Stracener_EMIS 7305/5305_Spr08_03.18.08 1 Systems Supportability Analysis Overview Dr. Jerrell T. Stracener, SAE Fellow Leadership in Engineering EMIS

Stracener_EMIS 7305/5305_Spr08_03.18.08

1

Systems Supportability Analysis Overview

Dr. Jerrell T. Stracener, SAE Fellow

Leadership in Engineering

EMIS 7305/5305Systems Reliability, Supportability and Availability Analysis

Systems Engineering ProgramDepartment of Engineering Management, Information and Systems


2


3

Supportability – DoD Definition

The degree to which system design characteristics and planned logistic resources, including manpower, meet system peacetime operational and wartime utilization requirements


4

Supportability Elements

•Reliability

•Maintainability / LSA

•Testability

•Logistics Engineering

•Integrated Logistics Support


5

Problem / Objective

•Problem

Too many / conflicting parameters to effectively influence weapon system and support system design

•Objective

Develop meaningful (relative to design) effectiveness / supportability figures of merit applicable to

weapon system & support system design influence

measurement of weapon system & support system effectiveness / supportability


6

Benefits

•Provide rational quantitative basis for design decisions relative to effectiveness / supportability

-evaluate point designs

-evaluate impact of design changes

-evaluate design alternatives

-trade studies

-sensitivity analysis to identify drivers

•Figures of Merit which are

-meaningful to the Customer

-understandable by Management

-relevant to the Designer


7

Approach

Develop Effectiveness / Supportability Figures of Merit

Develop Analysis / Measurement Capability Requirements

Develop Analysis / Measurement

Capabilities (Models)

Automate & Integrate with CAE / CAD


8

Caution

•Supportability can be an all encompassing buzzword

•The “system” requirement is more than supportability

•A “system” is required to counter a threat therefore

-a system is designed to counter the threat

-not be supportable

-supportable is just one element


9

Effectiveness / Supportability

Favorable Adverse

Equipment Architecture

Minimum Loss of Essential Functions Reliability Effectiveness Supportability

EquipmentDesign

Reduce failure & maintenance rates Reliability Effectiveness -

Equipment Access

Reduce time rqd to get to equipment Maintainability

Effectiveness / Supportability -

Equipment Location

Make high maintenance items easy to get to Maintainability

Effectivness /Supportability -

Low Observable

Reduce Radar Cross Lection

Reliability & Maintainability Effectiveness Supportability

Design Element

Impact


10

Defense Acquisition ManagementDefense Acquisition ManagementDefense Acquisition Management

Funding:

•• Process entry points at Process entry points at Milestone A, B, or CMilestone A, B, or C

•• Entrance criteria met Entrance criteria met before entering phasebefore entering phase

•• Evolutionary Acquisition Evolutionary Acquisition or Single Step to Full or Single Step to Full CapabilityCapability

•• Conduct Conduct AoAAoA, refine , refine initial concept & initial concept & develop Technology develop Technology Development Development StrategyStrategy

ConceptRefinement

Full-Rate Prod &Deployment

•• Full rate Full rate productionproduction

•• Deployment of Deployment of systemsystem

Requirements:

System Integration

System Demo

System Dev & Demonstration

IOC

CriticalDesignReview

LRIP

Operations& Support

•• I ntegrate Integrate subsystems, subsystems, complete complete detailed design, detailed design, and reduce and reduce systemsystem--level level riskrisk

SystemIntegration

ConceptRefinement

TechnologyDevelopment

Concept Decision

FRP & Deployment

Production & Deployment

Low-Rate InitialProduction

•• Create Create efficient efficient manufacturinmanufacturing capabilityg capability

•• LRI PLRI P•• IOT&E, IOT&E,

LFT&E of LFT&E of prodprod--rep rep articlesarticles

C

Pre-Systems Acquisition Systems Acquisition Sustainment

User Needs & Technology Opportunities

(BA 1 & 2)

FOC

•• Complete Complete developmentdevelopment

•• Demonstrate ability Demonstrate ability of system to of system to operate in useful operate in useful way consistent with way consistent with KPPsKPPs

•• Combined DT/ OTCombined DT/ OT

SystemDemonstration

•• Reduce technology Reduce technology risk & determine the risk & determine the appropriate set of appropriate set of technologies to be technologies to be integrated into a full integrated into a full systemsystem

•• Demo the Demo the technologies in a technologies in a relevant environmentrelevant environment

Technology Development

BA 3/4 BA 5 BA 5/Procurement Proc/Operations & MaintenanceBA 5

CDD CPD

Validated & approved by operational validation authority

ICD

Increment II

Increment III

B DRR C FRP

B DRR C FRP

BA

FRPDecision Review

5 Year Cost To Own*5 Year Cost To Own*Source: Edmunds.com Source: Edmunds.com

0.680.741.360.480.40Cost/Mile

50,74755,397101,94536,17729,808**Total 5 Yr Cost

8188452,026795648Repairs

5,0325,5423,5243,2983,713Maintenance

14,64814,15311,8158,7127,411Fuel

1,8262,0754,6791,251937Taxes & Fees

4,0854,2057,6273,8653,764Insurance

5,33656,34815,4863,6192,547Financing

19,002(58%)22,229(61%)56,788(60%)14,637(67%)10,788(67%)Depreciation

$32,871$36,616$95,415$22,298$16,199Purchase Price

Pickup(Dodge 1500)

SUV(Chevrolet Tahoe)

Luxury Car(Jaguar XJ)

Large Car(Chevrolet Impala)

Medium Car(Ford Focus)

*Model year 2006 data**Based on 15,000 miles per year

Op

erat

ing

Co

st


15

Supportability

Supt PlaningR,M & SLSAFlight Test

Config.MgmtProvisioning Tech Data

SparesSupt Equip

Training Sys Initial ContractorSupportTraining Prog Mgmt Field/

Base SuptTech Supt Serv

Depot Maint/ModsSpares Inven Mgmt

Engine/Comp Maint, Repair & Overhaul

Dsgn Influ & SuptSys Devlp

Support SystemProduction

Initial Support

Sustainment

Concept Development Production Post Prod. Retirement


16

Supportability Requirements

Supportability design requirements evolve fromthe customer’s need, which is typically expressed in terms of system operationaleffectiveness

OperationalReliability

AvailabilityPerformance

Capability

OperationalEffectiveness

How well How Long How Often


17

System Operational Parameters

Operational Effectiveness

• Readiness or Availability• Mission Success

Ownership Cost

• Logistic Support Cost• Operating Cost


18

Availability (Operational Readiness)

“The Probability that at any point in time the system is either operating satisfactorily or ready to be placed in operation on demand when used under stated conditions.”


19

Operational Availability (Ao):

Ao includes the impact of logistics on availability

- logistics elements included must be defined in advance

MDTMTTRMTBF

MTBFAo


20

Availability Analysis Flow Diagram

• Mission Reliability

• MTBF

• MTBM

Reliability Analysis

Availability Analysis

• MTTRMaintainability

AnalysisCost Effectiveness

Analysis

• MDT (A)

• MDT (L)

Supportability Analysis

Life Cycle Cost

Analysis


21

Reliability and Supportability

Requirements

Systems Operational Performance

ReliabilitySupportability

Effectivenessand Availability

Life Cycle Cost

Design


22

Supportability Functions

• System Design Influence– Requirements Development– Design Input– Evaluation and Trade Analysis– Resource Identification– Test and Evaluation

• Development of Support Resources (Products)– Trained Personnel– Support Equipment– Supply Support

• Fielding and Customer/Product Support


23

• Maintenance Planning• Manpower and Personnel• Materials Management• Support Equipment• Technical Data• Training and Training Support• Computer Resources Support• Facilities• Packaging, Handling, Storage and Tranportation• Design Interface• Physical Distribution

Elements of System Supportability


24

The process conducted to evolve and establish maintenance concepts and requirements for the lifetime of the system.

Maintenance Planning


25

Manpower and Personnel

The identification and acquisition personnel with the skills and grades required to operate and support the system over its lifetime.


26

• All management actions, procedures, and techniques used to determine requirements to acquire, catalog, receive, store, transfer, issue and dispose.

• Includes provisioning for both initial support and replenishment supply support.

• Includes the acquisition of logistics support for support and test equipment:– Raw Material– In-Process Material– Finished Products and Spare Parts

Materials Management


27

• All equipment (mobile or fixed) required to support the operation and maintenance of the system.

• Includes associated multi-use end items, ground handling and maintenance equipment, tools, metrology and calibration equipment, test equipment, and automatic test equipment.

Support Equipment


28

• Scientific or technical information recorded in any form or related medium (such as manuals and drawings).

• Computer programs and related software are not technical data; documentation of computer programs and related software are.

• Excluded are financial data or other information related to contract administration.

Technical Data


29

• the process, procedures, techniques, training devices, and equipment used to train personnel to operate and support the system. – Individual and crew training (both initial and

continuation) – new equipment training– Logistics support planning for training

equipment and training device acquisitions and installations

Training and Training Support


30

• Permanent, semi-permanent or temporary real property required to support the system, including:

• conducting studies to define facilities or facility improvements

• locations, space needs, utilities, environmental requirements, real estate requirements and equipment requirements.

Facilities


31

Resources, processes, procedures, design considerations and methods to ensure that all system, equipment, and support items are preserved, packaged, handled and transported properly, including:– environmental considerations– equipment preservation requirements for short

and long term storage– transportability.

Packaging, Handling, Storage and Transportation


32

Relationship of logistics related design parameters to readiness and support resource requirements. – expressed in operational terms rather than as

inherent values – specifically relate to system readiness

objectives and support costs of the system.

Design Interface


33

– Storage / Warehousing– Inventory Maintenance– Materials / Product Packaging & Handling– Transportation– Materials / Product Scheduling

Physical Distribution


34

Some Other Elements of System Supportability

• Traffic and transportation• Warehousing and storage• Industrial packaging• Materials handling• Inventory control• Order processing• Customer service levels• Demand forecasting• Procurement• Distribution communications• Plant and warehouse locations• Return goods handling• Parts and service support• Salvage and scrap disposal


35

Supportability in Product Development

• The primary thrust is two-fold

- Influence product design to ensure reliability, usability, safety, etc system

- Identify the resources to ensure supportability of the delivered product andcustomer support

• Supportability translates performance, user requirements and user experience into the operational, maintenance and support concepts


36

Supportability in Product Development - continued

• Logistics design criteria and guidelines are provided to design

• As the schedule progresses, maintenance andsupport requirements (scheduled and unscheduled)are determined

• Requirements for support equipment, spare parts,publications, training, facilities, personnel and skillsare established


37

Build-to-Package

Build-to-Package

Productdesign

Productionplanning

Qualityplanning

Tooldesign

Process

Logisticscharacteristics


38

Build-to-Package

SupportabilityDefinition Package

Logisticsupportanalysis

Manpower,personneland skills

ProvisioningTraininganalysis

Technicalsupport

data


39

Benefits of Design For Supportability

• System Characteristics

– Inherent Reliability– Easily Operable and Maintainable

• Support System Characteristics

– Adequate Supply of Trained Personnel– Minimal / Low Cost Support Equipment– Capitalize Existing Facilities– Transportable Design

• Achieves Goals in:

– Availability– Cost Effectiveness

Life Cycle Cost (LCC)Operating & Support (O&S) Cost


40

Supportability During Design

Conceptual Initial FinalObjective:

Minimum DowntimeMinimum LCC


41

Supportability During Conceptual Design

• A system’s design establishes the basic requirement for support resources

• Support is a design parameter• Support features must be included in the

conceptual design


42

Support System design and Development Analysis

• Maintainability Analysis• Supply Chain Analysis• System PHM Analysis• Reliability Centered Maintenance Analysis (RCMA)• Level of Repair Analysis (LORA)


43

Maintainability Objective

To design and develop systems and equipment which can be maintained in the least time, at the least cost, and with a minimum expenditure of support resources, without adversely affecting the item performance or safety characteristics


44

Maintainability Metrics

• Times– MTTR : Mean Time to Repair– T5o% : Median Time to Repair– TMAX : Maximum Time to Repair

(usually 95th percentile– LDT : Logistics Delay Time– SDT : Supply Delay Time– MDT : Mean Down Time– DTM : Down Time for Maintenance– DTS : Down Time For Supply

• Events– MTBM : Mean Time Between Maintenance– MTTPM : Mean Time to Preventive Maintenance– MTBPM : Mean Time Between Preventive Maintenance

• Manpower– CS : Crew Size– MMH/FH : Man-hours per flight hour

• Diagnostics– FD : Fault Detection– FI : Fault Isolation– FA : False Alarms


45

Basing Site

Depot/Warehouse Site

Manufacturing Site

Operational Unit

What is a Supply Chain?Parts and Information

LocalPart

Repair

DepotPart

Repair

Remanufacture

Product Use

Product Maintenance

LocalStock

Warehouse

Manufacture

InformationSystem

Good Parts DataBad

Dispose

Dispose

Dispose

Dispose


46

Objectives Supply Chain Analysis

Structure of the Supply Chain: – “Optimal" numbers– Locationbased on considerations such as customer service requirements,

leadtimes, operational costs, and capacities. – Supply Uncertainty:

Relationship with suppliers Selection of suppliers

based on cost, flexibility in supply contracts, expected learning curves of suppliers, and agreements on cost and information sharing.

– Operational Policies: Inventory control policies Information-sharing strategies.

Analysis provides understanding of critical tradeoffs and alternatives in practical decision-making for a range of inter-related supply chain management issues:


47

Prognostic Health Management Analysis

The purpose of Prognostic Health Management is to repair systems before they fail, while maximizing useful life consumption, and to have the necessary parts, tools and maintainers waiting nearby to resolve the correct problem as quickly and efficiently as possible.


48

Supportability – How do you do it?

• ITS Objective: design for support– Consider each ILS functional element during design process

to minimize support– Develop clearly stated design objectives

• Design for support– Discard at failure

• Eliminating repair reduces support burden• Possible for small end items, not realistic for large

weapon systems• Repair versus discard quantifiable in terms of cost of item

versus cost of repair– Modular replacement

• Designing for discard would naturally include designing for modularity and modular replacement

• Optimize modules in terms of size, cost of components and functions

48


49

Supportability – How do you do it? (cont)

• Design for support (Continued)– High reliability parts

• Reduce number of times item must be repaired– Bite/Integrated diagnostics/standard TMDE

• If it fails, bite is best mode to determine failure– Standard test points

• External test equipment– Accessibility

• If failure occurs design for ease of maintenance– Quick release fasteners

• Shorten R/R times– Standard parts

• Reduces numbers of different parts• Reduces numbers and types of tools

49


50

Supportability – How do you do it? (Cont)

•Design for support (continued)

-Simplicity

•Reduce sheer number of components that comprise end item

-Lifting points for transportability

-Reduced Weight / Cube

-Soldier / Machine Interface

•Limitations of target audience

•ILS Objective: Design of Support

-Equal balance of performance and support objectives is logistician’s goal

-If performance objectives are met at expense of support objectives then design of support is critical


51

Supportability – How do you do it? (Cont’d)

•Design of Support

-Reduce number of parts

•Lower cataloging, inventory and pipelines costs

-Reduce number of reparable

•Reduces number of types of maintenance actions

•Reduces attendant logistics tail (TOOLS, TMDE, TM PGS, ETC.)

-Reduction / consolidation of common tools / TMDE

•Simplifies maintenance actions

-Eliminate special tools, TMDE, and skill requirements

-Reduce manpower

-Reduce skill required

-Reduce training course lengths

-Increase modes of transportation

-Reduce number of TM pages


52

Supportability – How do you do it (cont’d)

• How do you achieve the objectives?

– Early Planning via front-end LSA

– Sound ILS RFP/Contracts

– Comprehensive Program Reviews

– Logistics Testing

– Post Deployment Assessments

52


53

Supportability – How do you do it? (cont’d)

• How do you measure achievement?

53

Design for support scorecard

System name

System MTBFNumber of PartsNumber of ReparableNumber of Special ToolsNumber of Common ToolsNumber of PersonnelNumber of Different SkillsTransportation ModesNumber of TM pages..

Factor Baseline System New System


WEAPON SYSTEM O&S

Documents

Stracener_EMIS 7305/5305_Spr08_03.18.08 1 Systems Supportability Analysis Overview Dr. Jerrell T. Stracener, SAE Fellow Leadership in Engineering EMIS