Enhanced ISF Test Environment for the Future of Satellite System Test

1. Jack L. Amsell, Sr. Project Engineer (Jack.L.Amsell@Boeing.com) Systems Engineering Verification & Mission (TV-72) Autotestcon - September 24, 2003 Enhanced ISF Test Environmentfor the Future of Satellite System Test

2. ISF Test’s Roadmap to the Future • …BSS will aggressively pursue opportunities [in the commercial satellite market]while continuing to improve its business and technology practices. "When it comes back, we'll be well positioned to compete. Meanwhile, we need to remain focused on improving processes and reducing costs," Albaugh said … • “July 28 BSS employees meeting” • Boeing News Now, August 4-8, 2003

3. BSS Must Validate to Deliver Products! • It is important to realize that this project addresses a production validation problem. It includes a set of industry-standard applications that use hardware and software tools. • The project solves three critical problems within the Integrated Satellite Factory’s (ISF) test environment in three interrelated phases: • Stabilizes the T&C environment so that testing can remain viable. • Creates a productive general test architecture so that the cost of testing is cost competitive. • Improves enterprise connectivity so that all test-related business units will work together in a synergistic manner (network-centric).

4. Issues that cost us money • Asset management problem: the amount of equipment required and owned is strongly influenced by the proliferation of software products • Productivity is impacted by multiple incompatible systems and products • Duplication of system functionality and training impedes realizing economies-of-scale benefits • Test Engineers must be familiar with many systems • Multiple product support requires additional staffing, skill sets and cycle-time impacts • Maintaining multiple systems is costly

5. Today’s ISF Test Environment is Complex These efforts were necessary for the factory to maintain production demand and schedules

6. Bus PSTE TCIF XTLS 25 VSX Payload Communication Test TCRF Integrated RCU for dynamic calibration ISIS ARTS LabWindows TestBase SITE NextGen TOS NGSTE ISF Network 10 Mb to 1 Gb backbone Test Development Lab Co-locates all product lines STE Central High Bay Medium Bay SSL Annex BSS 702 Bus & Payload BSS 601 & 601 HP Bus & Payload BSS 376 Migrated for Launch use ISF Test Accomplishments (1996-2002) NextGen ISF Infrastructure Productivity Tools Hardware Migration to NextGen

7. Objectives • Reduce NRE software development and RE test labor cycle-time costs • Establish compatible user interfaces, tools, and environment across all BSS product lines • Drive toward a standardized interface for Test Equipment/Systems (e.g., Bus, Analog/DSP Payload) • Develop a standardized database structure • Maximize reusable engineering across all product lines • Minimize the cost of Test Programming development, maintenance and training • Streamline support requirements

8. ISF Test Environment Vision • Goals • Standardize T&C for the Factory • Standardized/Compatible Database Implementation (USSED) • Standardized T&C Environment (Engine(s) & “procs”) • Enhance Productivity • Test Programming Standardization (TPS, C, C++, etc.) • Standardized/Compatible Test Executive Strategy • Analog/DSP Test System Standard Interfacing (IEEE- 488, “firewire”, IVI, etc.) • Diagnostic Tools • Design-to-Test (CAEE Diagnostics Test Enterprise Connectivity) • Leverage Enterprise Resources • Why • Enhance Production Efficiencies • Enhance Our People’s Productivity • Control and Reduce Assets • How • As an example, think of Microsoft Office • COTS Components (e.g., Word, Excel, Access, PowerPoint, etc.) • Custom “Middleware” (e.g., macros, Visual Studio.NET, etc.)

9. Our Game Plan for Success • Follow Boeing’s “Best Practices” • Focus on core competencies • Strengthen strategic partnerships with internal and external suppliers • Develop ISF test architecture with the following features: • Focused enterprise database format • Standard T&C engine for a standardized approach to testing • Standard interface for Test Programming languages • Industry-standard extensible programming languages • ISF Test Executive based upon “open standards” requirements • Design-to-Test (DTT) tools to leverage engineering information • Diagnostic simulation and runtime solutions • Standard interface for Data Analysis tools • Migration to SEI/CMMI Standards • Migrate to a reduced set of compatible Test Equipmenthardware • Requiring self-contained system software with standard interface • Enhance Testbed and TPS simulator capabilities

10. USSED Database Standard Telemetry and Commanding (T&C) format No custom software changes Industry-standard XML data transfer format Same T&C database for Test & Mission (50% cost reduction) Economies of scale realized T&C Engine Standard T&C configuration Core product is COTS Uses industry "open standards" Uses same T&C database as Ground/Launch and Mission Test Programming (Step 1) Use or update current TCL/TK “Procs” Interface to new USSED Expand our processes to SEI/CMMI* standards Standard T&C Interfacing Focus on selected T&C engine Industry-standard interfacing Uses BSS defined Interface Control Document (ICD) Standardize T&C for the Factory (Phase I) * Software Engineering Institute / Capability Maturity Model Integration

11. Standardized T&C Environment

12. Test Executive Takes advantange of "open systems" Interface to industry-standard applications Enables DTT, TPS, TDMS and CM Enables auto Test Requirement Document (TRD) Standardize functionality in Unit and System test Standardized Test Strategy and Test Results databases Standard Test Equip.I/F for ISF Isolates factory test from Test System design Industry-standard interfacing Off-line support enhanced (SFT, CalVer, etc.) Uses BSS defined ICD Test Programming (Step 2) Uses industry-standard languages Interface to standard Test Executives TPS methology for better efficiency and CM control Minimize required test procedures SEI/CMM standardization Design-to-Test (DTT) Leverages Engineering design effort to automatically create test scenarios (today, all manual entry) Test cycle-time reduced (average 6 MM per spacecraft) Configuration errors minimized Enables addition of system diagnostics Provides test results to Unit or System Engineering groups Link to MRP/ERP systems Productivity Enhancement (Phase II)

13. Production Test Environment

14. Enhanced TPS Environment

15. Design-to-Test (DTT) Implementation

16. Enhanced DTT Environment

17. Enterprise Leverage (Phase III) • Test Results Data Analysis • Enables use of industry-standard COTS applications • Interface to BSS Test Data DataBase (TDDB) • Industry-standard XML data transfer format • Enables automated Fault Mode Analysis (FMECA*) • Can use standard Boeing applications (TRCS, Test Explorer, etc.) • MRP/ERP Linkages • Can use information generated in System Engineering design process (e.g., BoM) • Can use FMECA for inventory prioritization • Industry-standard XML data transfer format • Can provide diagnostic info to System Engineering, Test and Managment * Failure Mode Effect and Criticality Analysis

18. Future ISF Test Environment Standard T&C environment *** Productivity enhancements *** Phased approach

19. Business Case Analysis • Financial justification • Benefit/Cost ratio • Reduction in asset base • Costs related to upgrading capabilities • Leverages • Application software and database license savings • Common maintenance/operations for standardized hardware and software systems • Efficient utilization of personnel • Asset reduction due to common hardware and software systems • Cost-effective “strategic partnerships” with suppliers • Implementation costs for new architecture • New product/solution development • Support cost

20. Financial Justification Summary • Testing operations • Major Savings: Creation of one T&C database for System Test, Launch and Mission for all product lines reduces costs for the enterprise. • Major Savings: NRE labor reduction is a benefit of software reuse. • Major Savings: DTT eliminates or reduces Test Engineer’s manual Test Sequence database entry by at least 2-9 M/M per spacecraft • Reduced equipment proliferation and less complex Graphic User Interfaces (GUI) significantly improves the productivity of Test Engineers • Other Key Cost Savings • Outsourced tasks and multiple licensing fees eliminated or reduced • Misc. Overhead Administrative Support reduced • Additional Savings Realized from Asset Reductions • Reduction in types of Test Equipment/Systemsrequired to support test • HP RTE-A, Dec UNIX, Sun Solaris, Dec VMS and PC NT migrate to single compatible system

21. Summary of Project Benefits • BSS is committed to improving its test environment in 4 ways: • Standardize the software and hardware architecture in the factory • Continue to leverage the use of COTS and industry-standards • Enhance productivity and reduce cycle-time across BSS disciplines • Reduce continued dependency on obsolete hardware and software • Cycle-time will be reduced by: • Streamlining current processes and creating new more efficient processes for design, execution and support • The use of industry standards and methodologies • What benefit does this approach offer to Boeing? • BSS believes that it shares common challenges that are being experienced throughout all of Boeing • BSS must solve these challenges to be successful, and it will share its growing experience, expertise and knowledge

22. Acknowledgements • BSS Management Team: Bill Ballhaus, Marshall Short, Mike Caulfield, Anthony Pirozzi, Dillard Leslie, Ken Belyeu, Jon Brock, Michael Kane, Dennis Taylor, Greg Malone and Gayle Cadwallader • Agilent Technologies: Jim McGillivary, Dave Del Sontro, Larry Lerner, Greg Oldham, Rick Griffin, Jon Rogers, Randy Ricks and Art Dembowski • DSI, International: Craig DePaul, Jim Lauffer and Dan Hartop • TYX Company: Dick Gauthier, Dave Tyler, George Gathers, Ion Neag and Mike Rutledge • Special Thanks: Bob Rassa of Raytheon and Dr. Stephen Adam for their guidance and encouragement