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Systems Supportability Analysis Overview

Systems Engineering Program. Department of Engineering Management, Information and Systems. EMIS 7305/5305 Systems Reliability, Supportability and Availability Analysis. Systems Supportability Analysis Overview. Dr. Jerrell T. Stracener, SAE Fellow. Leadership in Engineering.

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Systems Supportability Analysis Overview

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  1. Systems Engineering Program Department of Engineering Management, Information and Systems EMIS 7305/5305 Systems Reliability, Supportability and Availability Analysis • Systems Supportability Analysis Overview Dr. Jerrell T. Stracener, SAE Fellow Leadership in Engineering

  2. Supportability – DoD Definition The degree to which system design characteristics and planned logistic resources, including manpower, meet system peacetime operational and wartime utilization requirements

  3. Supportability Elements • Reliability • Maintainability / LSA • Testability • Logistics Engineering • Integrated Logistics Support

  4. 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

  5. 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

  6. Approach Develop Effectiveness / Supportability Figures of Merit Develop Analysis / Measurement Capability Requirements Develop Analysis / Measurement Capabilities (Models) Automate & Integrate with CAE / CAD

  7. 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

  8. Effectiveness / Supportability

  9. Medium Car (Ford Focus) Large Car (Chevrolet Impala) Luxury Car (Jaguar XJ) SUV (Chevrolet Tahoe) Pickup (Dodge 1500) Purchase Price $16,199 $22,298 $95,415 $36,616 $32,871 Operating Cost Depreciation 10,788(67%) 14,637(67%) 56,788(60%) 22,229(61%) 19,002(58%) Financing 2,547 3,619 15,486 6,348 5,3365 Insurance 3,764 3,865 7,627 4,205 4,085 Taxes & Fees 937 1,251 4,679 2,075 1,826 Fuel 7,411 8,712 11,815 14,153 14,648 Maintenance 3,713 3,298 3,524 5,542 5,032 Repairs 648 795 2,026 845 818 **Total 5 Yr Cost 29,808 36,177 101,945 55,397 50,747 Cost/Mile 0.40 0.48 1.36 0.74 0.68 *Model year 2006 data **Based on 15,000 miles per year 5 Year Cost To Own* Source: Edmunds.com

  10. Production Concept Post Prod. Retirement Development Supt Planing R,M & SLSA Flight Test Config.Mgmt Provisioning Supportability Dsgn Influ & Supt Sys Devlp Support System Production Tech Data Spares Supt Equip Training Sys Initial Support Initial Contractor Support Training Sustainment Prog Mgmt Field/ Base Supt Tech Supt Serv Depot Maint/Mods Spares Inven Mgmt Engine/Comp Maint, Repair & Overhaul

  11. Supportability Requirements Supportability design requirements evolve from the customer’s need, which is typically expressed in terms of system operational effectiveness Operational Effectiveness Performance Capability Operational Reliability Availability How well How Long How Often

  12. System Operational Parameters • Operational Effectiveness • Readiness or Availability • Mission Success • Ownership Cost • Logistic Support Cost • Operating Cost

  13. 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.”

  14. Operational Availability (Ao): Ao includes the impact of logistics on availability • logistics elements included must be defined in advance

  15. Availability Analysis Flow Diagram • Mission Reliability • MTBF • MTBM Reliability Analysis Availability Analysis Cost EffectivenessAnalysis Maintainability Analysis • MTTR • MDT (A) • MDT (L) Supportability Analysis Life Cycle CostAnalysis

  16. Requirements ReliabilitySupportability Effectivenessand Availability Design Life Cycle Cost Reliability and Supportability Systems Operational Performance

  17. 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

  18. Elements of System Supportability • 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

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

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

  21. Materials Management • 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

  22. Support Equipment • 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.

  23. Technical Data • 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.

  24. Training and Training Support • 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

  25. Facilities • 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.

  26. Packaging, Handling, Storage and Transportation 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.

  27. Design Interface 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.

  28. Physical Distribution • Storage / Warehousing • Inventory Maintenance • Materials / Product Packaging & Handling • Transportation • Materials / Product Scheduling

  29. 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

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

  31. Supportability in Product Development - continued • Logistics design criteria and guidelines are • provided to design • As the schedule progresses, maintenance and • support requirements (scheduled and unscheduled) • are determined • Requirements for support equipment, spare parts, • publications, training, facilities, personnel and skills • are established

  32. Build-to-Package Quality planning Tool design Logistics characteristics Production planning Process Product design Build-to-Package

  33. Build-to-Package Provisioning Manpower, personnel and skills Training analysis Logistic support analysis Technical support data Supportability Definition Package

  34. 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

  35. Conceptual Initial Final Supportability During Design Objective: Minimum Downtime Minimum LCC

  36. 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

  37. Support System design and Development Analysis • Maintainability Analysis • Supply Chain Analysis • System PHM Analysis • Reliability Centered Maintenance Analysis (RCMA) • Level of Repair Analysis (LORA)

  38. 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

  39. 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

  40. Good Parts Data Bad What is a Supply Chain? Operational Unit Information System Product Use Parts and Information Dispose Product Maintenance Basing Site Local Part Repair Local Stock Dispose Depot/Warehouse Site Depot Part Repair Warehouse Dispose Manufacturing Site Remanufacture Dispose Manufacture

  41. Objectives Supply Chain Analysis Analysis provides understanding of critical tradeoffs and alternatives in practical decision-making for a range of inter-related supply chain management issues: Structure of the Supply Chain: • “Optimal" numbers • Location based 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.

  42. 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.

  43. 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

  44. 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

  45. 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

  46. 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

  47. 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

  48. Supportability – How do you do it? (cont’d) Design for support scorecard System name Factor Baseline System New System System MTBF Number of Parts Number of Reparable Number of Special Tools Number of Common Tools Number of Personnel Number of Different Skills Transportation Modes Number of TM pages . . How do you measure achievement? 53

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