Systems Engineering in Systems Deployment and Retirement

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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

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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

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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?

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Utilization Phases

• 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

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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

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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)

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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

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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

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Initial Distribution Customer Support

• Distribution and Customer Support
• Physical supply and distribution Role of
  distribution Material management, packaging,
  transportation, warehousing and handling

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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)

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LCC Operations Cost Categories

• 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.

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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

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Operational/Field Data (contd)

• Life Cycle Costs gtgt
• 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

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SE Tasks, Skills and Methods

• 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.

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Maintenance Phase Out Costs

• 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

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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.

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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

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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.

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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

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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_at_earthlink.net
• Joe OBrien, CPL at j.f.obrien_at_worldnet.att.net

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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 RDTE,
  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/ )

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THANK YOU!!

• SOLE The International Society of Logistics