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Systems Reliability, Supportability and Availability Analysis. Systems Supportability Analysis Overview. B. A. C. B. C. A. Comparison of 2003 vs. 2008. Defense Acquisition Management Framework- 2003. User Needs & Technology Opportunities. Program Initiation. FOC. IOC. Concept

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comparison of 2003 vs 2008

B

A

C

B

C

A

Comparison of 2003 vs. 2008

Defense Acquisition Management

Framework- 2003

User Needs &

Technology Opportunities

Program

Initiation

FOC

IOC

Concept

Refinement

Technology

Development

System Development

& Demonstration

Production &

Deployment

Operations &

Support

Design

Readiness

Review

FRP

Decision

Review

Concept

Decision

Defense Acquisition Management System - 2008

User Needs

Technology Opportunities & Resources

ProgramInitiation

IOC

FOC

MaterielSolutionAnalysis

Technology Development

Engineering and

Manufacturing Development

Production & Deployment

Operations &

Support

FRP Decision

Review

Materiel Development Decision

Post PDR

Assessment

Post-CDR

Assessment

Focus of major changes

3

3 Dec 2008

supportability dod definition
Supportability – DoD Definition

The degree to which system design characteristics and planned logistic resources, including manpower, meet system peacetime operational and wartime utilization requirements

supportability elements
Supportability Elements

Reliability

Maintainability / Logistic Support Analysis (LSA)

Testability / ID / PHM

Logistics Engineering

Integrated Logistics Support

problem objective
Problem / Objective

Problem

Too many / conflicting parameters to effectively influence weapon system and support system design

Objective

  • Develop meaningful (relative to design) effectiveness / supportability figures of merit applicable to
    • weapon system & support system design influence
    • measurement of weapon system & support system effectiveness / supportability
benefits
Benefits

Provide rational quantitative basis for design decisions relative to effectiveness / supportability

  • evaluate point designs
  • evaluate impact of design changes
  • evaluate design alternatives
  • trade studies
  • sensitivity analysis to identify drivers

Figures of Merit which are

  • meaningful to the Customer
  • understandable by Management
  • relevant to the Designer
approach
Approach

Develop Effectiveness /

Supportability Figures

of Merit

Develop Analysis /

Measurement Capability

Requirements

Develop Analysis /

Measurement

Capabilities (Models)

Automate & Integrate

with CAE / CAD

caution
Caution

Supportability can be an all encompassing buzzword

The “system” requirement is more than supportability

A “system” is required to counter a threat therefore

  • a system is designed to counter the threat
  • not be supportable
  • supportable is just one element
supportability

Production

Concept

Post Prod.

Retirement

Development

Supt Planing

R,M & SLSA

Flight Test

Config.Mgmt

Provisioning

Supportability

Dsgn Influ & Supt

Sys Devlp

Support System

Production

Tech Data

Spares

Supt Equip

Training Sys

Initial Support

Initial Contractor

Support

Training

Sustainment

Prog Mgmt Field/

Base Supt

Tech Supt Serv

Depot Maint/Mods

Spares Inven Mgmt

Engine/Comp Maint,

Repair & Overhaul

supportability requirements
Supportability Requirements

Supportability design requirements evolve from the customer’s need, which is typically expressed in terms of system operational effectiveness

Operational

Effectiveness

Performance

Capability

Operational

Reliability

Availability

How well

How Long

How Often

system operational parameters
System Operational Parameters

Operational Effectiveness

  • Readiness or Availability
  • Mission Success

Ownership Cost

  • Logistic Support Cost
  • Operating Cost
availability operational readiness
Availability (Operational Readiness)

“The Probability that at any point in time the system is either operating satisfactorily or ready to be placed in operation on demand when used under stated conditions.”

operational availability a o
Operational Availability (Ao)

Ao includes the impact of logistics on availability

  • logistics elements included must be defined in advance
availability analysis flow diagram

Mission Reliability

  • MTBF
  • MTBM

Reliability Analysis

Availability Analysis

Cost EffectivenessAnalysis

Maintainability Analysis

  • MTTR
  • MDT (A)
  • MDT (L)

Supportability Analysis

Life Cycle CostAnalysis

Availability Analysis Flow Diagram
reliability and supportability

Requirements

ReliabilitySupportability

Effectivenessand Availability

Design

Life Cycle Cost

Reliability and Supportability

Systems Operational Performance

supportability functions
Supportability Functions
  • System Design Influence
    • Requirements Development
    • Design Input
    • Evaluation and Trade Analysis
    • Resource Identification
    • Test and Evaluation
  • Development of Support Resources (Products)
    • Trained Personnel
    • Support Equipment
    • Supply Support
  • Fielding and Customer/Product Support
elements of system supportability
Elements of System Supportability
  • Maintenance Planning
  • Manpower and Personnel
  • Materials Management
  • Support Equipment
  • Technical Data
  • Training and Training Support
  • Computer Resources Support
  • Facilities
  • Packaging, Handling, Storage and Tranportation
  • Design Interface
  • Physical Distribution
maintenance planning
Maintenance Planning

The process conducted to evolve and establish maintenance concepts and requirements for the lifetime of the system.

manpower and personnel
Manpower and Personnel

The identification and acquisition personnel with the skills and grades required to operate and support the system over its lifetime.

materials management
Materials Management
  • All management actions, procedures, and techniques used to determine requirements to acquire, catalog, receive, store, transfer, issue and dispose.
  • Includes provisioning for both initial support and replenishment supply support.
  • Includes the acquisition of logistics support for support and test equipment:
    • Raw Material
    • In-Process Material
    • Finished Products and Spare Parts
support equipment
Support Equipment
  • All equipment (mobile or fixed) required to support the operation and maintenance of the system.
  • Includes associated multi-use end items, ground handling and maintenance equipment, tools, metrology and calibration equipment, test equipment, and automatic test equipment.
technical data
Technical Data
  • Scientific or technical information recorded in any form or related medium (such as manuals and drawings).
  • Computer programs and related software are not technical data; documentation of computer programs and related software are.
  • Excluded are financial data or other information related to contract administration.
training and training support
Training and Training Support
  • the process, procedures, techniques, training devices, and equipment used to train personnel to operate and support the system.
    • Individual and crew training (both initial and continuation)
    • new equipment training
    • Logistics support planning for training equipment and training device acquisitions and installations
facilities
Facilities
  • Permanent, semi-permanent or temporary real property required to support the system, including:
  • conducting studies to define facilities or facility improvements
  • locations, space needs, utilities, environmental requirements, real estate requirements and equipment requirements.
packaging handling storage and transportation
Packaging, Handling, Storage and Transportation

Resources, processes, procedures, design considerations and methods to ensure that all system, equipment, and support items are preserved, packaged, handled and transported properly, including:

  • environmental considerations
  • equipment preservation requirements for short and long term storage
  • transportability.
design interface
Design Interface

Relationship of logistics related design parameters to readiness and support resource requirements.

  • expressed in operational terms rather than as inherent values
  • specifically relate to system readiness objectives and support costs of the system.
physical distribution
Physical Distribution
  • Storage / Warehousing
  • Inventory Maintenance
  • Materials / Product Packaging & Handling
  • Transportation
  • Materials / Product Scheduling
some other elements of system supportability
Some Other Elements of System Supportability

Traffic and transportation

Warehousing and storage

Industrial packaging

Materials handling

Inventory control

Order processing

Customer service levels

Demand forecasting

Procurement

Distribution communications

Plant and warehouse locations

Return goods handling

some other elements of system supportability1
Some Other Elements of System Supportability

Parts and service support

Salvage and scrap disposal

supportability in product development
Supportability in Product Development

The primary thrust is two-fold

- Influence product design to ensure

reliability, usability, safety, etc system

- Identify the resources to ensure

supportability of the delivered product and

customer support

Supportability translates performance, user requirements and user experience into the operational, maintenance and support concepts

supportability in product development continued
Supportability in Product Development - continued

Logistics design criteria and guidelines are provided to design

As the schedule progresses, maintenance and support requirements (scheduled and unscheduled) are determined

Requirements for support equipment, spare parts, publications, training, facilities, personnel and skills are established

build to package
Build-to-Package

Quality

planning

Tool

design

Logistics

characteristics

Production

planning

Process

Product

design

Build-to-Package

build to package1
Build-to-Package

Provisioning

Manpower,

personnel

and skills

Training

analysis

Logistic

support

analysis

Technical

support

data

Supportability

Definition

Package

benefits of design for supportability
Benefits of Design For Supportability
  • System Characteristics
    • Inherent Reliability
    • Easily Operable and Maintainable
  • Support System Characteristics
    • Adequate Supply of Trained Personnel
    • Minimal / Low Cost Support Equipment
    • Capitalize Existing Facilities
    • Transportable Design
  • Achieves Goals in:
    • Availability
    • Cost Effectiveness
      • Life Cycle Cost (LCC)
      • Operating & Support (O&S) Cost
supportability during design

Conceptual

Initial

Final

Supportability During Design

Objective:

Minimum Downtime

Minimum LCC

supportability during conceptual design
Supportability During Conceptual Design
  • A system’s design establishes the basic requirement for support resources
  • Support is a design parameter
  • Support features must be included in the conceptual design
support system design and development analysis
Support System design and Development Analysis
  • Maintainability Analysis
  • Supply Chain Analysis
  • System PHM Analysis
  • Reliability Centered Maintenance Analysis (RCMA)
  • Level of Repair Analysis (LORA)
maintainability objective
Maintainability Objective

To design and develop systems and equipment which can be maintained in the least time, at the least cost, and with a minimum expenditure of support resources, without adversely affecting the item performance or safety characteristics

maintainability metrics
Maintainability Metrics
  • Times
    • MTTR : Mean Time to Repair
    • T5o% : Median Time to Repair
    • TMAX : Maximum Time to Repair

(usually 95th percentile

    • LDT : Logistics Delay Time
    • SDT : Supply Delay Time
    • MDT : Mean Down Time
    • DTM : Down Time for Maintenance
    • DTS : Down Time For Supply
  • Events
    • MTBM : Mean Time Between Maintenance
    • MTTPM : Mean Time to Preventive Maintenance
    • MTBPM : Mean Time Between Preventive Maintenance
  • Manpower
    • CS : Crew Size
    • MMH/FH : Man-hours per flight hour
  • Diagnostics
    • FD : Fault Detection
    • FI : Fault Isolation
    • FA : False Alarms
what is a supply chain

Good

Parts Data

Bad

What is a Supply Chain?

Parts and Information

Operational Unit

Information

System

Product Use

Dispose

Product Maintenance

Basing Site

Local

Part

Repair

Local

Stock

Dispose

Depot/Warehouse Site

Depot

Part

Repair

Warehouse

Dispose

Manufacturing Site

Remanufacture

Dispose

Manufacture

objectives supply chain analysis
Objectives Supply Chain Analysis

Analysis provides understanding of critical tradeoffs and alternatives in practical decision-making for a range of inter-related supply chain management issues:

  • Structure of the Supply Chain:
    • “Optimal" numbers
    • Location
    • based on considerations such as customer service requirements, leadtimes, operational costs, and capacities.
    • Supply Uncertainty:
      • Relationship with suppliers
      • Selection of suppliers
    • based on cost, flexibility in supply contracts, expected learning curves of suppliers, and agreements on cost and information sharing.
    • Operational Policies:
      • Inventory control policies
      • Information-sharing strategies.
prognostic health management analysis
Prognostic Health Management Analysis

The purpose of Prognostic Health Management is to repair systems before they fail, while maximizing useful life consumption, and to have the necessary parts, tools and maintainers waiting nearby to resolve the correct problem as quickly and efficiently as possible.

supportability how do you do it
Supportability – How do you do it?

Objective: design for support

    • Consider each ILS functional element during design process to minimize support
    • Develop clearly stated design objectives

Design for support

  • Discard at failure
    • Eliminating repair reduces support burden
    • Possible for small end items, not realistic for large weapon systems
    • Repair versus discard quantifiable in terms of cost of item versus cost of repair
  • Modular replacement
    • Designing for discard would naturally include designing for modularity and modular replacement
    • Optimize modules in terms of size, cost of components and functions
supportability how do you do it cont
Supportability – How do you do it? (cont)

Design for support (Continued)

  • High reliability parts
    • Reduce number of times item must be repaired
  • Bite/Integrated diagnostics/standard TMDE
    • If it fails, bite is best mode to determine failure
  • Standard test points
    • External test equipment
  • Accessibility
    • If failure occurs design for ease of maintenance
  • Quick release fasteners
    • Shorten R/R times
  • Standard parts
    • Reduces numbers of different parts
    • Reduces numbers and types of tools
supportability how do you do it cont1
Supportability – How do you do it? (Cont)

Design for support (continued)

  • Simplicity
    • Reduce sheer number of components that comprise end item
  • Lifting points for transportability
  • Reduced Weight / Cube
  • Soldier / Machine Interface
    • Limitations of target audience

ILS Objective: Design of Support

  • Equal balance of performance and support objectives is logistician’s goal
  • If performance objectives are met at expense of support objectives then design of support is critical
supportability how do you do it cont d
Supportability – How do you do it? (Cont’d)

Design of Support

  • Reduce number of parts
    • Lower cataloging, inventory and pipelines costs
  • Reduce number of reparable
    • Reduces number of types of maintenance actions
    • Reduces attendant logistics tail (TOOLS, TMDE, TM PGS, ETC.)
  • Reduction / consolidation of common tools / TMDE
    • Simplifies maintenance actions
  • Eliminate special tools, TMDE, and skill requirements
  • Reduce manpower
  • Reduce skill required
supportability how do you do it cont d1
Supportability – How do you do it? (Cont’d)
  • Reduce training course lengths
  • Increase modes of transportation
  • Reduce number of TM pages
supportability how do you do it cont d2
Supportability – How do you do it (cont’d)

How do you achieve the objectives?

  • Early Planning via front-end LSA
  • Sound ILS RFP/Contracts
  • Comprehensive Program Reviews
  • Logistics Testing
  • Post Deployment Assessments
supportability how do you do it cont d3
Supportability – How do you do it? (cont’d)

How do you measure achievement?

Design for support scorecard

System name

Factor

Baseline System New System

System MTBF

Number of Parts

Number of Reparable

Number of Special Tools

Number of Common Tools

Number of Personnel

Number of Different Skills

Transportation Modes

Number of TM pages

.

.

r m analysis process

Failure Rate Prediction Handbook

DesignData

Inherent MaintenanceRate

ComparabilityAnalysis

ExperienceData Base

InducedFactor

No Defect Factor

InherentFailureRate

TotalMaintenanceEvent Rate

OrganizationalMMH/FH

FMECA

ORG & INT

OR

OR

OR

OR

OR

Critical Failure Rate

MTTR

Total UnscheduledMMH/FH

ORG & INT

CrewSize

MissionReliability

ORG & INT

IntermediateMMH/FH

SubsystemMTBCF

R&M Analysis Process

53

slide54

Role of Supportability in Design Solution Includes:

  • Identify & design support tasks
  • Determine support resources
  • Develop support products & processes
    • Maintenance, Supply, and Training Plans
    • Technical Publications, etc
  • Define & implement PBL support environment
early decisions affect life cycle cost

Life-Cycle Cost Effectively

Cumulative

Rendered Unchangeable

For a Given Design

Percent of

Life-Cycle

Cost

Life-Cycle Cost

Actually Expended

Early Decisions Affect Life-Cycle Cost

100

90

80

70

50

System Life-Cycle

10

Milestones

A

Out of Service

aircraft total ownership life cycle cost composition
Aircraft Total Ownership/Life Cycle Cost Composition

Source: http://www.ncca.navy.mil/resources/ncca_strategic_business_plan.pdf

life cycle cost distribution

Acquisitions Costs

28%

Operations Cost

12%

Logistics Support Costs

60%

Recurring Support Costs

92%

Fabrication - 72%

Personnel - 67%

Repair

Materiel

10%

Maint Labor

70%

Investment Costs - 8%

Misc

1%

Design

12%

Installation

Checkout

14%

POL

32%

Documentation

2%

Replenishment

Spares - 20%

Initial Trng 7%

Initial

Spares

68%

Other 25%

Life Cycle Cost Distribution

F-16 O&S Costs = 78%

tactical aircraft affordability objective
TACTICAL AIRCRAFT AFFORDABILITY OBJECTIVE

O&S

60%

LETHALITY

SURVIVABILITY

SUPPORTABILITY

PRODUCTION

35%

RDT&E

5%

CAPABILITY

COST

Affordability

Cost Objectives Shall Be Set To Balance Mission Needs With Projected Out-Year Resources, Taking Into Account Anticipated Process Improvements In Both DOD And Defense Industries.

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

5 year cost to own source edmunds com

Medium Car

(Ford Focus)

Large Car

(Chevrolet Impala)

Luxury Car

(Jaguar XJ)

SUV

(Chevrolet Tahoe)

Pickup

(Dodge 1500)

Purchase Price

$16,199

$22,298

$95,415

$36,616

$32,871

Operating Cost

Depreciation

10,788(67%)

14,637(67%)

56,788(60%)

22,229(61%)

19,002(58%)

Financing

2,547

3,619

15,486

6,348

5,3365

Insurance

3,764

3,865

7,627

4,205

4,085

Taxes & Fees

937

1,251

4,679

2,075

1,826

Fuel

7,411

8,712

11,815

14,153

14,648

Maintenance

3,713

3,298

3,524

5,542

5,032

Repairs

648

795

2,026

845

818

**Total 5 Yr Cost

29,808

36,177

101,945

55,397

50,747

Cost/Mile

0.40

0.48

1.36

0.74

0.68

*Model year 2006 data

**Based on 15,000 miles per year

5 Year Cost To Own*Source: Edmunds.com