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H. Brent Baker, MAJGEN, USAF (Ret)
November 15th 2017
The Internet of Things and DoD's Third
Offset Strategy...a Perfect Match
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GOOGLE EARTH EXAMPLE
So many people are justifiably reluctant by the prospect of 'connected' technologies in the DoD that
they are only speaking about them in the abstract. But to adopt faster than our enemies, we need to have
the collective courage to speak about them in the specific.
Abstractions... Specifics...
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• Art of the possible - start with the end-state in mind
• Digital and physical convergence
• How IoT relates to SCOR , Third Offset and OODA Loop
• 5 fundamental principals of supply chain excellence
• AR-enabled maintenance
• Connected, cloud-based supply chain optimization
• Additive manufacturing
• PLM as a foundation
• UAV Demo
• Questions
AGENDA
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ART OF THE POSSIBLE - START WITH THE END-STATE IN MIND
.
• Diagnostics and Remediation - An F-35A landing
gear could diagnose its own problem and order a
replacement part, or alert maintenance crews of an
impending breakdown before it happens.
• Knowledge Sharing - Tribal knowledge type insights
unique to the maintainer of one aircraft could be
verified with empirical data, then shared through
augmented reality with other F-35A maintainers.
• Use of Legacy Data - Historical flight data coming
from F-35A sensors could be automatically analyzed
to create the basis of new mission profiles.
• Spares Optimization - A set of optimal sparing
scenarios of F-35A assemblies could be created given
unique parameters for aircraft availability during
combat.
• Digital Twin - An induvial F-35A’s digital twin could
be the analytical platform to better understand the
climates and situations under which the actual aircraft
has performed. These findings would drive the
additive manufacture of new components to be printed
in forward locations.
• Sustainment and Repair - Digital spares designs for
the F-35A could be stored and through the IoT
connected to available additive manufacturing assets
close to the point of need, decreasing the logistics tail.
• Augmented Reality for Maintenance - Using AR
goggles in a depot, determine where the
malfunctioning F-35A fuel pump is and see its
animated repair procedure in augmented reality.
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THIS WAS THE CONVERSATION 5 YEARS AGO
Product
Development
Product
Service
Lifecycle
Requirements Product
Optimization
Release
To
Manufacturing
Provisioning & Technical
Information
Systems
Design
Service Information
Delivery
Service
Program & Contract
Definition
Upgrades &
Overhauls
Service
Record
Management
Warranty
Management
Scheduled
Maintenance
Customer Support
Service
Performance
Analysis
Equipment
Utilization &
Performance
Analysis Detailed Design
Reliability & Maintainability
Testing
Logistics Support Analysis
Service
Optimization
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THIS IS THE NEW REALITY: INTEGRATING DIGITAL AND PHYSICAL WORLDS
INTERNET OF THINGS
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• Condition-Based Maintenance
• Real-Time Fleet Management
• Inventory Management
• Base Management /Energy Efficiency
CSIS WHITEPAPER - 9/2015
Recommendations for DoD's IoT adoption
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SUPPLY CHAIN OPERATIONS REFERENCE MODEL (SCOR)
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HOW SCOR RELATES TO IOT
Plan
Source
Make Deliver
Return IoT
Applications for smart,
connected products
IoT now links smart, connected products and all SCOR processes
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THIRD OFFSET - OPERATIONAL COMPONENTS RELATING TO THE IOT
Autonomous
"Deep Learning"
Human-Machine
Collaboration
Assisted Human
Operations
"Cyber hardened"
semi autonomous
At the middle of all of this is
data coming from signals,
sensors, machines, or other
humans. So the IoT will
play a central role.
Human-Machine
Combat Teaming
Ex. - NSA algorithm makes a threat
profile based on ISIS posts to social
media
Ex. - F-35 Helmet using data from
multiple systems into one layout for pilot
Automated analysis with no human
Machines help humans w/ decisions Machines help human operate better
Ex. - Parking assist or the 'Iron Man'
exoskeleton
Humans and unmanned operating together Ex. - P8 and Triton unmanned system or
swarms of unmanned systems
Weapons that survive cyber threats Ex. - Small diameter bomb still operating
without GPS
Source: DoD (Dep SECDEF Bob Work, at Center for a New American
Security12/14/2015
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HOW THE OODA LOOP CAN APPLY TO THE IOT
• Collection of data by 'means of the senses'
• Time is the dominant parameter - must complete the OODA cycle quicker than enemy
• Decision-making changes on the fly based on introduction of new and quickly changing data
• Can apply tactically to battlespace or strategically (i.e. Third Offset Strategy)
Col John Boyd, USAF
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1. Know the customer
2. Adopt lean philosophies
3. Create a supply chain information infrastructure
4. Integrate business process
5. Unify decision support systems
5 FUNDAMENTAL PRINCIPALS OF SUPPLY CHAIN EXCELLENCE
The essential foundation for all is integrated systems... From here we consider four examples of the latest
technology platforms the Air Force can use to achieve an integrated systems approach to supply chain
excellence in a connected world.
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• IoT pulls from the physical world to the digital...AR pushes from the digital world to the physical.
• Product data, sensor data and procedural data can be provided directly into the eyes and ears of the user, using smart hardware that intelligently guides the maintainer through their required job activities in diagnosis and remediation.
• AR is a much more practical alternative and provides rich, interactive and context specific views that are rooted in the gaming experiences on which today’s maintainers were raised.
• Cranfield University Professor Howard Lightfoot recently commented “The application of AR in field service operations is potentially a massive game changer.”
AUGMENTED REALITY ENABLED MAINTENANCE
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AUGMENTED REALITY ENABLED MAINTENANCE - EXAMPLE
• Fast diagnosis
•OEM sends patch
• Insights shared
The Air Force can invest in this capability today for affordable relevance. When combined with
the IoT, AR will revolutionize the way information is created, managed, delivered and absorbed by DoD
maintenance personnel in support of sustainment operations.
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• Exact targets for equipment availability and specific budget amounts are now the ‘inputs’ for new state-of-the-art inventory scenario forecasting capabilities from industry.
• Will be greatly enhanced when combined with real-time IoT data.
• In late 2016 USAF selected a Service Parts Management (SPM) SaaS solution to deliver integrated supply chain planning and enhance weapon systems support at Air Force Sustainment Center (AFSC) locations around the globe.
• 5,000 aircraft, 650,000 items, and supports weapon systems in 1,500 locations across a global theatre of operations.
CONNECTED, CLOUD-BASED SUPPLY CHAIN OPTIMIZATION
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CONNECTED, CLOUD-BASED SUPPLY CHAIN OPTIMIZATION - EXAMPLE
• Outcomes = inputs
• Scenario mapping
spares for locations,
cost, Ao
• Real usage data, not
guesses
SPM is already helping to unify decision support systems in AFMC, NAVSUP and
USCG. All of this
enables the idea of managing knowledge to better spare, maintain,
repair and operate complex systems.
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• Private sector is actively embracing AM.
• GE has invested $7.1B in acquisitions and research centers...Aviation is the initial focus...Already 3D printing 30% of GE's Advanced Turboprop (ATP) engine and wing brackets for the A-350.
• Distributed manufacturing grid that supports the production of repair items closer to the point of need reduces standby transportation capacity to support unpredictable fluctuations in demand.
• AM's true value lies in new component design, and will reduce component counts in complex systems, thus reducing the number of items a supply chain will have to manage.
ADDITIVE MANUFACTURING OVERVIEW
Greater
Uptime
•Don’t wait for replacements
•Reduced inventories
Fast Product
Development
•GE has dropped cycle time for ATP Engine (GE 93) from 4 to 2.5 years
•This benefits DoD also
New Capabilities
•New component design to match changing threat and mission profiles
•Less reliance on contractor data rights
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RECENT STATS AROUND ADDITIVE MANUFACTURING
.
• Global 2016 revenues for AM were $15.9B 2016, will double to $35.4B by 2020.
• Demand for computer-aided design (CAD) software is expected to triple over the next 5 years. Pull through for PLM?
• AM is a priority to the DoD in FY 2018 NDAA for “revolutionizing the industrial supply chain" through 1) Use 3D printers at “tactical levels,” 2) Create Defense Manufacturing Innovation Institutes 3) Produce obsolete parts.
Sources: IDC and NDAA 2018
Market Doubling...
3X Demand for CAD...
Major DoD Priority in FY 2018...
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• Product dev cycle / lead times - No tooling or assembly + tight feedback loop
• Manufacturing cost - Limited tooling, machining, or castings and lower material
• MRO - Turbine blades on tanks, aircraft - add material to damaged blades
• Uptime - Fewer supply lines + reprint damaged / obsolescent items
• Cost of launch - Lightweight materials to lower cost or increase payload
• Novel geometries - Designs previously impossible to improve eng performance
• Data rights - A changing dynamic through 'hardware hacking'
• Efficiency - Recycling spent shell casings or packaging materials
• Green - Lower 'cradle to gate' footprint with no tools, dies, material scrap and fewer harmful emissions (produced in vacuum)
ADDITIVE MANUFACTURING VALUE DRIVERS
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THE PROMISE OF ADDITIVE IS GREAT BUT HOW TO GET THERE?
.
• Redesign
• Multi CAD
• 'Machinist Gap'
• Print Accuracy
• Certification
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ADDITIVE MANUFACTURING - EXAMPLE
• Forward deploy only
needed materials
•Reduced cost
•Reduced inventory
The benefits of additive manufacturing will drive component consolidation that will reduce component
counts in complex systems, thus reducing the number of items a
supply chain will have to manage.
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• Having a PLM system in place accelerates the pathway to data quality in a program.
• Can be used for both acquisition and sustainment...NAVSEA PEO Ships example.
• Data coming from PLM systems will eventually be rendered to and from logistics operations in the field with IoT and AR.
• PLM will act as the rock-solid base from which loftier goals like AR based maintenance, additive manufacturing, and supply chain optimization will spring.
PLM AS A FOUNDATION
PLM to desktop
Cost Analysis
Meta Data Linkages
Acquisition Library
Key Decisions
Config
Mngt
PLM to field
3D CAD product models
Warranty
details
Reqs links to design
Diagnostic and Repair procedures
Testing data
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PLM AS A FOUNDATION - EXAMPLE
•Superior Config Mngt
•Deliver engineering
artifacts
•OEM improves
designs
Configuration Knowledge vs Configuration Control. This isn’t just static tracking
for how
each unit is arranged; it is about better and more strategic
decision-making across an entire aircraft fleet based on empirical data.
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Questions?
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CONTACT INFO
Maj Gen (Ret) H. Brent Baker, Sr.
801-388-4580
