CTMA Connector April 2015
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National Center for Manufacturing Science
News and views from the world of manufacturing

Pendaran Offering Free Tuition for Transitioning Veterans

Pendaran, home of the Virtual Workplace Simulator, is now offering free tuition to U.S. veterans transitioning from active duty and preparing for civilian careers.

“We want to give back,” said Founder and CEO Hossein Nivi. “Pendaran has had the privilege of working with Department of Defense Maintenance depots over the past several years. Our team has developed a deep appreciation for the sacrifice being made by those who serve in our military and this is something we can do to show our gratitude.”

The Virtual Workplace Simulator is a boot camp for business. Students and teams learn by experiencing the failures and successes of running a complex operation. U

nlike traditional Power Point training, the Virtual Workplace incorporates an innovative experiential learning approach that combines the attributes of “business boot camp” in a flight simulator-like environment, leading to deep discovery and sustained learning.

For information, contact Carol Michaelides, VP at (734) 268-5242

Project Announcements

Project Announcement – Integrating 3D Technical Data Packages (TDPs) into a Product Lifecycle Management (PLM) Environment 

Suppliers and vendors must be ready and willing to accept three-dimensional (3D) models in place of two-dimensional (2D) drawings whenever possible, as failure to do so will result in extended product development schedules, increased costs and poor product quality.  However, moving to a Model-Based Enterprise (MBE) approach requires a significant shift in how end users create, visualize and interact with design representations, either 2D or 3D.  This brings up the question – Are industry suppliers ready to make 3D drawings the master to manufacture parts?
A cultural change is necessary to embrace a 3D model-centric deliverable that extends beyond the internal boundaries of the organization.  Industry will need standards and policies during the creation of the 3D model.  Additionally, industry department organizations such as quality, inspection, manufacturing and service must have mechanisms to accept and work with 3D models as the primary document, relying less and less on 2D drawings or eliminating them.
A comparison of the CREO Parametric models with the new PRC and STEP model files will be conducted to ensure that these models define an identical geometry.  The proposed solution is to partner with industry leaders to formulate a MBD TDP.  The TDP will consist of engineering drawing formats that are compatible with the existing 3D PDF (PRC) solution and embedding STEP files into these PDF files.  In this initiative, the proposed solution is to partner with industry leaders to create a process, which will work with multiple CAD and PLM systems processes.
Those interested in participating in this initiative should contact Jeff Walker, (360) 782-1370
Project Announcement – T700 Improved Durability Compressor Coating Hardware Processing to Support Qualification / Field Service Evaluation
 The T700-GE-401C engine is operated in all military services, powering H-60, AH-64 and AH1 aircraft.  These types of aircraft are operated in both erosive and maritime environments. These austere operating environments degrade compressor airfoil condition and performance.  The commercial version of the T700 is the CT-7 engine that is widely used across the commercial industry. Commercial gas turbine engines also exhibit compressor airfoil erosion due to contaminates entering the engine inlet. Contaminants such as road dust erode turbine air compressor blades used by the commercial aviation industry, degrading engine performance and increasing fuel consumption.
The application of an erosion/corrosion resistant coating on T700 and similar commercial engine compressor airfoils could result in retaining engine performance for longer operational periods; decreasing compressor blisk, variable vanes and vane segment replacement; decreasing total operational costs and increasing aircraft readiness and availability. 
This effort is addressing these challenges by optimizing and validating the performance of erosion-resistant (ER) coat­ings designed for gas turbine engine applications such as the T700 and commercial variations. 
Those interested in participating in this initiative should contact Debbie Lilu, (734) 995-7038
Project Announcement – Expeditionary Fluid Analysis Capability (Phase II)
Effective fluid analysis can be central to a unit’s preventive and predictive maintenance programs.  Whether the interval to change oil or check equipment fluids is based on calendar days, mileage, or a combination of measures, a sound fluid analysis program lays the foundation for improving equipment readiness and availability.  During preparations for training exercises or deployments, units may conduct fluid changes in order to begin the training or deployment with the freshest, most effective fluids in their equipment.  Contrary to this particular practice, multiple studies of fluid analysis programs within the Department of Defense has determined that over 80% of the recovered oil still met or exceeded manufacturers specifications after it was recovered during equipment oil changes.  
A portable, deployable, reliable fluid analysis device can quickly and accurately determine fluid condition and provide immediate feedback on fluid condition and quality.  These devices provide vehicle operators and maintenance personnel the ability to quickly and accurately determine oil/fluid quality on a real-time basis utilizing a minimal sample size.  The Expeditionary Fluid Analysis Capability (EFAC) will provide participants a portable fluid testing and diagnostic tool that provides maintenance personnel with real-time assessments of equipment fluid condition. 
The strategic objectives of the EFAC are to:
  • Enhance and modernize the joint oil analysis program
  • Rapidly deliver fluid assessment results to maintenance personnel
  • Provide a mechanism to virtually connect oil analysis laboratories with the maintenance community at the POM
  • Refine laboratory operations and analysis
  • Improve maintenance execution
  • Improve the condition, reliability, and readiness of the weapon systems employed by the military Services
Those interested in participating in this initiative should contact Debbie Lilu, (734) 995-7038
Project Announcement - Joint Maintenance Data Enterprise Interoperability (Phase II)
In today’s global net-centric service industry, it is commonplace for maintenance of complex aviation, ship, railway and automotive to be contracted to the best-value provider.  In order for this third-party service provider to execute the most effective and efficient maintenance, pedigree information regarding that hardware must be made visible and actionable to that provider.  Currently, commercial industries are lacking in software and system capabilities that communicate information not only from system to system but also to multiple facilities globally and across service providers.  Any sharing of information, resources or services is usually ad hoc, disjointed and informal with no traceability, and lacks accounting for life-cycle management or cost considerations.  Another result of the shortfall in this capability is a significant redundancy of parts stocks, consumable inventory, maintenance capability, and services.  All these inefficiencies are ultimately passed to the consumer in terms of the cost paid for goods and services. 
Both industry and the military services have been pursuing efforts, (IT, process, procedural and contractual) in an attempt to rectify this issue.  Through the International Standards Organization (ISO) and industry associations such as AIA and NDIA, industry has been actively engaged in rectifying this shortfall through the development of overarching information system-agnostic standards for the exchange of hardware pedigree data required for maintenance and sustainment.  DoD has also been an active participant in this endeavor and has taken specific actions to evaluate these data interoperability standards through efforts such as Joint Logistics Integration (JLI), Naval Logistics Integration (NLI), MAGTF Logistics Integration (MLI), as well as Inter- agency Logistics Integration initiatives.  Although much has been accomplished to date, further work needs to be accomplished in order for the maintenance community to leverage these standards data exchange processes. 
Developing tools, technologies and processes that can leverage the benefits associated with operating across organizational boundaries will enable the maintenance and sustainment community to share logistics capacity and materials.  This initiative will develop a joint concept of operations (CONOPS) for sharing logistics information across a coalition enterprise in a secured cloud-enabled environment and demonstrate the capability to transmit, receive and manipulate this information between a minimum of two separate maintenance organizations in a logistics exercise that simulates operational conditions.  Along with the CONOPS, this initiative will establish agreed to business rules for publishing and subscribing information, continuing the identification and mapping of data using ISO 10303 application protocol 239 (PCLS) and methods for developing decision quality information across the coalition maintenance enterprise.
Those interested in participating in this initiative should contact Debbie Lilu, (734) 995-7038
Project Announcement – Optimizing the Performance of the H-60 Integrated Mechanical Diagnostic System (IMDS) and T-700 Engine Electrical System
The health of electrical systems are vital to the reliable operation for both commercial and military aircraft.  Related areas would include naval vessels, ground vehicles, trains, alternative energy generators, construction machinery, automobiles, etc. The design intent of electrical systems is to transmit signals or electrical power, continuously or intermittently.  Failure of electrical systems have led to catastrophic events in both the commercial and military sector.  Reliable predictive maintenance and testing of a potential electrical system failure would greatly benefit the military and public good. A study of rotorcraft accidents from 1990 to 1996 found that related causes of accidents were due to various systems and structural failures (Aviation Safety 1998). This study lead to the recommendation of the design of Health and Usage Monitoring Systems (HUMS) capable of predicting impending equipment failure for on-condition maintenance, and more advanced systems capable of warning pilots of imminent equipment failure.  Developed for the commercial sector the Integrated Mechanical Diagnostic System (IMDS), also known as Health and Usage Monitoring Systems (HUMS) was first implemented in the SH-60 aircraft using Commercial-off-the-shelf (COTS) components.   Like other systems in aircraft today the effectiveness of the IMDS-HUMS is dependent on the health of the electrical systems that connects it to the various sensors and mechanical devices that are monitored.  The proposed initiative will develop and validate DoD common electrical test equipment at the participating H-60 helicopter units across the U.S. Armed Services.  This proposed initiative focuses on key subsystems selected by the end users which include:
  • Integrated Mechanical Diagnostic System (IMDS), also known as Health and Usage Monitoring Systems (HUMS)
  • T-700 Engine Electrical System
Those interested in participating in this initiative should contact Steve Hale, (734) 995-4195
Project Announcement – Enhanced Environmental Performance for Safety Glass Concept Paper
Safety glass is ubiquitous and takes many forms, ranging from polycarbonate material to glass laminates, and even to aluminum oxynitride ceramic. Safety glass is used in many, many applications (including automotive glass) where some degree of protection from foreign object strike is needed. “Bullet proof” glass laminate safety glass protects bank tellers and store clerks from actions of violent criminals. Polycarbonate lenses in safety glasses protect worker’s eyes. Any application where transparency is required but potential for damage from some sort of projectile is possible is a candidate application for safety glass.  Rock strike damage, crack propagation, and delamination are known issues with laminated safety glass as is readily evident by the numbers of “free windshield repair” entrepreneurs gracing shopping mall parking lots and major street intersections. Those repair costs may be free to the auto owner but not to his/her insurance company. Data on the total cost to insurance companies isn’t available but is certain to be enormous.
Two current Army problems with safety glass, which the project will eliminate, are damage caused by rock strikes in military convoys and delamination of the layers.  Damage to safety glass requires replacement; therefore both of these problems have increased the logistical and life cycle costs to the Army.  The same problems plague auto and truck owners. Learning from this Army test bed can be extended to commercial automotive applications.
The intended solution for this project is to decrease the life cycle costs to the Army by developing safety glass without significantly increasing the weight or the cost of the solution.  For the rock strike problem this can be in the form of, but not limited to, new sacrificial strike plies that can be replaced/repaired in the field, or coatings that increase the materials resistance to strike damage.   For the delamination problem will be approached from three perspectives.  The first is to develop new interlayers, or coatings, that would decrease delamination.  The second is to investigate the effect of processing parameters on delamination. Thirdly investigate the effect of integration of the safety glass to metal frame work on delamination.
Those interested in participating in this initiative should contact Tony Haynes, (734) 995-4930 

Upcoming Events

April 28

JTEG Technology Forum: Non-Destructive Inspection

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May 26 - 28

CTMA Partners Meeting

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Pendaran: Virtual Workplace Simulator

Pendaran, Inc., NCMS member and originator of the Virtual Workplace Simulator, is extending a special offer for CTMA members to attend the upcoming Virtual Workplace Simulator session in Ann Arbor, the week of June 1 - 5 and July 20 - 24, 2015.

The Virtual Workplace incorporates an innovative experiential learning approach that combines the attributes of “business boot camp” in a flight simulator-like environment.  Participants learn to work as a team to identify and sustain operational improvements for improved business results.

Pendaran Virtual Workplace Simulator is being successfully deployed in NAVAIR FRCs and commercial industry.

Please contact Debbie Lilu at 734.995.7038 for more information.

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