Systems Engineering

1. Systems Engineering HOT RODDING AND SYSTEMS ENGINEERING Combine Disciplines And Create a Great End Result!

2. Who the Heck Are You? Systems Engineering I’m John D. Knapp! I’m an Eastern Montana kid! Degrees: A.A. (1965) Pre-Engineering, B.S. (1967 in Mechanical Technology, MBA (1975). I’ve worked in nuclear reactor operations and nuclear QA (7 years), commercial nuclear QA (6 years) , aerospace and supplier/subcontractor quality engineering (29 years). My Emphasis is in Procurement Quality Engineering! Working with people to get a quality product is my goal!

3. Who the Heck Are You? Systems Engineering I’m a Gear Head! I’ve been interested in cars since 1955! I’m always learning new skills and applications. Taking welding (Arc and MIG welding) and auto body repair classes @ CCOC in San Jose. Will be taking machining, automatic transmission repair, tune-up, electrical, suspension, brakes & steering classes. I don’t plan to retire – I’ll just continue to learn and apply, until I wear out. Boredom is a slow, painful death.

4. Systems Engineering - Definition! Systems Engineering • Systems Engineering (SE): An approach AND a discipline. • Identifies new methods/opportunities like other engineering fields. • Note: SE’s approach is holistic (i.e. concerned with complete systems) and interdisciplinary (i.e. works with other applicable disciplines). • Integrates work-processes and tools to handle projects, (large or small). It overlaps with technical and human-centered disciplines. • SE helps meld technical contributors into a unified team effort, forming a structured development process that proceeds from concept through production to operation. • It’s “hot rodding” (integrating subsystems into a “system” or “car”).

5. Premises of This Presentation Are:Systems Engineering 0. Eighty (80) Percent of All Hot Rodding Projects Never Get Done! Why? • Work Isn’t Done, Isn’t Planned/Funded! 2. Inadequate Preparation/Education! 3. No Commitment To Learn AND Do! 4. Inadequate Facilities/Tools/Expertise!

6. A Little Background! Systems Engineering Hot Rod - a car with an engine modified for linear speed. - typically a roadster or 2-door coupe that was modified for speed. - a roadster was light; the windshield could be removed. - burning out connecting rod bearings (hence the term, “hot rod”) was a very common failure in modified four-cylinder Model “T”, “A”, “B” and Model “18 (i.e. V8 Ford; particularly Model “T”s and “A”s with 4-cylinder engines with babbitted main bearings). The term “hot rod” was adopted in the 1930’s or 1940’s as a car that had been modified in various ways to achieve higher performance.

7. The Classic Hot Rod!

8. Still More Background! Systems Engineering Original hot rods were old cars that were modified to reduce weight, improve aerodynamics and performance. Typical modifications were removal of windshields, lowering the chassis, and modifying and tuning the engine for more power/torque or replacing it with a more powerful one for top speed. “Top chopping” (i.e. removing vertical parts of the car’s roof to lower the aerodynamic profile) occurred. “Sectioning” (the removal of a vertical “section” of metal from the body) also lowered wind resistance came a little later. Wheels and tires were changed for improved traction and handling. Hot rodder’s modifications may or may not have improved the appearance. Show cars in the 1950s replicated these modifications, added distinctive paint jobs and all kinds of interior/exterior modifications.

9. Even MORE Background! Systems Engineering In 1930’s, the Southern California Timing Association regulated top-speed trials @ dry lakes in California. The Bonneville Salt Flats became the home of top speed records in 1949. In the late 1940’s, NASCAR originated from moonshiner cars that used modified engine and suspension. Also, the National Hot Rod Association (NHRA) is born in the 1950’s! In the 1960’s, the Muscle Car emerged (i.e. the Hemi-Dodge; Ford Thunderbolt; Chevrolet Camaro with an aluminum 427 cu. in. engine).

10. Moonshiner Cars! Systems Engineering

11. Let’s Discuss The Hot Rodder Systems Engineering • The requirements placed on him or her are: • Skill Set – Current and Needed Skills & Experience. • Tools – What’s Needed? • Place(s) to Work – Size(s) and Facilities • Knowledge & Education – What Do You Know? • Is Your Education Adequate? • 5. Mentor(s) – Who Has The Skills That You Need? • Who Will Work With/For You? • Will They Train You? • 6. Financial Commitment - What’s the Dollar Budget? • What’s the Time Budget? • Do you have both or just one? • 7. What Kind of Record-Keeping System Will You Use?

12. Skill Set(s) / Abilities • Skills Needed: a. Welding – Metal-Inert-Gas (MIG) Welding Is the Minimum Requirement. Are you MIG/ TIG/ Gas/ Arc/ Stitch/Hammer Weld certified? b. Metal Fabrication Skill(s): 1. Cut Metal 2. Bead Roll 3. English Wheel 4. Shrinking/Stretching 5. Metal Preparation (Planishing/Hammering/Shaping/Hammer Weld) 6. Sanding. 7. Priming. 8. Painting. 9. Bend/Shape Tubing and Piping. 10. Machining 11. Heat Treat 12. Make Patterns 13. Do Metal Body Work? Have you taken any classes in the above subjects? Are you going to buy these skills? Will you buy some services and do some of the work?

13. A Place To Work Do you have a place to work that will: • Store all the needed tools? • Give you access to the needed tools? • Place the needed tools effectively? • Store the tools and supplies? • Store ancillary tools? • Discard and buy new or other needed tools? • Handle all the throw-away items legally/effectively? • Is it a legal place to do this work? • Or do you have access-to-use the needed tools?

14. Tools That Are Needed! • MIG Welder - a 110v or 220v unit (just for starters)! • Metal Fabrication: a. Bead Roller (Powered or Manual). b. English Wheel. c. A Shrinker and a Stretcher. d. Body Hammers/Dollies/Clamps e. Sanding Boards. f. Sandpapers – alltypes. g. Metal sheer, brake and bending tools. h. Drill press, milling machine, lathe. i. Grinders, sanders, profiling tools.

15. Knowledge and Education #1 Knowledge – have you done real work? Skills: Can you: 1. MIG weld? 2. English Wheel? 3. Bead Roll with or without templates? 4. Shrink and Stretch Sheet Steel/ Aluminum/Other Metal(s)? 5. Do all the metal cutting? 6. Can you do the metal preparation, welding, sanding and painting?

16. Knowledge and Education #2 Do you have the knowledge to put this car on the road? a. Can it be licensed? b. Will it comply with smog requirements? c. Can you obtain a legal title? d. Will the title that you get be transferrable? e. If not, will it become a trailer queen/show car/race car? f. Why are you doing this project?

17. One Path – There Are Other Paths! Systems Engineering A. Complete the following reviews: 1. Systems Requirements Review 2. Systems Design Review 3. Preliminary Design Review 4. Critical Design Review 5. Start The 1st Build !!!!!!

18. SYSTEM REQUIREMENTS REVIEW Systems Engineering The car must: 1. Operate (legally) on the street. 2. Accommodate three (3) people maximum. 3. Have > 400 horsepower @ the flywheel. 4. Use a 4- ,5- or 6-speed transmission. 5. Have a top speed of 140 mph. 6. Have the look of an American hot rod. 7. Be improved as-needed by the owner. 8. Be as presentable as possible @ a car show! .

19. System Design Review The Design Will Be a ’32 5-Window Ford Coupe! Rumble Seat Will Be Optional! V8-Powered with a 4-speed Automatic Transmission. All components shall be American Manufactured.

20. Preliminary Design Review Identify the sub-systems (and requirements) in the Design: 0. Accessories (Power Steering, Brakes, Windows, Seats; A/C) • Body – (Steel Body, Fenders, Hood, Doors, Trunk, Bumpers). • Brakes – (4 wheel disc’s) • Electrical – Retro Gauges with Modern Head & Tail Lights. • Engine Type (V8 – Chevrolet) • Exhaust System – Straight Thru Mufflers. • Frame – Modern Manufacture. • Interior – 1950’s Tuck and Roll (two colors). • Rear End – Quick Change for variability. • Suspension-Front – Standard I-Beam or Coil-Over • Suspension-Rear – Four-Link or ? • Tires and Wheels – Aluminum (Big and Little’s) • Transmission – automatic w/overdrive.

21. Critical Design Review – Compliance w/Subsystem Reqm’ts. Identify the “Make” or “Buy” Subsystems: • Body – Make the Body, Fenders, Hood, Doors, Floors from steel. Buy the Trunk, Radiator Shell and Radiator) (Use Lazze’s Metal Classes). 2. Brakes – Buy the Splindles, Rotors & Calipers After Market (Heidt’s). 3. Electrical – Buy Gauges (S&W), Make Wiring Harness (w/Custom Fuse Block). • Engine Type – Chev V8 block; parts from Gromm’s – YOU Assemble the Engine) • Exhaust System – Makethe Pipes (Quick-Way Muffler) ; Buy Mufflers (Thrush). • Frame – Buy a Modern-Made Frame (Heidt’s; Fat Man/ Chassis Works). 7. Interior – Buy Interior Fabric (Diablo) ; Make Interior Panels; Buy the Seats (?) • Rear End – Buy a Quick Change or Buy a Ford 9”) • Steering – Buy after-market (Fat Man Products). 9. Suspension-Front – Buy Coil-Over System (Fat Man Products). 10. Suspension-Rear – Buy Four-Link System w/Build-In Rear End (Fat Man Products.) 11. Tires and Wheels – Buy Aluminum Wheels & “Retro” Tires (Stockton Wheel) 12. Transmission – Buy a manual or auto (Chev 200R4 – you rebuild).

22. My Supplier Base! • Can my suppliers provide any or all of the hardware/ parts that I need to build this car? • Do my suppliers have the knowledge and/or access to the knowledge to help me? To support their product? • Do my suppliers have access to other suppliers who will also help me? • Have you created the supplier base that you need?

23. The Money – Do You Have It? Have you: a. Identified the parts sources AND costs? b. Totaled up the cost of the parts? c. Committed to spending that amount? d. Looked @ alternative parts w/lower costs? e. Identified cost(s) of tools and facilities? f. Identified educational & experience costs? g. Figured the time it will take to get good enough (experience-wise) to do the work? h. The cost(s) of buying the work? i. Hesitating? Why? j. Do I really want to do this? k. What’s my real goal? Got A Hidden Agenda? l. Will you finance the car? Got the cash?

24. What Plan(s) Do I Really Have To Build This Car? • Do I have a written plan or just an image in my head? • Will I use my own planning method or use a s/w tool? • Where do I want to start (or must I acquire skills)? • Can I start now or later? • Is this a Career, Family, Friends Limiting job? • Will I use it once it’s done? Or is it a one-off or?

25. You’ll Get To Run YOUR OWN Quality Program! You’ll Create: 01. An Organization 02. Your QA Program 03. Design Control 04. Procurement Control 05. Write Procedures 06. Document Control 07. Control Purchases 08. Identify Parts 09. Control Special Processes 10. Do Inspections 11. Do Testing. 12. Control Measuring & Test Equipment 13. Handle, Store Hardware 14. Status the Project 15. Disposition Defects 16. Use Corrective Action 17. A Records System 18. Audits

26. How Are You Going To Document the Build? • Photos (Incremental or Sub-Assembly or Assembly?) • Will You Prepare an Incremental Traveler or Shop Order or a Master- Build Traveler/Shop Order? • Will You Integrate Photos and Steps in the Build? • Will You “Document/Proceduralize” the Use of Your Skills in the Incremental or Master-Build Traveler/Shop Order to Do Each task or only certain tasks? • Will This Be The Only Build of This Vehicle? • Is there software available to prepare/document/ integrate this build with or without photos? • Will the build paper track time, progress, costs, each try, re-try, failure and success? • What record(s) do you want, after the build is done?

27. Maslow’s Hierarchy of Human Needs – Part 2. You’ve probably guessed this: 1. You’re not building a car, you’re going to have an experience and build YOURSELF + a Car. 2. You have a choice – use your own design, someone else’s or a totally new design! 3. One idea of this build is to challenge your understanding and your point-of-view (i.e. what I see and how I see it) through experience(s) and application(s). This challenge will build, grow, mold & “polish” you. The car is the by-product of this experience!

28. What’s Not Mentioned In Maslow’s Hierarchy? We’ve talked about building a person and a car but we’ve missed a VERY important point! We haven’t talked about TRANSCENDENCE! You’re going to transcend your: a. Point-of-view. b. Current knowledge. c. Current understanding. d. Previous experience(s). e. The experience(s) of other’s who’ve also done this work. f. Our previous self-actualization.

29. Then You Get Into the “Real” Stuff! • The “Real” Stuff is THE KNOWLEDGE that you find out about the hardware, the build and the insight that you get from this experience – THAT NO ONE ELSE BUT YOU AND A FEW OTHERS (WHO’VE DONE THIS WORK) ACHIEVED!

30. Lessons of Previous Automotive Work! • The “De Saxe” Principle in Ford Flathead V8 and 1920’s Ford Four-Cylinder Engines! The crankshaft is offset 0.265” to the left of engine center! Why?

31. The “Side-Oiler” Ford OHV V8 Block! The main bearings get the oil first, in a side-oiler Ford V8! Why? What was the application?

32. The SR-71 Engine Experience! “Lockheed’s gearbox manufacturer had NO experience with metals or materials that would see the temperatures of the flight regime of this aircraft”. Neither Did We – But, We Were Already Committed To Learn! Bill Brown–Pratt & Whitney Program Manager for the J-58 Engine (1981/82 Lockheed Magazine).

33. What Did You Know About Threaded Fasteners?

34. Get Ready – You’ll Learn What Others Don’t OR Won’t! • Why are torque wrenches an ineffective way to preload (i.e. “torque”) threaded fasteners? • What’s the most effective installation method for T/F’s? • Why is a stud (a bolt with threads @ each end) much more effective @ clamping than a screw? • Why was the first thread that was standardized, more effective, in its time than other types of threads that were developed later?

35. You’ve Been a GREAT Audience! • Thank YOU for attending and allowing me to share my “gear head” experience(s)/insights with you. • Your Attention is VERYMUCH appreciated. • Please continue to be an eternal student – a continual learner AND share your knowledge with other students (i.e. be a “genuine” (i.e. agape) teacher, with no strings on your sharing your knowledge) . • If you’d like to provide feedback about this presentation, please call John Knapp @ (408) 743-1802 or send an e-mail to john.knapp@lmco.com.

36. Last But Not Least……… A Hot Rod Should Be Constantly Improved or Changed. Why?-------------Because Technology Changes/Improves. ******************************************************************Change (not necessarily improvement) is the law of life. And those who look only to the past or present are certain to miss the future…..John F. Kennedy You must do the things that you think that you cannot do…..Eleanor Roosevelt. Knowing is NOT enough. We must APPLY. Goethe.