Configuration Management Challenges with the V-22 Osprey

1. Configuration Management Challenges with the V-22 Osprey 18th Annual Configuration Management Benchmarking Group (CMBG) ConferenceSheraton Society HillJune 22nd 2011 Bruce Oestreich Director Systems Engineering Boeing Military Aircraft

2. Incredibly Brief V-22 Program Overview • V-22 CM Challenges • Engineering / Production / CM / Support Tools • Production Flow of Fuselage through Final Delivery • Waivers / Deviations • Complexity of System Specification • New traceability on both sides • Early Incorporation vs Retrofit • Recommendations for the Nuclear Industry AGENDA

3. What We Do Work Split Philadelphia, PA Fort Worth, TX • Composites • Rotor • Dynamics • Wing / Nacelle • Over-wing Fairing • Final Assembly • Flight Test/Delivery • Fuselage • Landing Gear • Avionics • Electrical and Hydraulic • Performance • Flying Qualities • Empennage • Ramp Amarillo, TX Program of Record USN 48 MV-22 Fleet Logistics Support Personnel Recovery Special Warfare Support USSOCOM 50 CV-22 Long Range Special Operations (SpecOps) Contingency Operations USMC 360 MV-22 Combat Assault & Amphibious Assault Sustained Land Operations

4. Making an Impact

5. Current Program Status • 10 USMC and 3 AFSOC Squadrons operational • 156 aircraft delivered (137 MV-22 /19 CV-22) • Exceeded 100,000 flight hours on the fleet; over 50% in last 2 years • Readiness Improvements In Progress • 5-year, $4.6B Multi-Year Procurement (MYP) contract - Mar 2008 • 167 aircraft (141 MV-22, 26 CV-22) with options • Second MYP in work for 122 Aircraft, $4B with options • 5-year Performance Based Logistics (PBL) Contract • Phase I (Integrated Logistics Support Management) signed Jan 09 • Phase 1.5 – (Reliability & Maintainability improvements) signed Jun 09 • Phase II (Supply Chain Management) estimated contract in 3Q 2011 • Growing domestic and international interest Ospreys are Fielded and Maturing

6. Long Term Delivery Profile Fuselage Deliveries Actual| Projected MY I | Projected MY II Annual production rate declines after Multi-Year 1

7. V-22 Osprey Configuration Management Challenges Configuration Management is the process of identifying and defining the items in the system, controlling the change of these items throughout their lifecycle, recording and reporting the status of items and change requests, and verifying the completeness and correctness of items. -- IEEE-Std-729 (1983)

8. Different Considerations for Configuration Management • We all understand the importance of tracking the delivered item; but what about: • Hardware / Software Tools used to develop and deliver it? • People who interact with the entire process? • Different environments through which it traveled? • Data used to track development? • Services provided along the way? • In most instances, keeping configuration control of these elements is just as critical as knowing about the end product • What does your Customer expect? • What will your Customer accept?

9. V-22 Configuration – Specific Challenges • Engineering / Production / CM / Support Tools • Production Flow of Fuselage through Final Delivery • Waivers / Deviations • Complexity of System Specification • New traceability on both sides • Early Incorporation vs Retrofit

10. V-22 Configuration History • Some basic airframe parts derived from Full Scale Development (FSD) program – 1985 • Mylar Drawings • Some 2-D CAD/CAM drawings • Some aircraft design components carried over from the Engineering & Manufacturing Development (EMD) program – 1992 • Introduction of CATIA 3-D • Currently in Lot 14 of Production • Goal of limiting configuration changes to Lot Effectivity not practical / achieved • Customer desire to incorporate new changes as soon as possible • Incorporation in earlier aircraft minimizes retrofit activity

11. Engineering / Production / CM / Support Tools • It would be much easier if we only had to worry about the Aircraft itself • Instead – there are multiple products to track and maintain • Aircraft Hardware and Software • Technical Publications and all Technical Data • Trainers – Maintenance, Part Task, Aircrew, etc… • Simulators – Maintenance and Flight • Now consider conflicting / incompatible tools that hinder configuration management • Engineering data in one system • Production data in another system • CM in database – tries to interface with others • Boeing system / Bell system / Government system all different (Corporate commonality) • Configuration Management of the tools is just as critical as CM of the products! • What did we do to overcome? • Communications! Asked each other for HELP! • Configuration Audits to strike common baseline (Goodness!) • Resulted in Closed Loop Corrective Action process • Improved CM processes (Continual) • Customer Involvement

12. Engineering / Production / CM / Support Tools -500 Software Installation Drawing

13. Keeping Track of Fuselage Configuration through Final Delivery • Once drawings and planning released – we just build the fuselage – RIGHT?? • There are as many as 14 opportunities where configuration changes can be incorporated that must be managed • Engineering Effectivities • Manufacturing Planning paperwork • Unique Issues with the ‘Boeing’ fuselage • Boeing paperwork ‘closed out’ upon fuselage completion in PHL • When changes occur in Amarillo – which paperwork / CM system do we manage / track changes? • Another challenge is managing CM after delivery of the aircraft to the Customer (“post-DD250”) • Warfighter sometimes changes configuration out of necessity and our CM baseline is at risk

14. Opportunities for Insertion of Configuration Changes throughout the Fuselage Build Cycle Subsystem Primary System Primary Fuselage Primary CM CM CM 1 2 3 5 4 Amarillo Wing Mate Prep to Ship Fuselage Storage CM CM CM 10 6 7 8 9 Fuselage Completed Paperwork Closed Out Post DD250 Changes Final Assembly Flight Operations Customer Acceptance CM CM 14 11 13 12

15. Waivers / Deviations • V-22 Weapon System Specification – • Original Release – Oct 1985 • Over 5,000 pages of detailed requirements • Current Multi-Year Procurement (MYP) Contract – Fixed Price Incentive Fee (FPIF) • Spec interpretation conflicts are common • Deviations utilized to resolve conflicts • Still an issue after 25 years • How did we resolve this? • Work in Progress

16. Recent V-22 Deviation History (Example) Normalized Data

17. Early Incorporation vs Retrofit • Goal for maintaining configuration management is to minimize the amount of changes for improved accuracy tracking • Preferred Approach • Limit Configuration Changes to known / planned incorporation points • New Production Lot / New Contract / etc… • Allows for stable configuration to mature and learning curve objectives to be met • Customer Challenges (Conflicting Goals) • Acknowledge preferred approach • Also committed to provide as much capability as soon as possible • Change Incorporation: Production Line disruption vs Retrofit • Early on in program – Retrofit Funding not identified / targeted • Customer typically accepted risk of learning curve / production disruption to ensure Warfighter received maximum capability at the earliest possible point • Think ahead regarding Obsolescence Issues

18. Recommendations for the Nuclear Industry Refine Your Pro-Active Parts Obsolescence Management Program • V-22: DoD 2007 Industry Award Plan for Configuration Changes • Minimize iterative changes • Don’t change the same part 3 different times if you can all at once Develop Strategic Plan for each site • Communicate with Customer! • Then Communicate some more! • Anticipate changes and plan accordingly Ensure alignment on definitions • Determine ‘business case’ to ensure configuration changes done at the right time for the right reasons

19. Summary • Configuration Management challenges exist in every Industry in every aspect of daily operations • Managing expectations with Customers will go a long way in reducing CM challenges • Be Pro-Active! Anticipate and plan for known / likely changes • Utilize HELP NEEDED as a positive! You don’t have to do it alone!

20. QUESTIONS? Bruce Oestreich Director Systems Engineering & Integration Boeing Military Aircraft bruce.d.oestreich@boeing.com Office: 610 591 3410 Cell: 610 348 3286