"Delivering Value through Defense Manufacturing Technology"

Manufacturing InnovationA National Defense Imperative

Aerospace States Association Fall General Meeting

October 9, 2012

Ed Morris

NDIA Manufacturing Division Chairman

Director, Mechanical Engineering & Manufacturing

Lockheed Martin Corporate Engineering & Technology

Discussion Topics

• NDIA & Manufacturing Division Overview

• From a National Defense Perspective, What Is “Manufacturing Innovation” and Why Is It Important?

• Barriers to Manufacturing Innovation

• Manufacturing Innovations “In Work”

• Closing Thoughts

"Delivering Value through Defense Manufacturing Technology"

NDIA Overview• Vision:

– America’s leading Defense Industry association promoting National Security

• Mission: – ADVOCATE: Cutting-edge technology and superior

weapons, equipment, training, and support for the War-Fighter and First Responder

– PROMOTE:  A vigorous, responsive, Government – Industry National Security Team

– PROVIDE: A legal and ethical forum for exchange of information between Industry and Government on National Security issues

• Motto:– Strength through Industry and Technology

"Delivering Value through Defense Manufacturing Technology"

NDIA Overview (Cont’d)

• About Us: – Over 1,780 corporate members, 87,700 individual

members, 52 Chapters, 32 Divisions and 7 Industrial Working Groups

– Work with industry, government, all military Services, and academia

– Monthly journal National DEFENSE provides the latest developments in technology, arms and weaponry, and issues of concern to industry and the government

– NDIA traces its history to the American Defense Preparedness Association (ADPA), founded in 1919, and the National Security Industrial Association (NSIA), founded in 1944

– The new NDIA, founded in March 1997, is a non-partisan, non-profit, educational association with offices in Arlington, Virginia

"Delivering Value through Defense Manufacturing Technology"

NDIA Manufacturing DivisionMission: Enhance the security of the United States by promoting communications and interaction between the defense industry, academia, government and military in the area of manufacturing

Specific Objectives: Advocate national support for defense manufacturing Promote defense manufacturing excellence Support promising technologies, processes, and implementation

methodologies Support efforts to educate, recruit and train a highly skilled

defense manufacturing workforce Conduct research and analysis on manufacturing trends and

policies Conduct government-industry forums focused on defense

manufacturing

5"Delivering Value through Defense Manufacturing Technology"

Today’s Global Keep-Awakes . . .

• Current Conflicts– GWOT (Terrorism Anywhere)– Iraq & Afghanistan– Cyber Warfare– Piracy at Sea

• Global Hot Spots– Iran– North Korea– Others . . .

• The Global Economy• Energy Resources• Materials Availability• Counterfeit Parts• Pandemic Disease• Earthquakes??

"Delivering Value through Defense Manufacturing Technology"

National Defense Realities• Budget Control Act of 2011 Impact

– Program Cancellations– Program Stretch-outs– Few New Starts

• Aging, Worn-out Equipment– E-3A Airborne Warning And Control System aircraft

(AWACS) are running two 12-hour missions/day in Afghanistan – they are 30 years old

– B-52 has been in active service with the USAF since 1955; Current plan is to keep the B-52H in service until 2045 – 90 Years!

"Delivering Value through Defense Manufacturing Technology"

DoD Warfighter Perspective• We are in a long, global war – perhaps measured

in decades!• Our adversaries:

– Place little or no value on human life, including their own– Are skilled at rapidly adapting “just good enough”

technology at very low cost

• IEDs are still a major threat• Energy demands for today’s equipment must be

reduced • Weapon reliability is crucial

"Delivering Value through Defense Manufacturing Technology"

“Need quality products on time”

Defense Manufacturing Mandates

• Rapidly field the very best new equipment• Upgrade & modernize existing systems• Rapidly incorporate new technologies into new

and fielded systems

While . . .• Adjusting to changing requirements and budgets• Maintaining a Viable Defense Industrial Base• Ensuring product affordability

"Delivering Value through Defense Manufacturing Technology"

MONAX 3G Wireless Communications

Systems

Manufacturing Innovations Enable Disruptive Warfare

• Disruptive Warfare Technologies– Castles, ladders, hot tar & motes,

catapults . . .– Night Vision, Laser target designation,

Low Observable technologies . . . – IEDs, MRAPs, Bigger IEDs . . .

• Disruptive Engineering Technology Shifts

– Computing Power– Engineering Computing and CAD– Portable Computer Storage Media

"Delivering Value through Defense Manufacturing Technology"

Some Definitions• Production versus “Big M” Manufacturing

• “Advanced Manufacturing” is a family of activities that:– Depends on the use and coordination of information,

automation, computation, software, sensing, and networking

– Makes use of cutting edge materials and emerging capabilities enabled by the physical and biological sciences, for example nanotechnology, chemistry, and biology

– Involves both new ways to manufacture existing products, and the manufacture of new products emerging from new advanced technologies

"Delivering Value through Defense Manufacturing Technology"

Innovation, the Process & Product of Introducing Something New, Is the Engine for Advanced Manufacturing

Barriers to Manufacturing Innovation

• Fixated on the Past & Present – “We’ve always done it this way”

• Fear of Failure – “Too risky”

• Finances – “Not the first investment choice for Venture Capitalists”

• “Tipping Point” Barriers – “Can engineers use the innovation in new product designs?”

• Surviving the “Valley of Death” – “How can we bridge the gaps?”

"Delivering Value through Defense Manufacturing Technology"

Technology Readiness Level (TRL) and Manufacturing Readiness Level (MRL) Must Stay in Sync

Innovative Manufacturing Game-Changers In-Work

• Robot Technology Including Machine Vision

• Machine Communication Standards (like MTConnect)

• Embedded Sensors for In-Process Inspection, Feedback & Heath Monitoring

• Automated Creation of More Efficient Machine Tool Paths based on In-House Capability and Geometric Component Features

• Reductions in Consumables Such as Coolant and Development of Longer Cutting Tool Life

• Friction Stir Welding

"Delivering Value through Defense Manufacturing Technology"

Innovative Manufacturing Game-Changers In-Work (Cont’d)

• Friction Stir Welding

"Delivering Value through Defense Manufacturing Technology"

Innovative Manufacturing Game-Changers In-Work (Cont’d)

• Advanced Composites Manufacturing

Direct Digital Manufacturing / Additive Manufacturing

Manufacturing Modeling & Simulation

Integrated Computational Materials Science & Engineering

"Delivering Value through Defense Manufacturing Technology"

Several Are Still Short of Their “Tipping Point”

1997

National Network for Manufacturing Innovation (NNMI)

"Delivering Value through Defense Manufacturing Technology"

• FY13 President’s Budget – a $1B, one-time investment to create the new National Network for Manufacturing Innovation Program – “Public-Private Partnership”

• National Additive Manufacturing Innovation Institute (NAMII) pilot institute established – 1st of 15 institutes

• $30 million in federal funding, matched by $40 million from the winning team led by the National Center for Defense Manufacturing and Machining (NCDMM)

Additive Manufacturing

"Delivering Value through Defense Manufacturing Technology"

Sample Technique: Electron Beam Direct Manufacturing

eBDM Process Flow

"Delivering Value through Defense Manufacturing Technology"

eBDM Unit Cost Comparison

"Delivering Value through Defense Manufacturing Technology"

First Part

Machining

MachiningRaw Material, Actual

Forging Processing

Machining

Raw Material (LTA)

Forging Processing

Machining First Part

Predicting the future12% Rate Improvements

Learning Curve Reduction

Near-Net Forgings

Learning Curve Reduction

Titanium Pricing & Improved Forgings

Raw Material (LTA)

Raw Material (LTA)

Deposition

Direct ManufacturingForging Process

Deposition

Unit Cost(average cost over many parts)

LTA: Long-Term Agreement

eBDM Lead Time Comparison

"Delivering Value through Defense Manufacturing Technology"

Direct Manufacturing

Deposition

Forging Processing

Machining

Forging Process

Heat Treat

Machining

Inspection

• Lead time with ingot, plate and wire in stock

• Faster machining due to nearer net part

• Forging lead times are approximately 16 weeks for small parts, large parts are up to 30 weeks

Innovative Manufacturing Modeling & Simulation

"Delivering Value through Defense Manufacturing Technology"

Discrete Event Simulation

Human Factors

Robotic SimulationDigital Work Instructions

Augmented Reality

Risk Modeling

Visualization

Ergonomic Simulation

Assembly Simulation

DFX Simulation

Human Immersive Lab

Virtual Development Center

Innovative Materials Approach for Design & Manufacturing

• Integrated Computational Materials Science & Engineering (ICMSE)

– An integrated process for design, certification, and manufacture of materials and components

– Concurrent design of materials and components– Designing to novel / flexible mfg processes– Eliminating barriers to introduction of materials– Being pursued by AFRL Nonmetallic Materials Division

and industry

"Delivering Value through Defense Manufacturing Technology"

Injection Molding

Extrusion

Rotational Molding

Thermoforming

Compression Molding

Closing Thoughts . . .

"Delivering Value through Defense Manufacturing Technology"

“The best way to predict the future is to invent it.”

- Alan Kay

“Good Leadership Is Knowing How Much of the Future to Implement in the Present.” -

Anonymous 

“Even if you are on the right track, you'll get run over if you just sit there.” - Will Rogers

"We must hang together, gentlemen...else, we shall most assuredly hang separately.”

- Benjamin Franklin