NIST Technical Note 1753

Model Based Enterprise /

Technical Data Package
Summit Report
Joshua Lubell
Kenway Chen
John Horst
Simon Frechette
Paul Huang
http://dx.doi.org/10.6028/NIST.TN.1753

NIST Technical Note 1753

Model Based Enterprise /

Technical Data Package
Summit Report
Joshua Lubell
Kenway Chen
Simon Frechette
Systems Integration Division
Engineering Laboratory
John Horst
Intelligent Systems Division
Engineering Laboratory
Paul Huang
United States Army Research Laboratory
http://dx.doi.org/10.6028/NIST.TN.1753

August 2012

U.S. Department of Commerce

Rebecca M. Blank, Acting Secretary
National Institute of Standards and Technology
Patrick D. Gallagher, Under Secretary of Commerce for Standards and Technology and Director

Certain commercial entities, equipment, or materials may be identified in this

document in order to describe an experimental procedure or concept adequately.
Such identification is not intended to imply recommendation or endorsement by the
National Institute of Standards and Technology, nor is it intended to imply that the
entities, materials, or equipment are necessarily the best available for the purpose.

National Institute of Standards and Technology Technical Note XXXX

Natl. Inst. Stand. Technol. Tech. Note XXXX, NNN pages (Month and Year)
http://dx.doi.org/10.6028/NISTTN.XXXX
CODEN: NTNOEF

Abstract
This report summarizes the presentations, discussions and recommendations from the ModelBased Enterprise Summit held at the National Institute of Standards and Technology in
December of 2011. The purpose of the Summit was to identify challenges, research,
implementation issues, and lessons learned in manufacturing and quality assurance where a
digital three-dimensional (3D) model of the product serves as the authoritative information
source for all activities in the products lifecycle. The report includes an overview of modelbased engineering, technical challenges, summaries of the presentations given at the workshop,
and conclusions that emerged from the presentations and discussions.
Acknowledgment
We wish to acknowledge the individuals who organized and participated in the Model Based
Engineering / Technical Data Package Summit particularly those who presented to the group as
a whole, many of whom provided comments and suggestions on an earlier draft of this
document. We would like to acknowledge Richard Neal, whose meeting notes were invaluable in
writing the presentation summaries in this report, and Roy Whittenburg for his thorough review
of this document.

Keywords
Model-based, manufacturing, quality, MBE, MBD, technical data package

Introduction

The National Institute of Standards and Technology (NIST) Engineering Laboratory and the
Office of the Secretary of Defense (OSD) hosted the third annual Model-based Enterprise and
Technical Data Package1 (MBE/TDP) Summit from December 12 through December 15, 2011,
at NIST. Over 150 participants from industry and government met to share the latest
technological developments and best practices for model-based engineering (MBE) 2, and to
continue work on a new version of the MIL-STD-31000 Technical Data Package (TDP) standard
[1] to include requirements for 3D models. The Department of Defense (DoD) Engineering
Drawing and Modeling Working Group is responsible for updating MIL-STD-31000 to support
delivery of model-based technical data for defense systems. Table 1 lists the organizations that
attended the Summit.
The Summit consisted of a series of technical presentations focusing on different aspects of
model-based engineering. The summit included separate working group meetings devoted to
revising MIL-STD-31000 and related DoD standards. This report is concerned with the technical
presentations and technical discussions related to MBE. The results and materials from the MIL
standards working group meetings are not included in this report.
Section 1 of the report provides a brief introduction. Section 2 describes the main concepts of
MBE and its advantages for manufacturing. Section 3 highlights technical challenges to adopting
MBE in manufacturing. Section 4 summarizes each of the technical presentations. Conclusions
and recommendations are in Section 5. The appendix contains a table of acronyms used in the
report, agenda, and all presentations approved for public distribution.3

The Technical Data Package (TDP) is the collection of all product data needed to manufacture and maintain the product.

Model-based Enterprise and Model-based Engineering are often treated as interchangeable terms. For the purposes of this
document, we define the terms as follows.

Model-Based Engineering an approach to product development, manufacturing, and lifecycle support that uses a
digital model to drive all engineering activities.

Model-Based Enterprise an organization that uses model-based engineering.

Those not included were not approved as of the publication of this Technical Note.

Table 1. Organizations participating in the Summit

ACIT
Aerospace Industries Association (AIA)
South Carolina Research Authority
(SCRA)
Automation Alley

Action Engineering
Anark Corporation
Autodesk, Inc.
B&W Y-12, LLC National Security
Complex
Bell Helicopter Textron
CT Core Technologies
Decision / Analysis Partners
GE Energy
ICF International
ITI TranscenData
Jotne North America Inc.
LMI Government Consulting
Lucrum Group
Mitutoyo America Corporation
Nextec Applications Inc.

BAE Systems
Boeing Company
Dassault Systemes
Defense Logistics Agency
Honeywell
Imagecom, Inc.
Jacobs Engineering
L-3 Combat Propulsion Systems
Lockheed Martin Missiles & Fire Control
Metrosage LLC
National Institute of Standards and
Technology
Northrop Grumman Technical Services
Peerless Technologies Corporation
PTC
RECON Services/Army
Renishaw PLC
Sandia National Laboratories
Spatial Integrated Systems, Inc.
U.S. Air Force
U.S. Air Force Warner Robins Air
Logistics Center (WR-ALC)

OSD Manufacturing Technology

Pratt & Whitney
Raytheon Company
Renaissance Services, Inc.
Rolls-Royce North America
Siemens PLM Software Inc.
TSR Optima
U.S. Air Force Research Laboratory
U.S. Army Armament Research,
Development and Engineering Center
(ARDEC)
U.S. Army Research, Development and
Engineering Command (RDECOM)
U.S. Army Tank Automotive Research,
Development and Engineering Center
(TARDEC)
U.S. Marine Corps
U.S. Naval Facilities Expeditionary
Logistics Center (NFELC)

U.S. Army Materiel Command Logistics

Support Activity (USAMC LOGSA)
U.S. Army Research Laboratory
U.S. Coast Guard
U.S. Naval Air Systems Command
(NAVAIR)
U.S. Naval Sea Systems Command
(NAVSEA)

Model-Based Engineering

Until recently, most engineering and manufacturing activities relied on hardcopy and/or digital
documents (including 2D drawings) to convey engineering data and to drive manufacturing
processes. With the advent of new manufacturing data format standards and more powerful
engineering software, it is now possible to perform all engineering functions using data models.
The model-based engineering (MBE) approach uses these models rather than documents as the
data source for all engineering activities throughout the product life cycle. The core MBE tenet is
that models are used to drive all aspects of the product lifecycle and that data is created once and
reused by all downstream data consumers.
A model is a representation or idealization of the structure, behavior, operation, or other
characteristics of a real-world system. A model is used to convey design information, simulate
real world behavior, or specify a process. Engineers use models to convey product definition or
otherwise define a products form, fit and function. In MBE, models can be applicable to a wide
range of domains (systems, software, electronics, mechanics, human behavior, logistics, and
manufacturing). Models can be either computational or descriptive. Computational models are
meant for computer interpretation and have a machine-readable format and syntax. Descriptive
models are human interpretable and meant for human consumption (symbolic representation and
presentation). Core to MBE is the integration of descriptive models with computational models.
Computer aided design (CAD) models used in manufacturing are a good example. Early CAD
models were meant only for human viewing. Today, CAD models can be directly interpreted by
other engineering software applications. A variety of standard interchange formats now exist to
enable application-to-application transfer of engineering data.
In the context of manufacturing, model data drives production and quality processes. A product
model used in manufacturing is a container not only of the nominal geometry, but also of any
additional information needed for production and support. This additional data, known as
Product Manufacturing Information (PMI), may include geometric dimensions and tolerances
(GD&T), material specifications, component lists, process specifications, and inspection
requirements.
Two critical factors give MBE significant advantages over drawing-based or document-based
engineering: 1) computer interpretability and 2) data associativity. The primary reason to use a
data model in engineering and manufacturing is that a model can be processed directly by
engineering software applications. In a document-based environment, humans must interpret the
engineering documents and then enter the information into the specific user interface of each
engineering application. Whether it is finite element analysis (FEA) or computer aided
manufacturing (CAM), each application creates its own internal model. In the past, the only
access to this model was through the applications user interface (keyboard and screen). With
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MBE, the applications read and write the models directly. This results in fewer errors and a
drastic reduction in processing time.
Data associativity is critical to model integrity. Data association within and between documents
is very difficult to maintain. Tolerances, material specifications, surface finish, hardness, and
other information must be associated with specific features in the model. In analysis models, for
example, boundary conditions are associated with the point at which they act. In assembly
models, components must be associated with and oriented toward mating components. Data
associativity is critical for model interpretation by software applications and is built-in to the
model representation formats and data exchange standards.
Quintana et al. [2] define a products Model-Based Definition (MBD) as a dataset containing the
models precise 3D geometry and annotations. The annotations specify manufacturing and life
cycle support data and may include notes and lists. The model comprises a complete definition of
the product, without relying on supplemental documents such as 2D drawings. 2D drawings are
not needed when annotations are associated with objects in the model and can be viewed with the
model.
Not only do humans have to be able to understand the model, but software applications have to
understand the model as well. Quintana outlines requirements for engineering models.

CAD systems must be able to manipulate, import, and export 3D solid models.
CAM software must be able to define and validate machine-readable instructions for
making the model, and must document the process definition.
Computer Aided Engineering (CAE) software must be able to validate and optimize the
product definition.
Product Lifecycle Management (PLM) software must be able to control access and
manage change of the various models and documents associated with the product.
Applications such as Enterprise Resource Planning and Manufacturing Execution
Systems need to extract raw material and component information from product models.

The key to achieve interoperability across software applications is open standards, i.e., those
developed by consensus either within a standards development organization or a consortium of
stakeholders. No single software tool can perform all of the engineering tasks needed to design
and manufacture a product. No single software product can do it all well. Users will mix and
match software products according to their business objectives. Standards define an agreed-upon
syntax and semantics of 3D modeling constructs and annotation so that users can understand one
anothers models. Standards for representing, exchanging, and determining the fidelity of PMI
are of particular importance because PMI (includes GD&T annotations) is essential to
manufacturing. Driven by industry, standards are adopted nationally and internationally,
positively affecting interoperability across software applications.
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Open standards are vital for MBE. Unlike industry standards, where the underlying technology is
neither open nor democratically managed, no single company can exert an inordinate amount of
control over the intellectual property in an open standard.[3] As a result, a company whose
product model is based on open standards is less likely to find itself in a situation where it must
rely on a competitors software in order to understand the model or, even worse, support a
product whose digital model was created using software and computer hardware that is no longer
available. Avoiding the latter scenario is of particular concern for companies such as aerospace
manufacturers whose products have lifecycles measured in decades far longer than the typical
lifetime of a CAD software application or computer operating system.

Benefits, Opportunities, and Challenges

MBE yields significant benefits to manufacturers and their customers. MBE has been shown to
substantially improve productivity and reduce manufacturing costs. A study by the Aberdeen
Group documented significant time and cost savings when model-based techniques are compared
to conventional engineering practices.[4] Another study found MBE methods result in time
savings of a factor of three for first-article product development and a factor of four for
engineering change management.[5]
Model-based engineering increases the potential value of archived product data. As mentioned in
Section 2, MBE enables Product Manufacturing Information (PMI) including Geometric
Dimensions and Tolerances (GD&T), annotations, and notes to be integrated with the products
digital 3D representation. Incorporating PMI into the model eliminates the need for 2D drawings
and other supporting documents. MBE can also improve the accuracy of GD&T annotations by
enabling the association of GD&T semantics with features in a 3D model of a part. Software
tools can detect inconsistencies between the GD&T and the part geometry. New PMI standards
for dimensioning and tolerancing make this possible. As Bill Tandler states in his presentation
(4.11.4), emerging standards and technologies have the potential to prevent useless and costly
decoration of models.
Scott Lucero, OSD, states (4.7), MBE facilitates cross-domain coupling, i.e., integration across
a complex system spanning more than one engineering discipline. Cross-domain coupling results
in benefits such as improved integration of modeling and simulation, which in turn can lower
product development costs.
Recent technical and standards developments now make the vision of MBE possible for even the
smallest manufacturers. Developments include the implementation of 3D PMI (e.g., GD&T)
standards in CAD software, and the availability of low-cost software using new formats for
viewing and potentially exchanging models. The result is a dramatic lowering of the cost of
MBE, particularly for small businesses. For example, a 3D CAD model with GD&T annotations
and other supporting information can now be exported to the 3D Portable Document Format (3D
PDF).[6] A 3D PDF file can, in turn, be viewed with the Adobe Reader, free software that is a
standard application on most computers.
As discussed in Section 2, an open standards-based approach provides many advantages to
achieve interoperability between the applications creating and accessing model-based
engineering data. Still needed are new standards for the syntax and semantics of PMI symbols,
standards for the exchange of annotated 3D model data between systems, and standards for lowcost, efficient formats such as 3D PDF used for collaboration with partners and customers. Key
to the success of standards is effective deployment and risk reduction. Test methods for

validating that software applications correctly produce and interpret model data are an essential
component of standards development.
Validation testing is a multi-faceted, multiple-stage process. Not only must CAD systems
correctly implement dimensioning and tolerancing standards, but CAD systems must also be able
to exchange data with other CAD systems using standard formats. In addition, translators must
correctly export data to low-cost, collaborative formats. Finally, software for viewing and
manipulating the formats must correctly interpret the model.

Workshop Presentation Summaries

This section contains subsections summarizing each technical presentation. Subsection titles are
presentation titles. Italicized text following the subsection title identifies the presenter and
organization represented. Summary text for the most part paraphrases the actual ideas
communicated by the presenter. An exception is Bill Tandlers summary (4.11.4, second
paragraph), where we describe a real-time demonstration.
The Summit included two special sessions, each containing a group of presentations sharing a
common theme. The first, a session on quality control and quality assurance (4.11), was
organized by John Horst of NISTs Intelligent Systems Division, Engineering Laboratory, who
was responsible for choosing and inviting the speakers. The second special session, a series of
CAD vendor demonstrations, was organized by Rich Eckenrode of RECON Services.
4.1 OSD MBE / TDP Summit Objectives
Paul Huang, US Army Research Laboratory
The Department of Defense (DoD) Engineering Drawing and Modeling Working Group
(DEDMWG) provides technical coordination and policy guidance on weapon systems data for
acquisition, product design, analysis, simulation, manufacturing, provisioning and other product
lifecycle management functions. The DEDMWG works in concert with the Joint Defense
Manufacturing Technology Panel and DoDs Advanced Manufacturing Enterprise subpanel. A
major emphasis of the DEDMWG is to reduce costs by creating synergy across the community
utilizing work that has been done and avoiding reinventing the wheel in moving toward a
model-based enterprise. DEDMWG team members and collaborators include:

OSD Manufacturing Technology (ManTech)

Armed services (Army, Air Force, Navy/Marine Corps)
Defense Logistics Agency
Standards organizations such as the American Society of Mechanical Engineers (ASME)
and the Aerospace Industries Association
Government agencies including NIST, Department of Energy (DoE), and National
Aeronautics and Space Administration (NASA)

The scope of the DEDMWG includes standardization of technical data information requirements
for computer-aided design, engineering, manufacturing, data repository, data archival and
retrieval tools, and related applications for total product lifecycle management. Current
ManTech-funded activities where DEDMWG is playing a leadership role include definition and
validation of certified 3D models, use of 3D models across supply chains, reuse of 3D technical
data package (TDP) in technical publications, and revision of MIL-STD-31000. Key DEDMWG
accomplishments to date include:
8

Conversion of the MIL-DTL-31000C Detail Specification [7] to MIL-STD-31000

Improving synergy between ASME Y14.41 Digital Product Definition Data Practice
standard [8] and the Aerospace Industries Associations NAS3500 standard [9]
Refinement of annotations and delivery of schemas and validation guidebook into MIL
STD-31000
Over 60 subject matter experts participating in the revision to MIL-STD-31000

The MBE Summit supports the DEDMWG goals of encouraging cross-agency and
industry/government partnerships and discouraging duplication of efforts. The purpose of the
Summit for OSD is to communicate the state of the art, key research challenges, and to share
lessons learned and best practices.
4.2 NIST Engineering Laboratory Manufacturing Programs Overview
Vijay Srinivasan, Alkan Donmez, Mike Shneier, Fred Proctor, and Simon Frechette
National Institute of Standards and Technology
The Engineering Laboratory manufacturing program vision is to be the source for measurement
science and critical technical contributions underpinning standards used by the U.S.
manufacturing industry. Consistent with this vision, the Engineering Laboratory conducts
research to help advance standards and technology enabling U.S. manufacturers to compete more
effectively. The Engineering Laboratory has five manufacturing research programs: Smart
Manufacturing Processes and Equipment, Next Generation Robotics and Automation, Smart
Manufacturing Controls, Systems Integration for Manufacturing and Construction Applications,
and Sustainable Manufacturing.
The Smart Manufacturing Processes and Equipment Programs objective is to advance
measurement science enabling rapid and cost-effective production of innovative, complex
products through advanced manufacturing processes and equipment. There are three thrust areas
in the program: metal-based additive manufacturing, smart machining, and micro- and nano
manufacturing. The metal-based additive manufacturing thrust addresses the need to understand,
identify, and reduce uncertainties in metal powder characteristics coupled with uncertainties in
the advanced manufacturing process and equipment that lead to uncertainties in the final product.
The smart machining thrust addresses the need to integrate modeling and simulation with realtime measurements to optimize processes and equipment. The micro- and nano-manufacturing
thrust addresses the need to improve the quality and yield of micro- and nano-scale products
through new measurement methods for improved process control.
The Next Generation Robotics and Automation Programs objective is to advance measurement
science to increase the safety, versatility, autonomy, and rapid re-tasking of intelligent robots and
automation technologies for smart manufacturing and cyber-physical systems applications. There
are four thrust areas in the program: sensing and perception, manipulation, mobility, and
autonomy. Sensing and perception enables next-generation robots to collaborate with humans in
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unstructured environments. Manipulation enables robotic dexterity essential for agile

manufacturing operations and a greater breadth of applications through Robotic Industries
Association (RIA) or ASTM standards for measuring performance. Mobility aims at allowing
manufacturing vehicles to operate safely and more effectively in the same workspace as humans
through the development of industrial vehicle safety standards. Finally, autonomy enables
creation of agile and reconfigurable robots that are easily tasked to perform new manufacturing
operations through standards and measurement tools for intelligent planning and modeling.
The Smart Manufacturing Controls Program objective is to advance measurement science
enabling real-time monitoring, control, and performance optimization of smart manufacturing
systems in the factory. There are three thrust areas in the program: factory networks, information
modeling and testing, and performance measurement and optimization. The factory network
thrust aims at enabling cost savings and ease of integration for networked equipment and sensors
by developing performance and conformance tests for data exchange and cyber security
standards through the Institute of Electrical and Electronics Engineers (IEEE) and International
Society of Automation (ISA). The information modeling and testing thrust aims at enabling
seamless information exchange throughout production activities by developing validation and
conformance tests for information exchange standards through ISO and the Dimensional
Measurement Standards Consortium (DMSC). The performance measurement and optimization
thrust aims at enabling optimization of manufacturing across the shop floor by developing
standards for measuring key performance indicators through the Association for Manufacturing
Technology (AMT).
The Systems Integration for Manufacturing and Construction Applications Programs objective
is to develop and deploy measurement science for integration of engineering information systems
used in complex manufacturing and construction networks to improve product and process
performance by 2016. The program addresses industrys struggle to digitize manufacturing and
thus achieve the level of integration needed to make substantial breakthroughs in manufacturing
productivity, quality, and agility. The two major program thrusts are Model-based Engineering
and Service-based Manufacturing. The Model-based Engineering thrusts objectives are to
conduct research and deliver technical results to enable the transition from document-based data
to model-based data, support new manufacturing processes and quality improvement, and enable
end-to-end integration from systems engineering to manufacturing. The Service-based
Manufacturing thrusts objectives are to develop service-oriented architectures for
manufacturing, and to create supply chain service models that enable SMEs to participate in
manufacturing supply chains.
The Sustainable Manufacturing Programs objective is to develop and deploy advances in
measurement science to enable improvements in resource (energy, material) efficiency and waste
reduction across manufacturing processes and product assembly by 2016. The program addresses
the industrys need for well-defined sustainability metrics and a measurement science-based
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methodology to compose those metrics across global supply chains within manageable
uncertainty. The two major program thrusts are Methodologies for Characterizing Sustainable
Processes and Resources and Integration Infrastructure for Sustainable Manufacturing. The
Methodologies for Characterizing Sustainable Processes thrust aims to define sustainability
metrics of unit and assembly processes and use those metrics in life-cycle predictions and
decisions. The Integration Infrastructure for Sustainable Manufacturing thrust aims to develop a
sustainability testbed based on real manufacturing scenarios.
4.3 NASA Integrated Model-Centric Architecture
Paul Gill, NASA
The NASA Integrated Model-Centric Architecture is based on the general model-centric vision
of advancing from a document-centric engineering practice to one in which structural,
behavioral, and simulation-based models representing the technical designs are integrated
throughout the lifecycle.
There are several problems to be solved, including:
Lack of affordability of projects and activities
Mission complexity growing faster than the ability to manage it
Inability to share models in a collaborative environment
Ineffective testing and too many design reviews
Lack of early problem identification
Necessity of searching for needed data
Necessity of integrating pieces as opposed to total model solutions
Data model quality uncertainty
Moving to a model-driven environment with integration and simulation capability will help
resolve many of the issues listed above. NASA has developed three use cases to illustrate the
benefits of deploying the model-centric vision. The first scenario is a change in requirements late
in the development cycle where a fully model-centric program would enable the tracing of effect
of a change across all aspects of the product. The second scenario is an in-flight anomaly, where
a model-centric architecture would allow immediate definition of data and information needed to
address the problem and locations of spare parts and needed materials. The third scenario
involves the deluge of development data where the volume of data is huge, and a model-centric
architecture would accommodate that requirement.
The means of establishing a model-centric environment comes in two parts. The first is the
establishment of Communities of Practice (CoP) in several areas including model-based systems
engineering, product data and lifecycle management, models and simulations, and computer
aided design. The CoP mission goes beyond communication and discussion to include the
deployment of model-centric toolsets. Seven teams have been established to address various
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aspects of the challenge. They are Benchmarking, Foundations, Current Architecture, Concept
of Operations (ConOps), Communications Plan, Pilots, and Workforce Capabilities.
The second part is the development of a three-phase roadmap to guide the model-centric
activities. The first phase is preparation, which involves establishing a common vision and
developing strategic and implementation plans. The second phase is implementation, which
involves developing standards and policies for new capabilities and developing a standard suite
of modeling tools and technologies. The third phase is sustaining and improving, which involves
establishing an operational model-centric infrastructure and a mature model-based development
methodology.
Key benefits that NASA envisions from moving to a model-centric culture include enhanced
affordability, increased collaboration, earlier identification of problems, and quicker diagnoses
and solutions. Early results are already having an impact.
4.4 Affordable Readiness through Model-Based Enterprise
Shelley Diedrich, U.S. Coast Guard
A new goal for the Coast Guard is affordable readiness through a model-based enterprise. Coast
Guard equipment is aging. Much equipment is at least 40 years old and no longer has data for
sustainment and maintenance. The access to needed data for maintaining equipment is becoming
an important issue.
The Coast Guard defines logistics as all the activities associated with developing, acquiring,
sustaining, and eventually retiring the components of capability, including people, systems and
information. This definition of logistics includes mission requirements and regulation
requirements needed to support assets. This view of logistics is different from the more limited
view of logistics in certain circles.
The Coast Guard vision includes:
Affordable readiness
Spiral MBE implementation
Standard Coast Guard processes
Integrated modular architecture
A configuration-based business model
Baseline management
The three elements of the vision are a standard product model, standard business model, and
single information technology system. The approach to achieving the vision involves developing
systems engineering for business model management and leveraging of government and industry
best practices. A roadmap was created to outline the strategy plan for achieving the vision. Every

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organization within the Coast Guard must be transformed to embrace and implement the MBE
solution.
Several risks have been identified and need to be addressed. These risks include lack of a
comprehensive ISO 10303 (also known as STEP the Standard for the Exchange of Product
Model Data) [10] pilot, limited STEP expertise, competing standards and limited ability to
sustain them, and revisions to STEP standards making the end state a moving target.
4.5 Model-based Engineering / Manufacturing Review from Y-12 National Security
Complex
Donna Bennett, National Nuclear Security Administration
Y-12 is a manufacturing facility whose mission includes sustaining a safe nuclear arsenal,
processing highly enriched uranium, and preventing nuclear proliferation and nuclear terrorism.
B&W Y-12 operates it for the National Nuclear Security Administration (NNSA). Y-12 plays a
vital role in DOEs Nuclear Security Enterprise. It has four core areas of research and
development: defense programs, transformation, complementary work, and basic science.
Y-12 focuses on the link between design and manufacturing by emphasizing model-based
engineering and manufacturing, which includes the use of 3D models for defining refurbished
stockpile product, supporting certification, and integrating design, engineering, and
manufacturing activities throughout the lifecycle. The model-based engineering and
manufacturing concepts are applied during design, analysis/simulation, manufacturing,
inspection, and packaging.
Y-12 has model-based activities in four areas: packaging of materials, life-extension programs,
the integrated glove box program, and the uranium processing facility. Packaging of materials
involves designing a product and testing it for requirement fulfillment (e.g., designing a
container and then dropping it to analyze the impact result). Life-extension programs develop
business rules around MBE needs and requirements, and complete process planning using work
in-process models. The integrated glove box program uses virtual process planning to identify
problems in fixture design and allows for corrections of these problems before any builds. The
uranium processing facility involves conceptual and ergonomic design with the intent of
identifying and resolving problems early in the design process.
The Y-12 Complex collaborates with other Department of Energy sites and federal agencies as
well as universities and private industry. The Plant Directed Research, Development, and
Demonstration Program supports innovative or high-risk design and manufacturing concepts and
technologies with potentially high payoff for the Nuclear Security Enterprise.
4.6 Model-Based Enterprise Impact on Organizational Behavior
James DeLaPorte, NexTec
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Organizations have a large inertia, and change is difficult. It is analogical to Newtons law of
motion stating, A body in motion tends to stay in motion unless acted on by an outside force.
The model-based enterprise (MBE) is an outside force that can drive change.
People in an organization tend to establish and to reinforce normal behavior. MBE is a
fundamental shift to 3D from 2D for all major organizations, which is a major perturbation from
the normal behavior. The impacts are felt in engineering, operations, quality, service and support,
information technology, and finance and contracts. All of these business units are required to
adapt, which means there is a need to rebuild the organization to support the use of 3D, to update
training and instructions, and to manage new applications and processes.
In order to achieve MBE and organizational behavior transformation, four elements are needed:
(1) empowerment of leaders at all levels, (2) adaptation to changing roles and responsibilities, (3)
trust and encouragement, and (4) active pursuit of conflict resolution. People will follow the new
behaviors defined by the organizational leaders. Keeping people involved and informed will
increase the individual commitment to the new norms. This commitment will stabilize and
sustain the new organizations. The new organizational behavior will be much more dynamic and
flexible.
4.7 Engineered Resilient Systems
Scott Lucero, Office of the Secretary of Defense
Engineered Resilient Systems (ERS) is one of the seven Department of Defense (DoD) Science
and Technology priorities. ERS was established to guide FY13-17 defense investments across
DoD services and agencies. Although ERS is a systems engineering approach, it goes far beyond
process. New technologies, applied across a broad community, are imperative in addressing the
changing requirements. New tools help engineers and users understand interactions, identify
implications, and manage consequences. This scenario of operations points to an ability to
automatically evaluate many options, understand all implications, respond to requirements,
propagate tradeoffs, and adapt through a continuous learning process.
A ten-year technology and science roadmap is currently under development. Four technology
enablers have been identified. These are:

System representation and modeling capturing physical and logical structures, behavior,
interactions with the environment and other systems
Characterizing changing operational contexts directly capturing operational data,
deeper understanding of warfighter needs and operational impacts of alternatives
Cross-domain coupling- better interchange between incommensurate models, resolving
temporal, multi-scale, multi-physics issues
Collaborative design and decision support well-informed decision support among many
stakeholders.
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Research will develop the tools and technologies to enhance engineering productivity, resulting
in resilient systems that are effective in a wide range of situations, readily adaptable through
reconfiguration or replacement, with graceful degradation. The goals for success of the roadmap
include adaptable design, faster and more efficient engineering iterations, and decisions informed
by mission needs.
4.8 The National Digital Engineering and Manufacturing Consortium
Dennis Thompson, South Carolina Research Authority
The National Digital Engineering and Manufacturing Consortium (NDEMC) is a public-private
partnership that is part of the Presidents Advanced Manufacturing initiative. The goal of the
NDEMC is to provide high performance computing capability for the small manufacturing
community. The consortium is providing Software-as-a-Service access to high performance
software and to the hardware on which it runs with an emphasis on modeling and simulation
capabilities.
There are two major thrust areas: 1) specialized consulting or training in modeling, simulation,
and analysis provided by teams of experts, and 2) on-line manufacturing support systems.
NDEMC stresses shared solutions. The goal is to provide tools that can serve a broader
community, not just satisfy very specific needs of a highly specialized application. The program
is focused across the product lifecycle. The benefits are realized by the original equipment
manufacturers, software providers, SMEs, and by the U.S. government.
Seven projects have been launched, and 30 to 40 projects are planned to be launched. A catalog
of 143 software tools is being developed and will be accessible by SMEs through the NDEMC
portal.
4.9

Department of Defense (DoD) MBE Program Reviews

4.9.1 Navy Digital Product Model

Ben Kassel, Naval Surface Warfare Center, Carderock Division
The Digital Product Model will be the authoritative source of data for the entire ships lifecycle.4
NAVSEA (Naval Sea Systems Command) is pursuing a two-level approach. At the first level,
the ship design is a collection of parts with the model supporting the management of the
collection. At the second level, there is an additional layer of information required to manage and
4

A memo signed by the Chief Engineer and Deputy Commander, Naval Systems Engineering Directorate SHIP DESIGN AND
ANALYSIS TOOLS GOALS, Ser 05T/015, Naval Sea Systems Command, Washington D.C., Sep 29 2010 "NAVSEA is
committed to creating and maintaining LEAPS models for every major ship class in the U.S. Navy to enhance lifecycle support
and incident response. A future goal is for NAVSEA to maintain a LEAPS model for every ship in the fleet." LEAPS (Leading
Edge Architecture for Prototyping Systems) is NAVSEAs product model repository implementation.

15

support the product from the as-designed and as-built derived models of the product. The Navy
believes that the STEP Product life cycle support standard (ISO 10303-239) [11] has emerged as
a useful mechanism to define product structure, the relationship between objects, and
configuration management, and that the STEP Core data for automotive mechanical design
processes standard (ISO 10303-214) [12] is a relatively mature mechanism for managing product
data. Contracts with the ship builder will specify that the contractor supply Data Exchange
Specifications (DEXs) based on the ISO 10303-239 information model supporting the
interpretation of data. In the future, the Navy will provide standard DEXs and will specify
compliance with those DEXs in all contracts.
4.9.2 Air Force Technical Data Objectives
Brench Boden, United States Air Force
The Air Force program Expeditionary Logistics for the 21st Century focuses on the
transformation of supply chain activities. It addresses major issues including data rights, data
availability, and acquisition strategy. A ManTech opportunity is seen in PLM integration and
new methodologies for managing product technical data. Interoperability is a major opportunity
area. Studies show the lack of interoperability costs billions of dollars per year.[13] The Air
Force ManTech program is developing a strategic vision and technical thrusts. The four focus
areas are:

Moving manufacturing left (i.e., developing technologies enabling early consideration of

manufacturing requirements during design)
Cradle-to-cradle digital thread
Responsive integrated supply base
Factory of the future

The cradle-to-cradle digital thread is particularly important to the TDP/MBE activities.

4.9.3 Army Research Objectives for MBE
Andy Davis, US Army Research Development and Engineering Command
The Army has identified three goals in achieving a model-based enterprise:

Fully integrated manufacturing enterprise to support weapons systems development

Digital thread connectivity from prototype to production
Establishment and implementation of best practices and standards for product data use

The Army is addressing challenges including lack of resources, competition from industry,
political interests, and institutional issues. Current investments include the Net-centric MBE
project ($ 8.9 million over 4 years) and Accelerated and Adaptive Army Fabrication Enterprise

16

($9.2 million over 4 years). The latter is a major activity focused on establishing an organic
capability within the army to pilot and demonstrate an advanced model-based enterprise.
4.9.4 Defense Logistics Agency Objectives for MBE
Rick Norton, Defense Logistics Agency (DL A)
There are three active MBE projects within DLA named Charter 1, 2, and 3. Charter 1 is an A-10
jet aircraft TDP exchange pilot. Charter 2 involves a contracting TDP within an MBE
environment. Charter 3 addresses supply chain activities. The Charter 1 project is a partnership
with the Air Force and Boeing that addresses parts provisioning using 3D model data. The
objective is to modernize the means of exchanging data. Charter 2 will begin with an in-depth
study of the present state of practice and emerging best practices in the model-based enterprise.
The study will include benchmarking supporting gap and trend analysis, and business case
analysis. Charter 2 will deliver a model-based enterprise/product lifecycle management
technology discovery and investment strategy for DLA. In summary, Charter 1 defines what
needs to be done in developing new MBE tools. Charter 2 determines what needs to happen to
drive contract deliverables within an MBE. Charter 3 will make MBE happen within the supply
chain.
4.10 Industry and ManTech Interaction Success
David Baum, Raytheon
Raytheon has four mission areas in addressing a technology-driven growth strategy:
Sensing, which expands beyond traditional Radio Frequency/Electrical-Optical to new
growth focus areas, including multi-mission areas.
Command, Control, Communication, and Intelligence), which broadens market presence
in communications, networking and knowledge management.
Effects (military actions or outcome), which leverages kinetic energy-based expertise into
Electronic Warfare, directed energy and cyber markets.
Mission support, engineering services, and training.
The objective is to identify and establish common product data management (PDM) systems,
engineering documentation standards, and process asset libraries. Technology-readiness level
and manufacture-readiness level should be defined in each lifecycle phase.
Raytheons capability development timeline is as follows:
2011: model-based definition complete an enterprise MBD specification,
2012: model-based manufacturing establish global supplier communication and deploy
CAD model derivatives,
2013: model-based engineering and lifecycle support implement virtual verification and
requirement allocations/derivations.

17

Raytheon leverages the Customer/Supplier Interoperability (CSI) ManTech program (see 4.13).
The vision of CSI is a flexible, configurable, standard-based system that automates common
tasks associated with customer supplier interoperability. Specific leveraging of the ManTech
work includes:
Working with industry partners PTC and ITI TranscenData to validate conversions of
CAD file formats,
Developing a standard MBD schema with start parts5 and PDM attributes,
Developing MBD model qualifications and workflows prioritized by modeling defect
causes,
Using ITIs model comparison software to identify model changes during the change
management process.
4.11 Special Session: MBE for Quality Control / Quality Assurance
John Horst, National Institute of Standards and Technology
The summit included a mini-session on MBE for quality control and quality assurance. Several
leading US quality measurement experts presented their perspectives on the potential offered by
a model-based approach to performing quality measurement. The presentations shared as a
common theme the improvement of the quality measurement process, i.e., making it more
efficient, less error prone, and more cost effective. They also touched on improving the
integration of the quality measurement process into the entire manufacturing enterprise
particularly that part of the enterprise focusing on product design, quality management, and
production. A model-based quality measurement process promises huge benefits, but also
presents huge challenges. A key challenge is intelligent use of model data.

4.11.1 Product Tolerance Representation: Critical Requirements for Product Definition

and Metrology Interoperability
Curtis Brown, Honeywell Federal Manufacturing & Technology
Full semantic product tolerance representation in digital information models is a critical
requirement for cost-effective and efficient manufacturing, where full semantic means that no
information in the digital model is mere decoration, but contains the complete and rich
association between geometry, feature definitions, tolerance frames, datum definitions, etc.
Current standard model-based product representations define nominal shapes only, and
unfortunately, one cannot manufacture nominally shaped parts. Parts that fit and function are

A start part is used to speed up the initial creation of a CAD model for a part, drawing, or assembly. Start parts can help to
encourage common modeling practices throughout an organization. Start parts are analogous to the document templates often
used with office suite applications to facilitate creation of reports, spreadsheets, or slide presentations.

18

manufactured via 2D drawings and, to a lesser degree, via proprietary 3D models. Product
tolerance representation that is correct, complete, unambiguous, and verified is essential for the
successful exchange of product models for next generation automated applications and the return
on investment promised by MBE. There is currently no model-based CAD system with the level
of robustness to adequately represent and transfer product tolerance.
A fully semantic product definition must include:

Solid models augmented with product tolerance.

Tolerance features, i.e., geometric features with tolerance frame attached, as is defined
in GD&T standards like ASME Y14.5.[14]
Correct tolerances automatically inferred per ASME Y14.5 and company standards.
Part functional tolerance definitions that are checked, validated, and scored.
The ability to exchange tolerance definition with other product definitions.
A published application programming interface suite for extending tolerance analysis,
integration with existing software applications, and supporting downstream activities like
manufacturing and measurement.

Downstream machining and inspection processes require tolerance information. Therefore,

product data standards such as STEP Managed Model Based 3D Engineering [15] [16], process
data standards such as STEP Numerical Controllers [17], and the Dimensional Metrology
Standards Consortiums (DMSC) Quality Information Framework (QIF) 6 all support
representation and exchange of tolerance semantics. GD&T validation tools are needed to ensure
the correctness of the tolerance information being exchanged.
4.11.2 MBE for Dimensional Quality within a Heterogeneous Supply Base
Nick Orchard and Ron Snyder, Rolls -Royce
There is a proliferation of incompatible CAD, PDM, PLM, and CAM software environments.
Rolls-Royce wants one single integrated environment. In the current Rolls-Royce PLM
environment, even though geometry can be linked between models, the system does not allow
users to link PMI, a capability that is essential to achieve the paperless office. In terms of
CAD models, one important question to ask is whether one size could fit all? For example, if the
analysis department doesnt like including blends and radii in the CAD Model but CAM
programmers and quality engineers do, then the answer is no.
An inflated CAD model is a concept where the CAD model has elements useful to
downstream processes. Such processes include analysis, machining, and inspection particularly

http://www.qifstandards.org

19

3D inspection (i.e., using non-contact optical systems). For point cloud data, there are concerns
about how to determine the validity of the results, how to determine the correct point density,
how to qualify optical measurement systems based on an optical based inspection standard, and
whether there is an optical based inspection standard.
4.11.3 Improving First Article Inspection in a Model-Based Environment
Ray Admire, Lockheed Martin
First-Article Inspection (FAI) in a model-based environment, compliant with industry
information standards (such as ISO STEP, Aerospace First Article Inspection [18], and the
Dimensional Measurement Standards Consortiums Quality Information Framework), will
deliver substantial benefits to manufacturers and their customers.
Challenges and risk to product quality in the supply chain include the uncertainty of experienced
talent, the supplier value stream, fixed price contracts, technical challenges in achieving quality
targets, vicissitudes in the national and international economy, uncertain performance of lower
tier suppliers, changes in government policy, changes in trade regulations, and increasing
Government Industry Data Exchange Program notifications.
Characteristic Accountability & Verification (CAV) is a process ensuring that all critical and
major characteristics are defined and accounted for in the product technical data package. CAV
also ensures that manufacturing and quality plans include controls adequate for conformance of
these characteristics.
FAI can be improved in a model-based environment. However, a barrier to model-based FAI is
that CAD data (including GD&T) does not flow seamlessly to downstream processes when
components are not from the same vendor. The GD&T is not fully associated to critical
characteristic features. This is because CAD vendors do not use standards, the standards are
incomplete, end users do not enforce standards compliance, and there are no formal tools or
methods for verifying CAD vendor compliance to the standards.
Top inspection process definition issues are:

Lack of comprehensive non-shape information available from the product including

CAD tolerance data, material properties, and optical properties.
Lack of a standard mechanism to capture and exchange knowledge including methods,
practices, resources, and rules.

As a result, costly rework is required at each step in the inspection process: planning,
programming, results generation, and analysis.
The importance of FAI is that it reassures the customer or supplier that lower tier suppliers are
compliant to all specified design characteristics (dimensional, material, etc.). The QIF model and
20

schema (from the DMSC) holds promise for facilitating successful FAIs. A pilot demo involving
joint efforts of NIST and Lockheed Martin is planned for demonstrating the joint benefits from
FAI and QIF.
4.11.4 The Key to Intelligent GD&T
Bill Tandler, MultiMetrics
MBD is absolutely essential for ensuring the intelligent application of GD&T, since the
concepts and symbolic language of GD&T are so complex that few individuals have the time,
skill or interest to master them. This lack of mastery leads to improperly defined GD&T, which
further leads to most GD&T being merely decorative and therefore, useless or even dangerous.
MBD holds promise for automating precise application of GD&T to part geometry and features
to enable correct execution of precision tasks such as tolerance stack-up analysis, manufacturing
process management, coordinate metrology, and assembly.
Tandler presented a live example of the problems with a decorative GD&T application on a
part not satisfying fit and function requirements, versus a correct GD&T definition satisfying fit
and function. He described an experiment demonstrating this process. In concert with an
unnamed 3D metrology vendor, Tandler was able to encode the geometry and features of the
same part, associate ASME Y14.5 standards-compliant and requirements-satisfying GD&T with
the critical features on the part, and exchange this information with the 3D metrology vendors
software. The vendors software then produced measurement results sufficient for analysis on fit
and function.
Prerequisites to achieving the goal of model-based definitions that produce parts that assemble
and function as required include:
Significantly improving the ergonomics of MBD technology to encourage its use.
Refining and solidifying the concepts, tools, rules, processes and best practices of GD&T
to enable large-scale automation of the encoding and decoding processes.
Largely automating the GD&T encoding process in the 3D CAD environment using the
refinements referenced in the previous bullet.
Fully automating the GD&T decoding process in the 3D CAD environment to
graphically illustrate the impact of the code during the encoding processes.
Largely automating the tolerance stack-up analysis process in the 3D CAD environment
and providing intelligent feedback to enable iterative refinement of the GD&T code.
4.11.5 3D Technical Data Package Validation Demonstration
Roy Whittenburg, Universal Technical Resource Services, Inc.
The 3D technical data package validation demonstration provides an illustration in which a
model is built and then broken down into segments, each segment having its own validation
point. The approach focuses on defining what needs to be validated and then working with the
21

industry to fill any technology gaps. Since DoD is inherently 2D and drawing based, there is a
fundamental distrust of 3D data. Verification and validation is needed to gain this trust.
The objective of the project is to provide a process to verify and validate whether the data quality
of the 3D TDP is sufficient for manufacturing. A team that consists of DoD service
representatives, vendors, and subject matter experts executes the project.
The demonstration of the 3D technical data package validation process is provided in three steps:
design model creation, product lifecycle management (PLM) check-in, and derivative model
creation. The demonstration intentionally selects different tools for each section of the
demonstration. The demonstration evaluates the model, determines issues causing deviations
between the model and its derivatives, and offers assistance in resolving the issues. The issues
are highlighted in the model and in the reports related to those models. The validation is not
limited to parts, but also operates on assemblies.
In the demonstration, a model is created, initial validation is conducted, and the model is checked
into the PLM system to enable sharing. An additional series of checks are executed to assure that
the model has reached certain levels of model maturity and usability. If the model passes the
checks, it is then available to be shared with others in either a released or unreleased state. After
the model is checked in, derivatives (translations) are created. The derivatives must be validated,
just like the original. In addition to the kinds of checking performed on the original model,
derivative models must also be checked for deviations from the original.
4.12 The 3D PDF Consortium
Jim Merry, Tetra4D
A 3D PDF document is any PDF document that contains CAD data in Universal 3D (U3D) [19]
or Product Representation Compact (PRC) [6] formats. Adobe no longer supports translation of
CAD data to PRC or U3D. They are still supporting insertion of U3D and PRC to create 3D
PDFs in their Acrobat Professional product. Although Adobes Reader software will continue to
support viewing of 3D PDF, partners have been chosen to continue the development and support
of the CAD to 3D PDF conversion technology. Tech Soft 3D has taken on development and
maintenance of the software toolkit for PRC-based CAD translator development, and is now
leading the PRC ISO standardization effort. Tetra 4D is now the sole distributor of the 3D PDF
conversion technology for the Adobe Acrobat platform and provides a plug-in enabling the latest
version of Acrobat Professional to generate 3D PDF documents from multiple 3D formats from
the mechanical CAD, architecture, engineering and construction, and digital content creation
domains. ProSTEP AG now provides a server-level capability integrating 3D PDF generation in
business processes and enterprise systems. Recent versions of Adobe Reader will read 3D PDFs,
providing ubiquitous access to CAD model information.

22

While PDF is commonly perceived primarily as a presentation mechanism, PDF supports other
functionalities relevant to the MBE environment such as information protection mechanisms and
digital rights management. The ability for Adobe Reader users to interact with the 3D model via
forms is another important capability. Support for digital signatures is important for document
workflows requiring approval and/or certification for information authentication assurance.
The 3D PDF Consortium is a newly formed non-profit organization comprised of users, software
developers, and solution providers whose goal is to accelerate 3D PDF standardization,
implementation, and industry adoption. The consortium intends to achieve this goal through
demonstration, communication, and evangelism. The consortiums website is
http://www.3dpdfconsortium.org.
4.13 Engineering Software Provider Session
Rich Eckenrode, RECON Services, moderated a session consisting of CAD vendor
demonstrations of new capabilities supporting MBE. Table 2 shows the vendors represented in
the session, software products demonstrated, and the people who gave the presentations.
Table 2. CAD vendor demonstrations.
Vendor
Dassault Systmes
PTC
Siemens
Siemens
Dassault Systmes

Software Product
CATIA
Creo
NX
Solid Edge
SolidWorks

Presenter(s)
Bob Brown and Israel Flores
Mark Nielson
Dennis Keating
Ricky Black
Craig Therrien

4.14 Reducing New Product Introduction Time and Cost through More Effective
Collaboration
John Gray, ITI TranscenData
Interoperability costs can easily add up. No manufacturer has an explicit interoperability
budget. The Customer Supplier Interoperability (CSI) program is a solution to reduce
interoperability costs.
The cost of interoperability is the summation of many small things that add to a significant dollar
amount. For example, a forty-year program can have up to four million interoperability issues,
costing in excess of $1 billion over the programs lifetime. Extrapolation of existing studies point
to the fact that the lack of interoperability is a $2 billion per year problem for DoD. CSI sought
to understand the interoperability issues and prototype some solutions. The steps in the CSI
approach included review (data contract language), analyze (failures), prioritize (opportunities),
identify (most value actions), and demonstrate (solutions in pilots).
23

The CSI vision involves a flexible and configurable standards-based system in which common
tasks associated with Customer-Supplier Interoperability are automated. A model for effective
interoperability was established and applied using a toolkit configured with tools from multiple
technology suppliers. Prototypes of automated solutions have been demonstrated. To support the
value proposition for CSI, a higher fidelity study of cost savings for the F-35 combat aircraft was
undertaken. The potential savings for the F-35 program were conservatively estimated at $140
million over the life of the program.
The CSI program is now initiating four new activities. These are:
Draw-to-PMI automating merging of 2D GD&T into a 3D model, producing

associative 3D PMI facilitating manufacturers migrating to a model based design

methodology in new projects.

Critical Problem Resolution Process detecting and resolving model issues in design for
manufacturability.
3D PMI Translation translating associative 3D models and 3D PMI between dissimilar
CAD environments with either BREP or Features.
3D ECO (Engineering Change Order) Documentation documenting model changes in a
3D PDF format that improves communication between different organizations in an
enterprise.

24

Conclusions

The December 2011 MBE/TDP Summit brought together a collection of stakeholders

representing a wide variety of organizations spanning both the public and private sectors.
Speakers included program managers, quality measurement experts, researchers, and solution
providers. Conclusions and recommendations that emerged from the Summit are summarized in
the following.
5.1 MBE is a key driver of affordability
Cost and affordability was a high priority for many organizations represented at the Summit. For
instance, Paul Gill (4.3) pointed out that one of NASAs major problems is the lack of
affordability of projects and activities. Other speakers agreed that implementing MBE can lead to
cost savings and provided promising progress and results. Donna Bennett (4.5) highlighted a
cost savings of $535K that resulted from using virtual testing instead of physical testing for
packaging in the Y-12 program. Brench Boden from the Air Force (4.9.2) highlighted several
studies substantiating the cost of the lack of interoperability in billions of dollars per year. In
summary, the consensus is that cost control is crucial and the use of a model-centric architecture
leads to increasing affordability.
5.2 MBE reduces errors
Current practices for communicating and accurately implementing changes in product
requirements are inefficient. Such practices still depend on email, phone communication, and
manual entry and reentry of data, creating opportunities for errors. These errors lead to delays
and additional costs. John Gray (4.13) presented a demonstration scenario of interactions
between an airframe manufacturer and mechanical equipment provider in the F-35 program. In
his scenario, human interaction was required on numerous occasions to complete processes such
as translating data into STEP, checking models for compliance issues, and verifying that the
translated file is correct.
Implementation of MBE will increase the efficiency in dealing with changing requirements,
especially during later development cycle stages. A fully model-centric software application
could trace the effect of that change through many viewpoints. In an example use case from
NASA (4.3) illustrating the use of such an application, a changing requirement resulted in
successful identification of the affected mission segment, functions, and parts. David Baum also
stressed (4.10) that one of the benefits of MBE is the reduction of time to implement changes in
systems by enabling design reuse and configuration management. Successful change
management and design reuse shows that MBE increases efficiency in processing change in
design requirements.

25

5.3 MBE enables effective data reuse across the entire system lifecycle
Many presenters emphasized the ability to communicate and manage product data across the
lifecycle. Paul Gill (4.3) stressed the ideal of a reusable model-driven environment with
integration and simulation capability applicable to every activity and extending across the
product lifecycle. Gill said that product data and lifecycle management are key to establishing a
model-centric environment. Dennis Thompson (4.8) stated that the National Digital Engineering
and Manufacturing Consortium (NDEMC) is focused on providing tools serving a broad
community across the product lifecycle. Ben Kassel (4.9.1) emphasized that a goal for the Navy
is the use of the digital product model as the authoritative source for the entire ship's lifecycle.
Gills, Thompsons and Kassels presentations indicate a growing consensus that while it is
important to achieve a model-centric environment and incorporating technical data into 3D
models, it is also equally important that this environment and the data contained in the models
are easily accessible and usable during the entire product lifecycle.
5.4 We need new research to achieve true model-based quality control
Software implementations of 3D geometry and PMI, both proprietary and standards-based, are
increasingly addressing information modeling requirements for automating downstream quality
control and quality assurance (QC/QA) processes. The presence of QC/QA domain experts at the
Summit (4.11) addressed the need to integrate manufacturing with QC/QA. The experts
presentations articulated a shared commitment to improve the quality measurement process by
making it more efficient, less error prone, and more cost effective. The development of new
research areas in test methods, measurement methods, and standards is the key to improve
product and process performance for manufacturing.
One key requirement for achieving these improvements is to fully incorporate GD&T data with
CAD models and allow these data to flow seamlessly to downstream processes. Currently,
GD&T data is often not associated with individual features of the part, making it impossible to
automate inspection process programming. If GD&T information is expressed as individual lines
and arcs in a CAD model or as notes on a drawing, it is not available to automated computer
processes that can use it.
Another key area of need is to develop methods to verify and validate that the data quality of the
3D technical data package is sufficient for manufacturing. As Roy Whittenburg pointed in his
presentation (4.11.5), there is a lack of trust in the data quality of 3D TDPs because current DoD
practices are inherently 2D and drawing based, and there is no method of verifying the quality of
the 3D data received. Hence, development of test methods for 3D TDPs is an area that needs
more research.
5.5 We need new open standards to achieve the full potential of MBE
As the industry continues to make progress in implementing MBE, it is crucial that common
conventions be agreed upon and that best practices are codified. Bill Tandler (4.11.4) argued that
26

the full value of MBE and GD&T will not be realized until the standards that support MBD and
GD&T are improved. He stated that GD&T almost fulfills its promise, but with great difficulty.
Other speakers outlined and discussed the approach that their organizations are undertaking in
developing new standards for MBE. David Baum (4.10) said that Raytheon is developing a
standard MBD schema with start parts and PDM attributes. Ray Admire (4.11.3) mentioned that
Lockheed Martin is working with other organizations to achieve agreement and common
understanding of metrology issues to enable standardization and best practices.
Curtis Brown (4.11.1) stated that modern product definition systems can successfully deliver
the representation and exchange of nominal shapes. However, no one can manufacture
nominally shaped parts. The use of PMI enables semantic and accurate specification of product
tolerances. As Brown pointed out, correct, complete, unambiguous, and verified tolerance
definitions are the critical enabler for realizing successful representation of product models such
that they can be consumed by next generation automation applications. Ron Snyder and Nick
Orchard (4.11.2) also agreed that the move to PMI provides a pathway to a better modeling
environment because this migration enables a participatory engagement in which manufacturing
challenges are addressed in the design configuration.

27

6 References
[1] MIL-STD-31000, Department of Defense Standard Practice: Technical Data Packages (TDP)
(05 NOV 2009) [Superseding MIL-DTL-31000C].
[2] Virgilio Quintana, Louis Rivest, Robert Pellerin, Frdrick Venne, Fawzi Kheddouci, Will
Model-based Definition replace engineering drawings throughout the product lifecycle? A
global perspective from aerospace industry, Computers in Industry, Volume 61, Issue 5, June
2010, Pages 497-508, ISSN 0166-3615, 10.1016/j.compind.2010.01.005.
[3] Russell S. Peak, Joshua Lubell, Vijay Srinivasan, and Stephen C. Waterbury. STEP, XML,
and UML: Complementary Technologies. J. Comput. Inf. Sci. Eng. 4, 379 (2004).
DOI:10.1115/1.1818683
[4] Aberdeen Group. The Transition from 2D Drafting to 3D Modeling Benchmark Report
Improving Engineering Efficiency. September 2006.
[5] Boehm B, ed. Systems 2020 Strategic Initiative. DoD Systems Engineering Research Center
Final Technical Report SERC-2010-TR-009, August 29, 2010. Online at
http://www.dtic.mil/cgi-bin/GetTRDoc?AD=ADA545210 (accessed July 26, 2012).
[6] ISO/DIS 14739-1.2. Document management 3D use of Product Representation Compact
(PRC) format Part 1: PRC 10001.
[7] MIL-DTL-31000C, Detail Specification: Technical Data Packages (9 July 2004)
[Superseding MIL-DTL-31000B].
[8] ASME Y14.41 Digital Product Definition Practices. New York: The American Society of
Mechanical Engineers. New York, NY. 2012.
[9] Aerospace Industries Association. NAS3500. Revision/Edition: 08. Date: 11/00/08.
Technical Data Package: Composition, Communication, and Application.
[10] STEP Application Handbook: ISO 10303 (Version 3 ed.), North Charleston, SC: SCRA,
30 June 2006. Online at
http://www.uspro.org/documents/STEP_application_hdbk_63006_BF.pdf
[11] ISO 10303-239:2005. Industrial automation systems and integration Product data
representation and exchange Part 239: Application protocol: Product life cycle support.
[12] ISO 10303-214:2010. Industrial automation systems and integration Product data
representation and exchange Part 214: Application protocol: Core data for automotive
mechanical design processes.
28

[13] National Institute of Standards and Technology. Planning Report 02-5. Economic Impact
Assessment of the International Standard for the Exchange of Product Model Data (STEP) in
Transportation Equipment Industries. December 2002. Online at
http://www.nist.gov/director/planning/upload/report02-5.pdf
[14] ASME Y14.5 Dimensioning and Tolerancing. New York: The American Society of
Mechanical Engineers. New York, NY. 2009.
[15] Aerospace and Defence Industries Association of Europe, Aerospace Industries
Association (US), PDES, Inc., ProSTEP iViP. Development of a Convergent Modular STEP
Application Protocol Based on AP 203 and AP 214: STEP AP 242 Managed Model Based
3D Engineering. Version 1.0. 2009-11-05.
[16] ISO/CD 10303-242. Industrial automation systems and integration Product data
representation and exchange Part 242: Application protocol: Managed Model-based 3D
Engineering. Stage 30.99 (2012-05-15).
[17] ISO 10303-238:2007. Industrial automation systems and integration Product data
representation and exchange Part 238: Application protocol: Application interpreted model
for computerized numerical controllers.
[18] SAE International. AS9102A. Aerospace First Article Inspection Requirement. 2004-01
13.
[19] Ecma International. Standard ECMA-363. Universal 3D File Format. 4th Edition. June
2007.

29

Appendix 1: Table of Acronyms

Acronym
AMT
ASME
ASTM
CoP
CAD
CAE
CAM
CAV
CSI
DoD
DEDMWG
DEX
DLA
DMSC
DOE
ECO
ERS
FAI
FEA
GD&T
IEEE
ISA
ISO
LEAPS
ManTech
MBD
MBE
NASA
NAVSEA
NDEMC
NIST
NNSA
OSD
PDF
PDM
PLM
PMI
PRC

Expansion
Association for Manufacturing Technology
American Society of Mechanical Engineers
American Society for Testing and Materials
Communities of Practice
Computer Aided Drawing
Computer Aided Engineering
Computer Aided Manufacturing
Characteristic Accountability & Verification
Customer/Supplier Interoperability
Department of Defense
Department of Defense Engineering Drawing and Modeling Working
Group
Data Exchange Specification
Defense Logistics Agency
Dimensional Measurement Standards Consortium
Department of Energy
Engineering Change Order
Engineered Resilient Systems
First Article Inspection
Finite Element Analysis
Geometric Dimensions and Tolerances
Institute of Electrical and Electronics Engineers
International Society of Automation
International Organization for Standardization
Leading Edge Architecture for Prototyping Systems
Manufacturing Technology
Model Based Definition
Model Based Enterprise/Engineering
National Aeronautics and Space Administration
Naval Sea Systems Command
National Digital Engineering and Manufacturing Consortium
National Institute of Standards and Technology
National Nuclear Security Administration
Office of the Secretary of Defense
Portable Document Format
Product Data Management
Product Lifecycle Management
Product Manufacturing Information
Product Representation Compact

QC/QA
QIF
RIA
SCRA
SME
STEP
TDP
U3D

Quality Control / Quality Assurance

Quality Information Framework
Robotic Industries Association
South Carolina Research Authority
Small or Medium Enterprise
Standard for the Exchange of Product Model Data
Technical Data Package
Universal 3D

Appendix 2: Final Agenda and Presentation Materials

The following pages contain:
1. The final MBE/TDP Summit agenda
2. Presentation materials from all Summit speakers who gave NIST permission to distribute
their slides.
In order to minimize page count, each page of presentation materials contains six slides. In some
cases, we deleted slides determined to be content-free (e.g., "Thank you" and "Any questions?"
slides) and slides that were partial builds of other slides (useful for "animating" presentations but
not of much value in a printed hard copy).
With the exception of presentations given by NIST staff (e.g., 4.2), inclusion in this Appendix
implies neither endorsement nor approval by the National Institute of Standards and Technology.

MBE/TDP Summit
NIST, Gaithersburg, MD
Green Auditorium

12 Dec. 2011
Time

Topic

0730-0830

Registration

Speaker(s)

Introductions and Admin

Simon Frechette, NIST & Paul

Huang, ARL

0840-0900

Opening Remarks

Dr. Harary, NIST & Ms. Radcliff,

OSD ManTech

0900-0930

OSD MBE/TDP Summit Objectives

Paul Huang/Simon Frechette

0930-1010

NIST Engineering Laboratory

Manufacturing Programs Overview

Vijay Srinivasan, Simon Frechette,

Fred Proctor, Alkan Donmez, Mike
Shneier, NIST

1010-1030

Break

1030-1110

NASA Integrated Model-centric

Architecture

Paul Gill, NASA

1110-1150

Integrated Data Management Strategy in

support of MBE life cycle management

Shelley Detrich, USGC

1150-1230

Model Based Engineering/Manufacturing

Review from Y-12

Donna Bennet, NNSA

1230-1330

Lunch Break

1330-1400

MBE Implementation at Enterprise Level

Requirements

James Delaporte, NexTec

1400-1430

Engineering Resilient System

Scott Lucero, OSD

1430-1510

EDA Overview

Dennis Thompson, ATI

1510-1530

Break

1530-1730

DoD Program reviews

0830-0840

30 min

Navy

Ben Kassel, NAVSEA

30 min

Air Force

Brench Boden, AFRL

30 min

DLA

Ric Norton, DLA-LIS

30 min

Army

Andrew Davis, RDECOM

1730

Wrap-up

All

MBE/TDP Summit
NIST, Gaithersburg, MD
Green Auditorium

13 Dec. 2011
Time

Topic

0730-0830

Registration

0830-0840

Opening Remarks

Paul Huang/Simon Frechette

0840-0920

Industry and ManTech Interaction success

David Baum, Raytheon

0920-0930

MBE for QC/QA

John Horst, NIST

0930-1010
1010-1030

Critical Product Tolerance

Representation Requirements for
MBD and Metrology Interoperability

Speaker(s)

Curtis Brown, DoE/KCP

Break

1030-1110

MBD for Dimensional Quality within

a Heterogeneous Supply Base

Ron Snyder, Rolls Royce

1110-1150

Improving First Article Inspection in a

Model-Based Environment

Ray Admire, Lockheed Martin

1150-1230

MBE - Enabler of Intelligent GD&T

Bill Tandler, MultiMetrics

1230-1330

Lunch Break

1330-1400

TDP Validation

Roy Whittenburg, UTRC

Vendor Session - MBD/MBE Capabilities

Rich Eckenrode, Army-Support

CTR

1400-1430

Dassault Systemes

Bob Brown, Michael Melton

1430-1500

PTC

Mark Nielson

1500-1515

Break

1515-1545

Siemens

Dennis Keating

1545-1615

SolidEdge

Ricky Black

1615-1645

SolidWorks

Craig Therrien

1645-1715

3D PDF Consortium

Jim Merry

1715-1730

Wrap-up discussion
Q & A session for vendors

ALL

MBE/TDP Summit
NIST, Gaithersburg, MD
Green Auditorium
14 Dec. 2011

MIL-STD-31000 & 973

Time

Topic

0730-0830

Registration

0830-0845

Intro and Admin

0845-0935

MIL-STD-31000 Working Group Updates

10 min.

Acquisition WG

Gary Sunderland/Hank Oakes

10 min.

Data Content WG

Ric Norton/Gordon Ney

10 min.

Data Delievery WG

Roy Whittenburg/Paul Huang

10 min.

Nomenclature

Simon Frechette

10 min.

Manufacturing WG

Fred Proctor/Rich Eckenrode

0935-1030

Review of 31000

Ric Norton/Paul Huang

1030-1045

Break

1045-1130

Review of 31000

Ric Norton/Paul Huang

1130-1200

Customer Supplier Interoperability

John Gray, ITI

1200-1230

Update on PowerLOG-J PLCS Adapter &

PLCS Implementor Form

Scott Motquin, LOGSA

1230-1330

Lunch Break

1330-1400

Joint Service Product Data Requirement

Detrmination

John Campbell, ARDEC

1400-1500

MIL-STD-31000 Review of Appendices

Simon/Roy

1500-1520

Break

1520-1700

MIL-STD-31000 Review of Appendices

Speaker(s)

Paul Huang/Simon Frechette

Simon/Roy

MBE/TDP Summit
NIST, Gaithersburg, MD
Gaithersburg Hilton
15 Dec. 2011

MIL-STD-31000 & 973

Time

Topic

Speaker(s)

0800-1045

MIL-STD-31000 WG breakout sessions

All

1045-1100

Break

1100-1230

Wrap-up and closing remarks

1230-1330

Lunch Break

1330-1600

AIA NAS3500 & 31000 WG joint

discussion

Paul Huang/Robert Morris

1600-1630

Wrap-up and closing remarks

Paul/Simon/Robert

http://www.nist.gov/el/msid/tdpsummit_2011.cfm

Ric/Paul

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For suppliers this
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the ability to drive
their CAM software
straight from the
model along with
numerous other
process
All of this reduces the
time to mission for
the Warfighter

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MBE Focus Areas

MBD Focus Areas (Continued)

CAD Interoperability

Product Definition within the CAD model

Working with CAD providers and users to define and

communicate translation requirements
Working with translation software providers to define
and communicate requirements
Developing translation validation process

Methods for organizing the PMI contained

within the model (CAD Model Schema)
Developing requirements for
enabling annotated models
within the light weight
viewers
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delivering a 3D TDP

Manufacturing Process Definition

Working closely with CAD/CAM providers to define

and communicating requirements
Sub-contracting the develop of productivity scripts
Developing and deploying 3D interactive Work
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Contents

NASA Integrated Model-Centric Architecture

(NIMA) Concept

Presented at the Model Based Engineering (MBE) Summit at

NIST

December 12th, 2011

Paul S. Gill

NASA Overview
Problem to be Solved
Model-Centric effort
Benefits
Vision/Use Cases

Determining the effect/impact of a requirement change

Designing a system
Performing a review
Working a mission anomaly

Goals
Roadmap

NASA Overview

Variety of Missions
Aeronautics Pioneers and proves new flight technologies that improve our ability to
explore and which have practical applications on Earth
Green aviation
Next Generation Air Transportation System (increasing safety and managing traffic
congestion)

Subscale model wind tunnel testing

Test Flight of the blended wing body X-48B

Researching ways to improve air traffic

flow in NASAs Air Traffic Operations Lab

Supersonic jet concept





Variety of Missions (Contd)

Science Explores the Earth, solar system and universe beyond;
charts the best route of discovery; and reaps the benefits of Earth
and space exploration for society
Earth: Weather, Carbon Cycle & Ecosystems, Water & Energy
Cycles, Climate Variability & Change, Earth Surface & Interior,
Atmospheric Composition
Heliophysics: Heliosphere, magnetospheres, Space
Environment
Planets: Inner Solar System, Outer Solar System, Small Bodies
Astrophysics: Stars, Galaxies, black holes, the big bang, dark
energy, dark matter, planets around other suns



Variety of Missions (Contd)

Human Exploration and Operations Focuses on International Space
Station operations and human exploration beyond low Earth orbit

ISS
Multi-Purpose Crewed Vehicle (Orion)
Space Launch System
21st Century Ground Operations



Problem to be Solved
Looking
 at our past experiences, our technical, cost and schedule performance
needs to be enhanced in order to accomplish our future plans
Some of the problems to be solved are:
Lack of affordability of projects and activities
Mission complexity is growing faster than our ability to manage it
Not identifying design or integration problems until late in lifecycle
Having to Search for data or supporting material during mission anomaly

resolutions

Inability to share models in a collaborative environment

Ineffective use of precious testing time and resources
Too many design reviews that reviews documents vice the design
System design emerges from the pieces, not from an architecture
Use of unvalidated models in simulations leading to incorrect/invalid

results

Moving to a more model-centric philosophy within the Agency will help

resolve many of these issues

Model-Centric Concept



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General Model-Centric Vision

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Mission: Advance from our current documentcentric engineering practice to one in which
structural, behavioral, physics and simulation-based
models representing the technical designs are
integrated and evolve throughout the life-cycle,
supporting trade studies, design verification and
system V&V

Future: Reusable model-driven with

integration & simulation capability
To do this we must provide:
Modeling development
environment and standards
Reusable models repository
Tool/model integration
Training
User community support
Partnerships

Today: Document driven & standalone models


10

Use Throughout Lifecycle

Vision/Use Case Examples

Use of a model-centric enterprise system throughout the lifecycle of a product will greatly
enhance its quality and affordability
Work products will be built and matured seamlessly eliminating need to re-create
them over the lifecycle

Determining the effect/impact of a requirement change

Working a mission anomaly

Example products are:

Pre-Phase A

Phase A

Phase B

Phase C

Phase D

Phase E

Phase F

Concept Studies

Concept & Tech

Dev.

Prelim. Design

Final Design & Fab

Assembly, test &

Launch

Ops &
Sustainment

Closeout

Conceptual
Models
Cost Estimation

Requirements

CAD designs

Refined CAD

Integration

Operations

Functional
Flows

Analysis Models

Refined
Analysis

Simulations

Anomalies

Verification

Simulations

Certification

Science Data

Prototype test
data

Decommissioning
Simulations
Data Archiving

Engineering
Data

Final Costs

Refined Costs
Manufacturing

Enhances Sound Engineering Practices and

Experience Does Not Replace It!
11

12

Scenario 1: Generic In-Flight Anomaly

Determining an Effect of a Requirement Change

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Premise: Late in a development

cycle a key requirement is changed.
Cost Impacts
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will
be able to trace the effect of that
change through many viewpoints

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This effort is primarily the integration and expansion of the

work already being performed separately in the following
Communities of Practice (CoP):
Model-Based Systems Engineering (MBSE)
Product Data and Lifecycle Management (PDLM)
Models and Simulation (M&S)
Computer Aided Design (CAD)
Mechanical CAD
Electrical CAD
The tools and methodologies are being employed by these
CoPs in support of existing and future Project and Programs
By having a common vision we will be able to coordinate and
enhance this work in a more effective way, learning and
leveraging off each others discoveries and insights
20

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Benefits
Moving to a model-centric culture will provide NASA many
benefits

Enhanced affordability
Increased ability for collaboration
Identification of problems earlier
Quicker and more accurate diagnosis and resolution of mission
anomalies
More effective use of testing resources
Better cost estimation and control
Better, more effective design reviews
Quicker understanding of cost, schedule and technical impacts of
requirement or design changes
Enhanced ability to do systems engineering
Quicker and more accurate analysis/simulations
23

Phase 1: Preparation

Phase III: Sustaining/Improving

Phase II: Implementation

Key Activities:

Key Activities:

Key Capabilities:

Establish a common vision

Establish an integrated
governance structure
Develop a Strategic Plan with
Needs, Goals and Objectives
Develop a detailed
roadmap/Implementation Plan
Establish a model-centric friendly
infrastructure that facilitates
collaborative activities
Perform piloted capabilities for
key areas
Identify and develop initial
standards, policies and processes
Develop a cadre of trained users
Develop Users guides and
handbooks
Establish an initial CM controlled
model repository

A fully operational model-centric

Infrastructure that enables
integration of physical models with
domain discipline analytical models,
simulations and cost models to
support activities throughout
lifecycle from concept through
disposal
A matured model-based
development methodology and
standards with training support
A fully CM controlled operational
model repositories that
collaboratively managed by projects,
lines and Institution
Models as well as
processes/methodologies are
continuously improved and updates
as more experience is gained

Incrementally bring on more

capabilities per Implementation Plan
Develop/update standards, policies
and processes as new capabilities are
brought on-line
Establish a standard suite of
modeling tools and methodologies
Populate the CM controlled
repository with validated reusable
models created from formulation to
implementation
Train at all levels users, managers,
executives
Identify whats not working and fix it
Identify what is working and
duplicate it

FY11

22

Continuous
Practice

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Presented within a Geometric Tolerance Feature

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Simple and Compound Datum Features
Extends ASME Y14.5.1M-1994 - DRFs

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Defines the next generation of product definition

Tolerance Definition

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Model-Base Applications

Provides explicit tolerance data for downstream applications

Tolerance Data Exchange

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