1. ETLS 509 - Validation & Verification University of St. Thomas Dr. Brian Leininger Fall 2014

2. Outline Left from last week – Availability Integrated Logistics Support

3. ETLS 509 - Session 10 Requirements Definition Logistics & Supportability

4. Availability The availability of a system, whether explicitly stated as a design requirement or not is one of the most important aspects of a system A number of different availability measures are discussed as certain systems may require significant amounts of non- failure related maintenance and it may not be desirable, on the users part, to include this type of maintenance in the availability numbers – Consider the maintenance on the former space shuttles that was required after each flight. This maintenance was know and factored into the total number of space shuttles in the fleet.

5. Availability A i is the inherent availability of a system – the probability that a system or equipment, when used under stated conditions in an ideal support environment, will operate satisfactorily an any point in time as required Where MTBF is the mean time between failures and MTTR is the mean time to repair – A i is what is normally referred to as availability

6. Achieved Availability A a or the availability achieved by a system is the probability that a system when used in an ideal support environment. It includes the preventative maintenance that is not included in A i the inherent availability of a system Where MTBM is the mean time between maintenance and is mean active maintenance time

7. Operational Availability Operational Availability (A o ) is the probability that a system when used under stated conditions in an actual operational environment will operate satisfactorily when called upon Where MTBM is the mean time between maintenance and MDT is the mean maintenance down time A o is the availability number that is of the most interest to a user of a system as it represents what is likely to be expected.

8. Final Thoughts RMA (Reliability, Maintainability, Availability) models for a system are general not know – There may be historical data on portions and building blocks of a system. These building blocks provide a basis for RMA predictions. – RMA is statistical in nature and the answers to general RMA questions are generally answered with statistics We predict how long a component will last, this is probabilistic by its very nature – Design techniques are utilized to increase the overall availability of a system by allowing faults to happen without degrading system performance One power plant going off-line, e.g., a fault causing it to have to be taken off-line, does (should not) impact the availability of electricity The RMA associate with a system on initial fielding can and usually does improve with time and design changes

9. Putting it together - the Air Transportation System – What are RM&A requirements for the air transport system? Requirement to maintain high dispatch availability.

10. 777 Project What are the reliability, maintainability, availability considerations for the 777? 21st Century Jet - Making the Boeing 777 2-4

11. Definition of Support Support / Supportability / ILS A composite of support considerations necessary to assure the effective and economical support of a system or equipment at all levels of maintenance for it’s programmed life cycle. It is an integral part of all other aspects of system acquisition and operation. from Blanchard

12. Integrated Logistics Support Integrated Logistics Support (ILS) is the management and technical process through which supportability and logistic support considerations are integrated into the design of a system or equipment and taken into account throughout its life cycle. It is the process by which all elements of logistic support are planned, acquired, tested, and provided in a timely and cost-effective manner. 1 ILS is principally driven by a system’s Reliability, Maintainability, and Availability (RMA) ILS can be a major cost driver in a system and has a major impact on systems design 1 U.S. Department of Defense, 2005, Dictionary of Military and Associated Terms.

13. Supply Chain Management – is the management of the flow of goods, flow of cash, and flow of information internally and externally of a company or a group of companies that share the same value chain – Just in time (JIT) is a strategy for having material available, “just-in-time” versus caring inventory. Just-in-time manufacturing aims to reduce inventory costs as well as inventory space by having components arrive as close to when they are needed as is possible – one implementation approach for supply chain management ILS focuses primarily on the support for systems when deployed, supply chain management tends to focus on the systems prior to this point.

14. Basic Elements of Logistics and Maintenance Support Logistics and Maintenance Support Logistics, Maintenance, and Support Personnel Supply Support – Spare/Repair Parts and Inventories Technical Data, Reports, and Documentation Packaging, Handling, Storage/Warehousing, and Transportation (Distribution) Logistics Information Training and Training Support Computer Resources (Hardware & Software) Maintenance and Support Facilities and Utilities Test, Measurement, Handling, and Support Equipment (Resources) System Requirements Figure 15.4 Blanchard

15. Logistics Cost The cost of logistics can be a major factor in total system cost of ownership. Total Logistics Cost (TLC) = cost of development of logistics cost of producing logistics elements cost of maintenance and support (sustaining) cost of operational logistics +++ cost of material processing material handling cost of operational logistics cost of material acquisition (purchasing) cost of distribution (transportation) cost of customer services ++ += Equation 15.1 Blanchard

16. Logistics in the Acquisition Process Systems Engineering Handbook Figure 9-1

17. Key Systems Engineering Interactions Figure 4-1 INCOSE Engineering Handbook How does ILS fit in?

18. Selected Technical Performance Measures for the Logistics & Support Infrastructure Maintenance Facilities Number of Items Processed/Period Item Process Time(s) Item Turnaround Time Waiting Line (Length of Queue) Materials Consumption Rate Utility Consumption/Maintenance Action Cos/Maintenance Action Supply Support Spares/Repair Parts Demand Rates(s) Mean Time Between Replacement Spares/Repair Parts Processing Time Probability of System Success with Spares Probability of Spares Availability Inventory Stockage Levels(s) Inventory Turnover Rates(s) Economic Order Quantity (EOQ) Cost/supply Support Action Test, Meas., Handling and Support Equip. Utilization Rate (Period of Usage) Utilization Time (Test Station Processing Time) Availability of Equipment Reliability (MTBF, ) Maintainability Calibration Rate and Cycle Time Cost/Test Action Cost/Hour of Utilization Maintenance and Support Personnel Personnel Quantities and Skill Levels Personnel Attrition Rate (Turnover Rate) Maintenance Labor Hours/Maint. Action Personnel Error Rate(s) Cost/Person/Organization Training and Training Support Quantity of Personnel Trained/Period Number of Personnel Training Days/Period Frequency and Duration of Training Training Program Input/Output Factors Training Data/Student Training Equipment/Program Cost/Person Trained Packaging, Handling, Stor., and Trans. Transportation Mode, Route, Distance, Frequency, Time, and Cost Packaging Materials/Items Shipped Container Utilization Rate Effectiveness of Transportation Successful Delivery Rate Package Damage Rate Computer Resources Software Reliability/Maintainability Software Complexity (Lang/Code Level) Number of Software Modules/Sys. Element Cost/Element of Software Technical Data/Information System Database Size Information Processing Time Change Implementation Time Number of Data Items/System Data Format and Capacity Data Access Times(s) System Requirements Technical Performance Measures (TPMs) for the system Maintenance and Support Infrastructure Effectiveness (Reliability) of Support Capability Logistics Responsiveness (Response Times) Efficiency of Support (Cost per Support Action) Figure 15.11 Blanchard

19. Classic Support / ILS disciplines Very people centric part of system design – – Maintenance Planning Preventive – frequency & scope Corrective Conditional based maintenance tasks – what are the indications Maintenance personnel skill requirements and staffing size – Training Requirements – Supply Support Spare requirements (preventative, corrective, and condition based) – Technical Data Requirements Form of technical data Maintenance record requirements – Support & Test Equipment – Facilities maintenance and training – Packaging, Handling, Storage & Transportation (PHS&T) Special requirements, e.g., fuels, batteries, flammable lubricants, temperature constraints – Computer Resources Support Test software Data bases Diagnostics – Other disciplines as needed How do we verify and validate the support/ILS for a system?

20. Supportability Analysis Reliability and Maintainability Predications System Operational Requirements Analysis Personnel Training Requirements Analysis Reliability Centered Maintenance Analyis Life-Cycle Cost Analysis Maintenance Test Analysis Failure Mode, Effects, and Criticality Analysis Supportability Analysis (SA) Data Requirements and Information Systems Analysis Spares/Repair Parts and Inventory Analysis Test and Support Equipment Analysis Level of Repair Analysis Operator Task Analysis Facility/Utility Analysis Transportation and Distribution Analysis System Requirements Effective Maintenance and Support Infrastructure Figure 15.12 Blanchard

21. System Support Requirements Develop a Support CONOPS Design for support / support the design When are support system requirements captured – What are the driving forces behind support requirements When writing requirements, what is the driving force What requirements are “shall” and what the implicit support requirements needed to meet the overall system measure of effectiveness (i.e., validating the system) Threshold and objective requirements to give the system design team room to make system trade-offs

22. Feedback Loop Logistics support in the System Life-Cycle Conceptual Design Feasibility study Operational requirements Maintenance concept Functionality requirements Technical performance measures Advanced systems planning Quantitative and qualitative supportability requirements for the system Detail Design & Development System/Product detail design System prototype test and evaluation System modification (as required) Design support, supportability analysis, provisioning and acquisition of logistic support elements, test and evaluation of logistic support capability, formal design review Preliminary System Design System functionality analysis Preliminary synthesis and allocation of design criteria System synthesis and definition Allocation of quantitative and qualitative supportability requirements. Preliminary supportability analysis, formal design review. Production/Construction Fabrication, assembly, and test of system and its components (as applicable) System construction Acquisition of logistic support elements; test and evaluation of logistic support capability; data collection, analysis, and corrective action. System Utilization and Life-Cycle Support Consumer utilization of system and its components Life-cycle system support Reprovisioning and acquisition of logistic support elements; data collection, analysis and corrective action; system/product modification (as required). System Retirement and Phase-Out Feedback Loop Blanchard Figure 15.10

23. ILS Impact on System Effectiveness Recall that the probability that a system when used under stated conditions will operate satisfactorily is normally stated as availability Availability is determined by a system’s reliability and maintainability – Maintainability is impacted by the availability of maintenance staff and spare parts Maintenance staff and spare part availability is part of logistics chain A system that is not operational due to lack of support has a direct impact on the system effectiveness of that system – A system that is not available will not be effective

24. Putting it together - the Air Transportation System – What are logistics & supportability requirements for the air transport system?

25. 777 Project What are the Logistics and Supportability considerations for the 777? What are the maintenance levels of the aircraft? – Line check – every flight – A check - performed approximately every 500 - 800 flight hours. It needs about 20 man-hours and is usually performed overnight at an airport gate. – B check - performed approximately every 4–6 months. It needs about 150 man-hours and is usually performed within 1–3 days at an airport hangar. – C check - performed approximately every 15–21 months or a specific amount of actual Flight Hours (FH) as defined by the manufacturer. The time needed to complete such a check is generally 1–2 weeks and the effort involved can require up to 6000 man-hours. – D check - occurs approximately every 5 years. It is a check that, more or less, takes the entire airplane apart for inspection and overhaul. Also, if required, the paint may need to be completely removed for further inspection on the fuselage metal skin. Such a check will usually demand around 40,000 man-hours and it can generally take up to 2 months to complete, depending on the aircraft and the number of technicians involved. It also requires the most space of all maintenance checks, and as such must be performed at a suitable maintenance base. Given the requirements of this check and the tremendous effort involved in it, it is also the most expensive maintenance check of all, with total costs for a single visit being well within the million-dollar range. 21st Century Jet - Making the Boeing 777 2-3 British Airways Boeing 747-400 in D-Check (http://www.youtube.com/watch?v=x_yHtfGH0nI)