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Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
Presentation on STEP-NC to the Aerospace States Association
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Presentation on STEP-NC to the Aerospace States Association

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Robert E. Mansfield, Jr., Brig Gen, USAF (RET) Aerospace Executive in Residence Embry-Riddle Aeronautical University Committee Chair

Robert E. Mansfield, Jr., Brig Gen, USAF (RET) Aerospace Executive in Residence Embry-Riddle Aeronautical University Committee Chair

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  • This should be a quick slide – people are used to standards in many industries/situations, the point of this slide is to show EXTENSION of Standards into the Supply Chain, (Design through Manufacturing) Two bolded items are the particular topic of today. Standards to Transform things, processes, etc.
  • STEP – The Standard for Product Data Exchange….. At the Design level that enables 3D modeling, enhanced visualization, enhances product understanding, speeds time from design to build to market. STEP for CAD data is the FIRST part of the data standard enabling supply chain production response. The SECOND part is enabling the use of STEP data at the sub-tier supplier (Manufacturer) through STEP-NC as show in the next slide.
  • STEP Design Data is only part of the overall story. Once an item is designed, it must be produced – when considering complex systems such as aviation and aerospace delivery systems (airplanes and the like), each system is the obvious assembly of thousands of parts, each of which must be produced – nothing new here, just reiterating the understanding within the context of manufacturing at the machine tool level. The point is that the STEP Design Data still must be interpreted into manufacturing instructions for cutting, drilling, milling, etc. This is where STEP-NC comes in. Using STEP Design Data, STEP-NC enables each sub-tier supplier to work from common (standardized) data to identify the Project, Work plan, and Working step, through the manufacturing process to specific machines, for every workpiece, and individual tool paths, to accomplish the piece part production to feed back up through the sub-assembly and assembly process, all driven from common – standards driven data. In many cases the OEM has thought about how to produce the individual piece parts. With STEP-NC, the OEM can distribute this knowledge throughout the sub-tier supply base for their direct or indirect use, thus saving time and money throughout the supply base. This also improves reliability and quality as the OEM's get what they intended.
  • These are representative of current STEP-NC Demonstrations which will be leveraged and extended in the ASA Deployment Projects, as well as brining in additional OEM’s (customers) and their suppliers.
  • So let’s look back “up the chain” for the advantages of STEP-NC for the Aviation/Aerospace Supply Chain. And remember, this is for each and every part within the overall Aero Delivery System, and across the entire supply chain from the OEM throughout the tiers of suppliers! (ok, so I’m being a little dramatic here – just want to make the point)
  • Current Situation: Customer (OEM’s) generate and send 2-D and in some cases 3-D data to/through their suppliers. At the supplier level, each stores that drawing data in one or more databases, then, depending on the CAD systems they have, each supplier converts that 2-D / 3-D data into machine specific instructions. Typically this is about 28 hours of work for each different part being produced. The supplier will also attempt to optimize the machine time depending on the variables they are trying to control, (i.e. production time per part, tool expense/wear per part, machine utilization, etc.) This also is time consuming and can lead to local optimization without regard to overall systems impact. With STEP-NC: The customer (OEM’s) generate the 3-D models and builds and supplies the STEP-NC data for all suppliers. Each supplier then uses a single STEP-NC Adapter (software tool) to customize and localize the STEP and STEP-NC provided data into the specific machine configuration for their shop. The STEP-NC Adapter can also provide the local machine optimizations to meet the needs of the individual supplier and enable the total system optimization to meet the customer (OEM) needs. The STEP-NC process assists in the version control situation by reducing the need for a variety of duplicated drawing and CAD systems interfaces. Data and Processes are enabled through application and extension of data standards.
  • This “The Ask” slide – may need to modify this but this is a start. And this might very well be the slide to end on. Slide 7 (next one) is there more as a backup to show that there are current industry participants working on this. Slides 8-12 are just the slides that were in the initial set, which I would propose be dropped, but I wanted to keep them in this version just for comparison purposes.
  • Transcript

    • 1. Presentation on STEP-NC to the Aerospace States Association Dr. Martin Hardwick President STEP Tools, Inc. Professor of Computer Science, RPI & Ray Patterson Capital Consulting Group
    • 2. Why Standards
      • Define connectivity and facilitate communication
      • Enable new levels of functionality
      • Create new markets and opportunities
      Transformation Stories Internet Protocols HTML IBM PC MS Word Postscript RS274D STEP STEP-NC Other Stories MAP SGML Ada or PL/1 Microchannel Wordperfect HPGL BCL IGES
    • 3. STEP – Standard for CAD data Started in 1991, released in 1997, universal in 2003
      • Advantages
        • Supplier can use $15K system instead of $50K
        • 3D models replace paper
        • Fewer errors, faster to market
      NIST estimate for total savings is > $1.2 B “ STandard for the Exchange of Product model data”
    • 4. What is STEP-NC and Why
      • But the supply chain still has to spend a lot of time making manufacturing plans after it gets the CAD data
      • STEP-NC is a new standard language for sharing OEM manufacturing plans with the supply chain
      CAD CAM CNC Old method OEM Supplier New method reduces costs Supplier
    • 5. Example of STEP-NC Program Work plan Working step Toolpaths Workpiece Machine Project
    • 6. Current state of STEP-NC Standard
      • Brief history
        • Started in Germany and Japan in 1999
        • 19 industry demonstrations in USA since 2000
        • ISO 10303-238 completed in April 2007
        • ISO STEP-Manufacturing team continues to develop and test the standard.
      • Current status
        • Complete the second edition of the standard
          • Enhancements for more accuracy and reduced tool wear
        • Enable networked machining
          • Link programs for distributed planning and simulation
    • 7. Who is currently participating
      • Industry
        • Boeing, Airbus, Lockheed
        • Pratt & Whitney, Honeywell
        • Sandvik, Scania, Rolls Royce
      Boeing Renton, May 2009
      • Vendors
        • STEP Tools, Fanuc, Siemens
        • Mastercam, GibbsCAM, UGS, Catia
        • Mitutoyo, NIST, KTH, CCAT
      Sandvik Sweden, March 2008
    • 8. Advantages for Aero Supply Chain
      • Suppliers get digital production plan instead of drawing
        • Reduces data preparation time from average 28 hours to average 4 hours
      • Machining is better
        • Optimization of feeds
        • Less tool wear
        • More accurate
        • Improved vendor qualification
    • 9. Advantages Comparison
      • STEP-NC
      • Customer sends STEP-NC data
      • Supplier selects machine tool, cutting tools and fixtures from options in the data
      • Software calculates best speeds and feeds and verifies process
      Drawing Database Drawing Database Drawing Database STEP-NC Database STEP-NC Adapter Machine Time 4 hours effort Built once for all suppliers 15% faster
      • Current Situation
      • Customer sends 2D drawing
      • Supplier interprets drawing to create CAM
      • Supplier determines feeds and speeds
      • Supplier and customer review for mistakes
      Drawing Database Machine Time 28 hours effort Customized for each supplier Optimizations are time consuming CAM System CAM System CAM System CAM Systems
    • 10. Current alternatives to STEP-NC
      • Continue using current method (G-codes)
        • This standard is now 50 years old
        • Every machine needs different codes
        • Makes manufacturing very labor intensive and time consuming
      • Put the OEM CAD system onto the controller
        • Suppliers have to buy more controllers
        • Suppliers have to buy $50+K CAD systems again
        • Makes SSM captive to single vendor; reduces opportunity for innovation
    • 11. How ASA can help?
      • Reduce costs for individual manufacturers and the aerospace supply chain
        • Strengthen domestic and global competitiveness
      • Expand SSM capabilities and opportunities
        • Reduce software entry costs
        • Give access to new markets
      • Speed STEP-NC standard adoption
        • Give voice to the small guys
      • Build on current STEP-NC demonstrations
        • Identify critical opportunities for demonstrations

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