Systems Engineering in Systems Deployment and Retirement

1. Systems Engineering in Systems Deployment and Retirement Presented to INCOSE by the Minneapolis – St. Paul Chapter of SOLE – The International Society of Logistics November 13, 2003

2. System Life Cycle Phases • Conceptual Design • Preliminary System Design • Detail Design and Development • Production and/or Construction • Utilization and Support • Retirement and Disposal - Logistics Engineering & Management, 5th Ed,, B. Blanchard

3. Systems Concept • Not to be covered – previously covered!! • Conceptual Design and Development • Systems Design • Production and Construction • What to cover in this meeting? • Utilization and Support • You are building this product and are going to deploy it. How do you support it (keep it running)? • Retirement and Disposal • When is this phase in its operational (service) life? • How are your firm, or the buyer, going to get rid of it?

4. Commercial Concept Install Phase Operation & Support Phase Conversion or Decommission Phase Support Analysis “Reliability, Maintainability, & Supportability - RMS” DoD/Military & Space Concept Utilization and Support Phase Retirement & Disposal Support Analysis “Integrated Logistics Support – ILS” Utilization Phases

5. SUPPORT ANALYSIS • Fielded System • How to support the system? • Leave It on the Loading Dock and Forget It? • Have the Customer Mail it Back When It Fails? • Have a Field Crew do Repairs? Whose Field Crew? • How much will support cost for the life of the system? • This Will Determine How You Support the System • This Will Also Determine Who Will Pay for Support

6. Build & Install • System “Key Dimensions” • Complexity Varies • Consumer products • Copy Machines, Sump Pumps • Industrial/Commercial products • Lighting, Office Products • Military systems • Ships, Airplanes, Boats • Space systems • Shuttle, Space Station • Mobility • Non-mobile (fixed, semi-fixed) • Moderately Mobile (vehicle) • Highly Mobile (space)

7. ILS Elements (DoD/Military)Commercial World has different mix and titles but tasks remain the same • Maintenance and Support Planning • Maintenance and Support Personnel • Supply Support (Spare/Repair Parts and Inventories) • Test, Measurement, Handling and Support Equipment • Technical Data, Information Systems and Database Structures • Training & Training Support • Computer Resources (Hardware and Software) • Maintenance Facilities • Packaging, Handling, Storage/Warehousing & Transportation • Disposal Planning

8. Post-Sale Time Stages of Systems • Distribution/Installation and Initial Use • Shipment, setup, construction/installation, test, acceptance • System & Equipment Customer Support (post-installation, continuing thru Service Life) • This is where you find out if your repair analysis and cost estimates were correct • System & Equipment phase-out and Disposition • This is governed by the initial support analyses made during design. This cost may make or break a program

9. Initial Distribution & Customer Support • Distribution and Customer Support – • Physical supply and distribution• Role of distribution• Material management, packaging, transportation, warehousing and handling

10. Customer Support (post-sale) • Customer support (post-installation) • Maintenance and repair • Field engineering and data; feedback & use • System Configuration Management • Configuration Identification & Control Plans • Hardware, Software, Firmware • Configuration Status Accounting, Authentication • Configuration Mgmt Performance Metrics • Ongoing engineering change insertion • Minor Upgrades (components) • Major Upgrades (system)

11. operator labor, repair labor, support equipment maintenance, recurring training, repair parts and materials, repair consumables, condemnation spares, technical data revisions, transportation, recurring facilities, recurring item management, software maintenance contractor services, engineering changes, and recurring warranties. LCC Operations Cost Categories

12. Operational/Field Data • Operational Use Factors Are Significant • We must know if a product is being used within the parameters for which it was designed • Service Can & Must Be Managed • To be cost effective • System Service Life Is Generally Long • And in these times getting longer • Maintenance Can Be Analyzed & Modeled • This is an on going process for the life of the product

13. Operational/Field Data (cont’d) • Life Cycle Costs >> • LCC Can Be Calculated with empirical info • This info can be used on future products as well as for upgrades on the presently fielded product • LCC of Design Options Can Be Compared • See if the option we used was the best • Minimum LCC Option is Preferred • Always

14. Tasks & Skills Close-loop field failure analysis (hardware) User feedback of applications (software) Processes in use. Human use scenario. Environmental impact. Interface situations. Methods Weibull Analysis Post-installation Configuration management Process analysis. Use analysis. Adaptation impact. Modification impact. SE Tasks, Skills and Methods

15. Maintenance & Support Maintenance Management Maintenance Personnel Spare/repair parts and Inventory Control Test and Support Equipment Maintenance Facilities Operator and maintenance training/training equipment Maintenance data Transportation and handling Systems modifications Retirement & Disposal Systems Management System/Product Retirement Disposal of non-repairable condemned items Documentation Maintenance & Phase Out Costs

16. Phase-Out and Disposition • Equipment phase-out and Disposition • Phase-out and replacement costs • Phase Management Costs • Demilitarization Costs • Handling and processing costs • Environmental clean-up costs • Unit Disposition, and • Scrap (disposal) • Reclamation • Salvage and reuse of usable components • Recycling of basic materials.

17. Analytical Models/Tools • Categories of Software Tools • Reliability & Maintainability Predictions • FMECA • Process Failure Modes and Effects Analysis • Level of Repair Analysis (LOR) • Life Cycle Cost (LCC) Analysis • LCC Models

18. Reference Books • DoD, Space & Large Systems • “Systems Engineering and Management” 3rd Ed., by B. Blanchard & W. Fabrycky • “Logistics Engineering & Management”, 5th Ed, by Ben Blanchard • “Product Assurance Technologies: Principles and Practices, by Dev G. Raheja, 1995 • Military & Commercial Systems • “Reliability, Maintainability, Supportability”, 3rd Ed. By SAE International RMS Committee, 1995. • “Reliability and Maintainability Guideline for Manufacturing Machinery and Equipment, 2nd Ed. SAE International & NCMS, 1999.

19. Extension Education • Stevens Institute of Technology • Office of the SDOE Program, SEEM Department, School of Engineering • Systems Design & Operational Effectiveness • “Design for System Reliability, Maintainability, and Supportability” SYS 645 • “System Supportability & Logistics” SYS 640 • One week courses • http://www.stevens-tech.edu/sdoe

20. SOLE & References • Visit web site at http://www.sole.org • SAE International at http://www.sae.org • CASA 8.0 Life Cycle Cost tool (free downloadable, see http://www.logsa.army.mil/alc/casa/ ) (9.47 MB) • Commercial Service Concepts • AFSMI at http://www.afsmi.org • This brief presented by: • Larry DeVries, CPL at larrydev@earthlink.net • Joe O’Brien, CPL at j.f.obrien@worldnet.att.net

21. LCC Tool • What is CASA? • The Cost Analysis Strategy Assessment (CASA) model is a Life Cycle Cost (LCC)/Total Ownership Cost (TOC) decision support tool. CASA can present the total cost of ownership depending on user selections: including cost of RDT&E, acquisition/production, operating/support, and disposal. CASA covers the entire life of the system, from its initial research costs to those associated with yearly maintenance, as well as spares, training costs, and other expenses. • CASA uses standard LCC/TOC and logistics equations for the computation of costs and resource requirements. CASA also enables optimization of spares allocation to be performed. • The link to free downloadable executable: • CASA 8.0 (free downloadable, see http://www.logsa.army.mil/alc/casa/ )

22. THANK YOU!! SOLE – The International Society of Logistics