Article

AM Travels to Distant Locations

Three industry partners team up to deliver
DDAM to Marines

By Aaron Johns, Siemens Government Technologies

Article originally appeared in Issue Twelve of the Annual Magazine of the Commercial Technologies for Maintenance Activities Program and reproduced here with permission of the National Center for Manufacturing Sciences.

Editor’s Note: Advanced Manufacturing (AM) has become a wellknown disrupter to traditional supply chains. However, these advances have typically required AM systems to be housed in a stable, digitally connected environment. A method for establishing AM capabilities in remote, disconnected environments has been a recognized need for bringing rapid parts replacement capabilities to new locations around the world. We asked Siemens Government Technologies to describe the CTMA project that’s making this goal a reality.

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In a new collaboration effort sponsored by the Office of the Deputy Assistant Secretary of Defense for Materiel Readiness (ODASD-MR) through NCMS’s CTMA Program, Siemens Government Technologies (SGT) and industry partners Guidehouse and Amazon Web Services (AWS) have demonstrated the first phase of a new distributed and disconnected advanced manufacturing (DDAM) capability. Through this project, the value of this technology can be explored at a rapid pace to solve defense maintenance, sustainment, and logistics challenges.

The team used an AWS GovCloud-hosted instance of Siemens’ Xcelerator industrial software platform, where Technical Data Packages (TDPs)—including machine code—may be pulled from a centrally hosted environment to a local manufacturing environment and accessed anywhere in the world, based on the DOD’s mission needs. At a high-level view, this solution was configured as the backbone that managed all the engineering data, while Siemens’ low code application development platform provided the ability to rapidly deploy the capabilities on-the-fly through working with Marines in the field. This application allowed the team to collaborate with the Marines to create a user interface that made the engineering data easily readable and accessible to its users. This collaboration provided immediate value to the DOD as the SGT team was able to test iterations of this solution at industrial bases around the world and apply changes onsite based on critical feedback from stakeholders in uniform.

The most common feedback received from the personnel responsible for maintaining and servicing the billions of dollars’ worth of DOD equipment was that the engineering data required to manufacture a part was in multiple places and often not standardized in a coherent format. This resulted in immense resource waste as engineers had to reverse engineer parts, test, redesign, and repeat. To solve this challenge, the SGT team utilized TDP templates to standardize part data format and include all pertinent documentation within one file that can be read on a mobile device, tablet, or laptop.

AWS provided rugged Snow devices, which are powerful and hardened edge computing devices used by the DOD. Edge computing allows devices in remote locations to process data at the “edge” of the network, either by the device or a local server. AWS provided invaluable integration support to ensure that Siemens products worked offline and could also sync to and from the edge device when resurfaced to the AWS GovCloud instance of Siemens Xcelerator.

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The team used an AWS GovCloud-hosted instance of Siemens’ Xcelerator industrial software platform, where Technical Data Packages may be pulled from a centrally hosted environment to a local manufacturing environment and accessed anywhere in the world, based on the DOD’s mission needs.

As the integration partner, Guidehouse took on the Authority to Operate (ATO) and Interim Authority to Test (IATT) initiatives to implement DDAM as well as the business process reengineering, governance models, and organization change management. These key tenets will be pivotal for successful implementation of DDAM across multiple, disconnected sites.

Furthermore, Guidehouse has continued collaboration efforts with the DOD and industry regarding intellectual property of data for manufacturing parts with OEMs.

Looking ahead, SGT, Guidehouse, and AWS are preparing to implement DDAM in approximately 50 more industrial bases around the world. Also, multiple manufacturing processes will be supported including computer numerical control (CNC) machining, robotic sheet metal forming, and metal selective laser melting (SLM); the first phase solution was demonstrated by additively manufacturing polymer replacement service parts. Finally, a quality feedback feature will be added, allowing shop floor personnel to properly inspect and certify critical parts.

Through a synergistic partnership between NCMS, SGT, AWS, and Guidehouse, access to critical engineering data can be available anytime and anywhere.

This successful demonstration couldn’t have been possible without the input of everyone in uniform who provided solutions and critical feedback about current processes. This is a great example of what can be achieved through teamwork across all the involved parties, including NCMS, the Marines, the industry team, and OSD leaders who understand the need for field personnel to be able to manufacture repair parts on demand through advanced manufacturing initiatives.

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