirstPayloadDisplacement, FirstPayloadWeight, FirstPayloadEnvelope, FirstBeamCurrent, FirstBeamCurrentDutyCycle, FirstHeadCurrent, FirstWaterDensity, SecondDepth, SecondDistance, SecondDuration, SecondRecharge, SecondSpeed, SecondPayloadPower, SecondPayloadDisplacement, SecondPayloadWeight, SecondPayloadEnvelope, SecondBeamCurrent, SecondBeamCurrentDutyCycle, SecondHeadCurrent, SecondWaterDensity, ThirdDepth, ThirdDistance, ThirdDuration, ThirdRecharge, ThirdSpeed, ThirdPayloadPower, ThirdPayloadDisplacement, ThirdPayloadWeight, ThirdPayloadEnvelope, ThirdBeamCurrent, ThirdBeamCurrentDutyCycle, ThirdHeadCurrent, ThirdWaterDensity, FourthDepth, FourthDistance, FourthDuration, FourthRecharge, FourthSpeed, FourthPayloadPower, FourthPayloadDisplacement, FourthPayloadWeight, FourthPayloadEnvelope, FourthBeamCurrent, FourthBeamCurrentDutyCycle, FourthHeadCurrent, FourthWaterDensity, FifthDepth, FifthDistance, FifthDuration, FifthRecharge, FifthSpeed, FifthPayloadPower, FifthPayloadDisplacement, FifthPayloadWeight, FifthPayloadEnvelope, FifthBeamCurrent, FifthBeamCurrentDutyCycle, FifthHeadCurrent, FifthWaterDensity)} VehicleVolume

VehicleWeight

VehicleLength

VerticalThrustersNumber

LateralThrustersNumber

FinNumber

PressureVesselMaterial

HullDrag

FourthPayloadWeight

FourthPayloadDisplacement

FourthPayloadDrag

FourthPayloadPower

FourthSpeed

FourthRecharge

FourthDuration

FourthDistance

FourthDepth

ThirdWaterDensity

ThirdBeamCurrentDutyCycle ThirdHeadCurrent

ThirdBeamCurrent

ThirdPayloadEnvelope

ThirdPayloadWeight

ThirdPayloadDisplacement

ThirdPayloadDrag

ThirdPayloadPower

ThirdSpeed

ThirdRecharge

ThirdDuration

ThirdDistance

ThirdDepth

SecondWaterDensity SecondHeadCurrent SecondBeamCurrentDutyCycle

SecondBeamCurrent

SecondPayloadEnvelope SecondPayloadWeight SecondPayloadDisplacement SecondPayloadDrag SecondPayloadPower

SecondSpeed SecondRecharge

SecondDuration SecondDistance SecondDepth

FirstWaterDensity

FirstBeamCurrentDutyCycle

FirstHeadCurrent

FirstBeamCurrent

FirstPayloadEnvelope

FirstPayloadWeight

FirstPayloadDisplacement

FirstPayloadDrag

PayloadInternal

FirstPayloadPower

FirstSpeed

FirstRecharge

FirstDuration

FirstDistance

FirstDepth

1 Launch:Mission Segment

Launch.segment_depth:float=0

« Attrib u te

Launch.segment_distance:floa

« Attrib u te

Launch.segment_duration:uns « Attrib u te

Launch.segment_ground_spee

« Attrib u te

Launch.segment_recharging:b

« Attrib u te

1 InactivePayload:Payload

SampleMission.InactivePayload.co

« Attrib u te

SampleMission.InactivePayload.dr « Attrib u te

SampleMission.InactivePayload.bu

« Attrib u te

SampleMission.InactivePayload.bu

« Attrib u te

buoyancy_envelope_volume:float=

« Attrib u te

1 LaunchEnvironment:Mission Segmen

SampleMission.LaunchEnvironmen

« Attrib u te

SampleMission.LaunchEnvironmen

« Attrib u te

SampleMission.LaunchEnvironmen

« Attrib u te

SampleMission.LaunchEnvironmen

« Attrib u te

1 Ingress:Mission Segment

Ingress.segment_depth:float=0

« Attrib u te

Ingress.segment_distance:floa

« Attrib u te

Ingress.segment_duration:uns « Attrib u te

Ingress.segment_ground_spee

« Attrib u te

Ingress.segment_recharging:b

« Attrib u te

1 IngressEnvironment:Mission Segme

SampleMission.IngressEnvironmen

« Attrib u te

SampleMission.IngressEnvironmen

« Attrib u te

SampleMission.IngressEnvironmen

« Attrib u te

SampleMission.IngressEnvironmen

« Attrib u te

1 IngressPayload:Payload

SampleMission.IngressPayload.dra

« Attrib u te

SampleMission.IngressPayload.bu

« Attrib u te

SampleMission.IngressPayload.bu

« Attrib u te

SampleMission.IngressPayload.bu

« Attrib u te

SampleMission.IngressPayload.co

« Attrib u te

1 Work:Mission Segment Work.segment_depth:float=0

« Attrib u te

Work.segment_distance:float=

« Attrib u te

Work.segment_duration:unsig

« Attrib u te

Work.segment_ground_speed

« Attrib u te

Work.segment_recharging:boo

« Attrib u te

1 WorkPayload:Payload

SampleMission.WorkPayload.buoy « Attrib u te

SampleMission.WorkPayload.buoy « Attrib u te

SampleMission.WorkPayload.drag_

« Attrib u te

SampleMission.WorkPayload.buoy « Attrib u te

SampleMission.WorkPayload.comp

« Attrib u te

1 WorkEnvironment:Mission Segment E

SampleMission.WorkEnvironment.e

« Attrib u te

SampleMission.WorkEnvironment.e

« Attrib u te

SampleMission.WorkEnvironment.e

« Attrib u te

SampleMission.WorkEnvironment.e

« Attrib u te

1 Egress:Mission Segment

Egress.segment_depth:float=0

« Attrib u te

Egress.segment_distance:floa

« Attrib u te

Egress.segment_duration:unsi « Attrib u te

Egress.segment_recharging:bo

« Attrib u te

Egress.segment_ground_spee

« Attrib u te

1 EgressPayload:Payload

« Attrib u te

SampleMission.EgressPayload.dra

« Attrib u te

SampleMission.EgressPayload.com

« Attrib u te

1 hull:Hull

Vehicle.hull.drag_CD_S:float=0

« Attrib u te

pv_material:int=2

« Attrib u te

1 pyld:Payload

pyld.payload_internal:boo

« Attrib u te

1 con:Control

* fin:Fins

con.fin.fin_number:int=0

« Attrib u te

* thrust:Thrusters

* latThrust:LateralThruster

con.thrust.latThrust.lateral_n

« Attrib u te

* vertThrust:VerticalThruster

con.thrust.vertThrust.vertical_

« Attrib u te

1 vhl:Vehicle

vhl.vehicle_length:float « Attrib u te

vhl.vehicle_volume:float « Attrib u te

vhl.vehicle_weight:float « Attrib u te

d Comp

System 

Architecture Model

Integrates System Engineering and Analysis Capabilities

to Provide Framework for Early Business Shaping

© Copyright 2012 Lockheed Martin Corporation 13

UUV Reference Component Model Suite

Electronics 

Pressure Vessel

Battery & 

Pressure Vessel

Propulsor Thruster(s)

Component 

Requirements Are 

Based on SystemLevel Allocation

Component Analysis 

Models Provide 

Higher-Fidelity 

Sizing & Design

Second CAUSE Run 

Captures Higher 

Fidelity Estimates & 

Identifies SystemLevel Impacts

CAD Reference Architecture is Driven 

by System-Level Analysis

re Vessel Pre

© Copyright 2012 Lockheed Martin Corporation 

14

CAUSE

MatLab

Routines

MatLab

Routines

Example: Integrated Propulsor Analysis

CAUSE

(External Propulsor Estimates)

Propulsor 

CAD

Propulsor

Analysis

CAUSE

(Internal Propulsor

Estimates)

Propulsor

Geometry

Start

Vehicle Drag, Propulsor Count

Propulsor Diameter

Stop

Propulsor Efficiency

Torque & RPM

CAUSE C CAUSE

Propeller Models Generate More Accurate Vehicle Assessment In Addition to 

Component CAD Suitable for Vehicle Arrangements and Future Analyses

Propulsor

CAD

Propulsor Weight 

& Volume

Results for LongDistance UUV (500 nmi)Propulsion 

Efficiency

Energy

(kWhr)

Vehicle 

Length (ft)

Material 

Cost

CAUSE B/L B/L B/L B/L

CAUSE w/ Model Results +3% -28 .5 -$70K

© Copyright 2012 Lockheed Martin Corporation 

MatLab

Routines Pro/E

15

System 

Analysis 

Model

S

A

Firmware 

/ Elect.

Model

Integration Clusters (Technical “How”)

System 

Architecture 

Model

System 

CONOPS

Model

Integrated Data Management Layer

Software

Model

Sof

M

Software

Model

System 

Test 

Model

System 

Requirements

Concept Development

Concept Refinement

Technology 

Development

Engineering & 

Manufacturing 

Development

Production & 

Deployment

Operations & 

Sustainment

Integration of Major Hubs 

Achieved through 

Integrated Data Management 

Layer

Lifecycle

Cost 

Model

Reliabilty

Model

Bill of 

Materials

Mech. 

Analysis 

Model

3D CAD 

Model

O&S Hub

M h

Producibility

Model

© Copyright 2012 Lockheed Martin Corporation 
 

 

 

 

 

 

 

 

 

 

 

 

16

«(U) Block Definition Diagram» Object Model Diagram [Package] Test Model Guidance Pkg [Test Domain - Sandy Diagram]

TestDomain

«(U) block»

TestContext1-Design

«(U) block»

1

TestContext2-Design

«(U) block»

1

TestContext1-Product

«(U) block»

1

TestContext2-Product

«(U) block»

1

SDUT

«(U) block»

1

1

SPUT

«(U) block»

1

1

SDUT

«instsanceOf»

1

TC2-P

«(U) block»

1

TC1-P

«(U) block»

1

TC1-D

«(U) block»

1

TC2-D

«(U) block»

«(U) verify»

R1

«Requirement»

«(U) verify»

R2

«Requirement»

1

TestSystemInventory

«(U) block»

1

TestEq1

«(U) block»

1

Test cases are operations of test context, and 

<<verify>> goes from test case to req

Model-based Program Execution

Enterprise 

Modeling

System Modeling

Component

Modeling

Firmware

Modeling

V&V 

Modeling

Requirements Flowdown

Architecture Definition

Interface Definition

Document Generation

ACE::ACE_Handler

tcFileReader

handle_read_file(result:ACE_Asyn...

tcFileWriter

handle_write_file(result:ACE_Asyn...

tcUdpReader

handle_read_dgram(result:ACE_As...

tcUdpWriter

handle_write_dgram(result:ACE_A...

tcDataReceiver

RegisterReceiver(arcInputId:OMString,apcModule:tcReceiverModule):void SendData(arcOutputId:OMString,arcMessage:ACE_Message_Block):void

mcInputs

1

*

tcDrHandler

mcId:OMString

handle_read_file(result:ACE_Asynch_Resu... handle_write_dgram(result:ACE_Asynch_R... handle_read_dgram(result:ACE_Asynch_R... handle_write_file(result:ACE_Asynch_Resu...

mcOutputs

1

*

«flow»

incoming_data

tcReceiverModule

svc():int ReceiveLoop():void ProcessMessage(acInputId:OMString...

mcReceivers

1 *

1

«flow»

data_to_receivers

ACE::ACE_Task

putq(msg:ACE_Mes...

tcDataRecorderXml

tcDataRecorderXml(acModuleId:O... ProcessMessage(acInputId:OMStri...

NOTE: the idea is that the messages are

converted to XML and then written to an output, but that requires some understanding of the binary message. Should we just dump binary, or use some sort of conversion strategy to make it XML?

Each individual handler has a 

reference to the handlers

interested in the data. The data

gets put on those handlers' queues.

Handlers created at startup from configuration

SW 

Modeling

HW

Implementation

SW 

Implementation

Product 

Integration

Analysis Tools Integration 

(ModelCenter, Matlab, ...)

CAD

Modeling

PDM/BOM Consistency

(Windchill)

© Copyright 2012 Lockheed Martin Corporation 17

Vision: Single Source Generative Practices

• Generating code,

interfaces, test cases,

documentation, and more

from models and higher

level languages

• Many programs at LM and

across industry leverage 

generative coding for

targeted problems

• Core to 2013 MBSD are 

refining the paths from

UML, SysML and Simulink

to software, firmware and

interfaces

© Copyright 2012 Lockheed Martin Corporation 

18

Not Just a Model but a Product Data Set 

Analyses

Data Set Notes

Drawing

Model

Mat’ls Parts 

Lists

Test

Data

Rqt’s

MFG

Rqt’s

Visualization 

Inspect. 

Criteria

Creation & Control

Association To Design

• 3D Model 

• Specifications

• Notes

• Metadata or Attributes

• Bill Of Material

• Design Requirements 

• Other Product Descriptive Info

A Product Data Set Contains 

Artifacts That Define A Product...

The Entire Data Set Must Be Managed

© Copyright 2012 Lockheed Martin Corporation 19

0%

100%

Product

Digital Mock-up (DMU) 

Product Engineering Focus

Fit, Collision, etc..

DMU)

Process

Process Linked Product

Process Sequence Validation

Tooling Validation

Ergo/Human Validation 

Product

Resource

In Station Context

Process Linked to Stations

Assembly Seq Validation

Resource Balancing

Tool & Manpower Allocation

Material Flow / Routing 

SSC’s Future in Virtual Manufacturing

Virtual Creation before Physical Creation

Enabler for a effective and early 

Engineering, Manufacturing, and 

Production collaboration

© Copyright 2012 Lockheed Martin Corporation 

20

Understanding and Managing the Supply Chain

• Considerations for Production 

should start in Systems Engineering

• Treating the supply chain as a part 

of the system allows logical needs 

to be mapped to both physical 

architectures and the organizations 

responsible for them

© Copyright 2012 Lockheed Martin Corporation 21

Digital Tapestry Highlights

• AS Enabler:

– Moving Information And Decisions Earlier

– Horizontal Agility Across Functions And Disciplines

– Creating Business Tools

– Connecting Mission To Solution Details

– Enhancing The Trade Space

• As Core Model Centric Approach

– Single Source of Truth

– Generate From Common Sources

– Clarity of Design and Traceability

– Technical and Performance Progress 

© Copyright 2012 Lockheed Martin Corporation
IBIF Projects and Business Case Analyses 

Denise Duncan, Cindy Flint 

13 December 2012 

MBE Summit, NIST 

IBIF projects 

• The Industrial Base Innovation Fund (IBIF)* program

recently solicited proposals in the area of technical

data 

Technical Area 1: Comprehensive Technical Data

Packages (TDPs) for Next Generation Business

Exchanges 

Technical Area 2: Technical Data Packages (TDP)

Integration and Validation for Government Delivery 

• LMI is tasked to help IBIF TDP project teams develop

high-level BCAs 

* Part of the OSD Defense-Wide Manufacturing Science and Technology 

(DMS&T) program 

2 

LMI’s role in IBIF projects 

• LMI is tasked to help IBIF project teams develop 

high-level business cases 

Collaboratively define metrics with project teams 

• We are currently completing a 2012 task – white 

paper on the Case for MBE 

Includes case studies from projects completed by the MBE 

community 

As much as possible, IBIF metrics should be similar to 

earlier studies 

3 

What is a business case? 

• Can depend on who you are talking to 

BCA, CBA, AOA, ROI, Cost-Benefit Ratio etc. 

• And what they need it for 

What have we gotten for the money? 

Milestone decisions 

Justify future/ongoing investment 

Prioritize investments 

Answer audit inquiries 

• Business case templates vary 

By agency or Service 

By investment dollar thresholds 

By investment type, e.g. major system, R&D, IT, etc. 

• However, there are standard steps in developing any business 

case 

4 

Business Case Steps 

• Step 1: Define the “As Is” Case 

Define the current process, technology, system, and/or 

standards being addressed . 

What problem or inefficiency is resulting from the status quo? 

Benchmark the current process, technology, system and/or 

specification (e.g. resources, cycle time, quality, maintenance, 

etc). 

To the extent possible, quantify the status quo. 

Business Case Steps (continued) 

• Step 2: Alternative(s) 

Define the alternate process, technology, system, and/or 

standards being studied. 

How does this alternative address the problem or inefficiency 

described in the "As Is" case? 

State the proposed benefits of the alternative. When the benefit 

will be achieved, who will benefit, certainty of the benefit. 

Is there industry and government support for the alternative and 

why? 

What, if any, impediments to implementing the alternative have 

you identified. 

To the extent possible, quantify the alternative. 

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Business Case Steps (continued) 

• Step 3: Supporting Information 

State any assumptions associated with the analysis. 

Document any policies, regulations, and/or standard operating 

procedures pertinent to the problem and resolution. 

For benefits that are qualitative in nature, document the benefit 

giving a description of the benefit and naming the stakeholder. 

Business Case Steps (continued) 

• Step 4: Economic Analysis 

An economic analysis is used to compare the status quo to the 

alternatives. Several methods can be used: NPV, statistical 

modeling, cost/benefit ratio, etc. 

The type of project and/or stage of the project may dictate the 

level of detail needed for the analysis. 

OMB circular A-94 "Guidelines and Discount Rates for BenefitCost Analysis of Federal Programs”: 

http://www.whitehouse.gov/omb/circulars/a094/a094.html#5. 

LMI Contacts 

• Project Lead: Cindy Flint, 703-917-7234 

cflint@lmi.org 

• Tech Data SME: Denise Duncan, 703-917-7378 

dduncan@lmi.org 

• LMI, 2000 Corporate Ridge, McLean, VA 22101 

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