Testability / Design-to-Test (DFMAT)

1. Testability / Design-to-Test (DFMAT) eXpress Users’ Group Meeting September 22, 2006

2. Agenda • Project Vision and Goals • Integrated Diagnostics/Testability Concepts • Sample Satellite Application • Functional overview of process • Sample diagnostic study • Exported test parameters • Specific examples of transferring of test vectors • Test vectors used by capable Test Executive

3. Project Mission • Enhance Boeing Satellite’s Integration and Test environment: • Implement an effective Testability Analysis capability incorporated into the spacecraft design processtoensurethat correct and efficient verification and validation is accomplished. • BIT only solves Unit level problems, System level is not analyzed. • Focused sequencing and real-time diagnostics are not available. • Outsourced suppliers need to be integrated into the design analysis. • Eliminate manual processes needed to create Bus TRD, Payload TRD and test databases, and enable validation of test databases prior to production. • Create a Standardized Test Environment that will eliminate or reduce complex NRE development costs and long cycle times. • Move to a strategy of Integrated Diagnostics and an embedded IVHM / ISHM system to leverage enterprise resources and enable self-maintenance. A standardized test architecture provides reliability, efficiency and cost savings, which directly impacts the ability for Boeing Satellites to be more cost competitive!

4. Areas of Focus • Integration of Functional Departments • Development/Enhancement of System Engineering processes • Risk Management • Identification • Risk prioritization • Mitigation strategies • Design For Manufacturing, Assembly and Test (DFMAT) implementation for Test (V&V) • Integration of Project Management and System Engineering • Proposal Development

5. System Engineering Hardware Engineering Software Engineering Test Engineering RMT&A Engineering Supplier Management Factory Support Engineering LogisticsEngineering Traditional Product Development Diagnostic products are distributed across many IPTs, skill families, Boeing business units, and suppliers. Many historical problems were due to poorly specified or poorly integrated products, and inconsistent or inefficient processes. This can occur even when the individual products meet their own local requirements.

6. Requirements Definition Architecture Definition Design Guidance (Lessons Learned) Design Analysis Verification & Validation Flight Testing & Field Maturation Factory SupportEngineering Hardware Engineering Software Engineering Test Engineering RMT&A Engineering LogisticsEngineering ID Requires a Structured SEIT Process Integrated Diagnostics System Engineering

7. DFMAT Vision

8. Future ISF Test Environment Stabilize environment *** Productivity enhancements *** Phased approach

9. Full Testability/DTT Environment

10. Basic eXpress Features • Documents and stores information in shared “data warehouse • Captures the functional design elements into dynamic models • Integrates various design, test and RMT information • Analyzes hardware and software interactions • Establishes dependencies among components • Identifies and characterizes hierarchical propagation of faults • Creates a test strategy • Identifies and analyzes test point locations • Develops a diagnostic flow • Identifies and enhances fault isolation capabilities • Improves focus on “fault groups” • Uses Concurrent Engineering to synergize Design and Test • Experts in different functional disciplines access (use) the same system • Removes “stovepiped” functions

11. eXpress’s Contribution to Fill the Gap • Diagnostic Improvement • Realize Concurrent Engineering benefits • Testability Improvement • Test sequence optimization • Test point placement • Reliability • Minimize regression testing • Test Optimization Improvement • Creating optimized test plans • In certain sequences • When units are missing • When failed units must be bypassed • Temporary unit placement • Assure 100% test coverage • Prevent over/under testing • Lower Mean Time to Isolate (MTTI) • Reduction in unresolved “No Fault Found” anomalies • Improved Safety Through Critical Fault Analysis (FMECA) • Reduced Life Cycle Cost

12. Integrated Diagnostic Analysis • Engineering Analysis • Test point placement • Test sequence recommendations • Fault coverage • Reliability, Maintainability and Testability Analysis • FMECA reports • Improve our ability to evaluate Risk and exploit Opportunities • Test Analysis • Sequence optimization • Special Test Request (STR) re-sequencing • Test Operations • Export / Import of “test vectors” via DiagML (ATML) • Automatic capturing of “Lessons Learned”

13. Testability Overview

14. Design-to-Test – eXpress Integration 1. UUT Model Input 2. Test Data Input

15. Design-to-Test – eXpress Integration… 3. Test Strategy Generation 4. DiagML Export

16. Satellite Payload Diagnostic Study

17. Exported Parameters to Excel

18. Diag-ML Export to Test Executive

19. Design-to-Test – eXpress Integration… 6. Test Strategy Execution 5. Test Strategy Import in TestBase

20. Conclusions • Enhance satellite production through better System Engineering design and analysis tools and processes • Integrated Diagnostics and Testability Analysis permits early evaluation of the validation strategy and coverage • Use of industry-standard tools like eXpress allows for consistent analysis and better interfacing with outsourced suppliers • eXpress enables integration of interrelated functional departments and suppliers • Use Design-to-Test methodology to close the loop and enable concurrent engineering processes • A compatible Test Exec can take advantage of the standard export of test vectors via the industry standard Diag-ML format • Feedback of test results to the System Engineering enables the concurrent engineering environment • Establish a foundation for implementation of IVHM/ISHM • eXpress establishes the foundation for the implementation of verifiable embedded-test in an IVHM/ISHM system