Dynamics of Naval Ship Design : a Systems Approach
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Calhoun: The NPS Institutional Archive Theses and Dissertations Thesis Collection 1998 Dynamics of Naval Ship design : a systems approach. Laverghetta, Thomas A. Monterey, California. Naval Postgraduate School http://hdl.handle.net/10945/8280 OUOIEY KNOX LIBRARY NAVAL POSTGRADUATE SCH MONTFREY CA 93943-5101 Dynamics of Naval Ship Design: A Systems Approach by Thomas A. Laverghetta I! BS Mathematics United States Naval Academy, 1990 SUBMITTED TO THE DEPARTMENT OF OCEAN ENGINEERING IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREES OF NAVAL ENGINEER AND MASTER OF SCIENCE IN OCEAN SYSTEMS MANAGEMENT AT THE MASSACHUSETTS INSTITUTE OF TECHNOLOGY JUNE 1998 © 1998 Thomas Laverghetta, All Rights Reserved The Author hereby grants to MIT permission to reproduce and to distribute publicly paper and electronic copies of this thesis document in whole or in part. DUDLEY I NAVAI Dynamics of Naval Ship Design: A Systems Approach by Thomas A. Laverghetta Submitted to the Department of Ocean Engineering on May 18. 1998 in Partial Fulfillment of the Requirements for the Degrees of Naval Engineer and Master of Science in Ocean Systems Management ABSTRACT The 1990 Naval Sea Systems Command Ship Design, Acquisition and Construction (DAC) Study provides a stepping stone for the implementation of improvements towards optimizing ship performance, cutting acquisition costs, and reducing design cycle time. With respect to performance, significant advances in computing power coupled with customer oriented design (QFD, AHP. evolutionary optimization, etc) provide both improvements and direct means to measure effectiveness of improvements. As for cost, implementation of world class building and design techniques (concurrent engineering, group technology. CAD/CAM/CAE. etc) coupled with higher fidelity costing methods ( ACEIT. PODAC. etc) provide savings and direct measures of effectiveness. Cycle time improvements have also been implemented (IPTs. Open System Architecture, 3-D Product Models, etc). However, ship design managers have been unable to identify and quantify' design process effectiveness with respect to the impact of those proposed cycle time improvements. In order to understand the impact of cycle time improvements, it is necessary to examine the mechanisms which have lead to increased cycle time including external influences (such as increasmg technological complexity and budgetary pressures), internal process delays (information flow delays and approval delays) and feedback processes (design iteration, error propagation and design change.) Modeling of such mechanisms, using the methods of System Dynamics, provides a means to study past programs (in particular, the DDG-51 Destroyer program of the 1980s), and to study the anticipated savings that can be generated with the introduction of process improvements. Of particular interest in modeling the naval ship design process with System Dynamics is the flow of design information. Traditional process analysis methods based on the design spiral represent the progression of design tasks as a linear process. However, actual design data propagation (a fundamental property resulting from the physical and architectural relationships of total ship systems) shows the process to be highly non-linear. These non- linearities are captured by system dynamics, providing a simulation tool that more fully captures the impacts of process improvements as they relate to the naval ship design process. Thesis Supervisor: Alan J. Brown Title: Senior Lecturer. Department of Ocean Engineering This thesis is dedicated to my loved ones, who make my life complete... Kimberley, Francesca and Thomas " DYNAMICS OF NAVAL SHD? DESIGN: A SYSTEMS APPROACH 1 1 Problem Statement 6 1.1 "Affordability Crisis" 6 1.1.1 Cycle Time 6 1.1.2 Requirements and Design Performance 13 1.1.3 Cost 20 1 . 2 Dynamic Modeling ofthe Design Process 30 1.2.1 Need for Modeling 30 1.2.2 What is System Dynamics? 31 1.2.3 Modeling Approach and Structure 32 2 Design Process External Influences 34 2. 1 Reciprocity and Proliferation ...the Needfor Naval Capabilities Evolution 37 " 2. 2 "Order ofBattle Dynamics.. Maintaining Force Levels 39 2.3 Design & Acquisition Rate Influences 42 3 Design Process Dynamics 45 3.1 Systems Engineering and Na\>al Ship Design 45 3.2 A cquisition Process . Points of \ lew 46 3. 3 Operational Process View 57 3.3.1 Design Phases 51 3.3.2 Scope Change Implementation and Detailed Design 53 4 Design Spiral and Task Dynamics 54 4. 1 "The Design Spiral 54 4. 2 Design Disciplines 62 4.3 Design Task Matrix 64 4.4 Programmatics 68 4.4.1 Program Management Tasks 71 4.4.2 Requirements Setting and Assessment 72 4.4.3 Risk Mitigation and Coordination 74 4.5 Systems Engineering 75 4.5.1 Logistics and Reliability Engineering 76 4.5.2 Design Integration and Specifications 77 4.5.3 Producibility and Production Engineering 78 4.5.4 Performance Assessment and Requirements Comparison 80 4.5.5 Manning 81 4.6 Hull Engineering 81 4.6.1 Hull Geometry 83 4.6.2 Weight Engineering 84 4.6.3 Hydrodynamics-Resistance and Powering 85 4.6.4 Hydrodynamics-Seakeeping 85 4.6.5 Hydrodynamics-Maneuvering. Control and Appendages 86 4.6.6 Structural Engineering 87 4.6.7 Space and Arrangements 88 4. 7 Machinery Systems Engineering 88 4.7.1 Machinery Systems Design and Integration 89 4.7.2 Propulsion Systems 90 4.7.3 Electrical Systems 91 4.7.4 Auxiliary and Support Systems 92 4.7.5 Deck. Handling and Aviation Support Systems 92 4. 8 Mission Systems Engineering 93 4.8.1 Mission Systems Selection, Design and Integration 93 4.8 2 Topside Design and Integration 95 4. 9 Cost Engineering 96 4.9.1 Cost Estimates and Analysis 96 5 Process Model Sectors 98 5. 1 Process Sector 98 5.1.1 Primary Work Flow 101 4 65432 5.1.2 Review and Approval Factors 101 5.1.3 Error Generation and Detection 102 5.1.4 Design Feedback 103 5. Scheduling Sector 1 03 5.2.1 Desired Schedule 103 5.2.2 Phase, Review and Approval Initiation 106 5. Productivity Sector 107 5. Manpower Availability and Assignment Sectors 109 5.4.1 Naval Ship Design Organization and Resource Structure 109 5.4.2 Manpower and Adjustments 117 5.5 Financial Sector 119 Hypothesis Testing, Modeling Resitts .and Conclusions 122 6.1 Baseline Model Results 122 6.2 WhatifCAE/CAD/CAMAre Used? 125 6. What ifConcurrent Engineering and IPTs Are Applied 127 Conclusions and Future Work 130 7. 1 Conclusions 130 7. Future Uses and Work 131 Appendices 133 8.1 Bibliography 133 8.2 Thank you..'. 137 8. Glossary and Abbreviations 138 8. Design Task. Discipline and Duration Resources 147 8. Baseline DDG-5 1 Task and Productivity Levels 149 8. Programmatic Task Development and Processing 152 8. 7 Na\>al Ship Design Process Model 158 1 Problem Statement In June 1990. under the direction of Naval Sea Systems Command (NAVSEA) Chief Engineer. RADM Roger Home, the United States Navy undertook a program to assess the effectiveness of the naval ship design, acquisition and construction (DAC) process. The focus of this project was "to identify the critical actions necessary to improve the quality of future ship designs (i.e. meeting customer's performance requirements), to reduce ship costs (from research and development through disposal), and to reduce the cycle time required from establishment of requirements to delivery of the lead ship ."' It was immediately recognized that naval ship acquisition is itself unique within the constrained framework of the Department of Defense (DOD) and Department of the Navy (DON) organization. In particular. Navy ships are bought in small quantities, have very long development cycles, and are 2 extremely costly. precluding the "fly before you buy" approaches required for purchase of other weapon systems. Additionally, the technical complexity of warship design has passed the point that any "one" individual can be an 3 "expert" in all aspects of the design. The resulting process is neither well documented nor well understood. Although the purpose for the DAC program was very wide-ranging, the specific reasons prompting the DAC effort were clear: increasing naval performance requirements are resulting in increasing ship costs and increasing 4 cycle times for delivery. The resulting "Affordability Crisis" put strong pressure on the DOD to reform the acquisition process. This "Crisis" is analyzed by examining three key symptoms: mcreasing design cycle time, constraints leading to sub-optimal system performance, and increasing cost trends. 1.1 "Affordability Crisis" 1.1.1 Cycle Time The time required to conceptualize, design and produce new ship designs has been increasing steadily over the years. Consider the trends for naval combatant programs shown in Figure 1 . Conceptual Design time (concept design and preliminary design) is increasing at a rate of 1 .5 months per year Contract Award time (from program start through completion of contract design) is increasing at a rate of 3 months per year. Time to deliver completed ships is increasing at a rate of 5 months per year. These trends are coupled with exponentially increasing man-day efforts required to deliver ship designs (Figure 1). These trends are disturbing as they represent a barrier to providing warfighters with timely systems necessary to meet threats. The causes of these trends are numerous and will be discussed in depth in Chapter 2. 1 RADM Roger B. Home, "Concept to Commissioning: Ship Design, Acquisition and Construction Process Improvement Workshop II", Richmond, VA, May 6-7, 1991. 2 Ryan and Jons, "Improving the Ship Design, Acquisition and Construction Process", Association of Scientists and lh Engineers, 28 Annual Technical Symposium, April 11. 1991 3 Tibbitts and Keane. "Making Design Everybody's Job". Naval Engineers Journal. May 1995, page 286. 4 Timothy P McCue, "The Dynamics of Naval Shipbuilding-a Systems Approach". Department of Ocean Engineering Thesis, Massachusetts Institute of Technology.