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Lecture 2. Integrated Logistics Support

Lecturer:

Prof. Anatoly Sachenko

Informatics in Logistics Management

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Lecture Overview

Definition and Importance Scope of logistic support management Standards Integrated Logistics Support Elements Adoption Benefits and Value of ILS Implementing an ILS Solution Overview of ILS Process Requirements System Engineering Process TOC and CAIV Logistics Support Analysis

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Definition

Integrated logistics support (ILS) is an integrated approach to the

management of logistic disciplines in the military, similar to commercial product support or

customer service organizations Although originally developed for military

purposes, it is applied by the private sector as well

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Definition

Two popular definitions:1. ILS – is a management function that provides

planning, funding, and functioning controls which help to assure that the system meets performance requirements, is developed at a reasonable price, and can be supported throughout its life cycle

2. ILS – encompasses the unified management of the technical logistics elements that plan and develop the support requirements for a system. This can include hardware, software, and the provisioning of training and maintenance resources.

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Definition

Integrated definition:

“A disciplined, unified and iterative approach to the management and technical activities necessary to:

(1) integrate support considerations into system and equipment design;

(2) develop support requirements that are related consistently to readiness objectives, to design, and to

each other; (3) acquire the required support; and

(4) provide the required support during the operational phase at minimum cost”.

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Definition

In general, ILS plans and directs the identification and development of logistics support and system requirements for military systems, with the goal of creating systems that last longer and require less support.

ILS therefore, addresses these aspects of supportability not only during acquisition, but also throughout the operational life cycle of the system.

The impact of ILS is often measured in terms of metrics such as Reliability, Availability, Maintainability and Testability (RAMT), and sometimes System Safety (RAMS).

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Importance

In the world of Aerospace & Defense programs, Sustainment & Supportability have become a major cost consideration within complex systems.

These two facets of the A&D product lifecycle are now being carefully considered and, in some cases, are being given more consideration than the initial purchase price when making the acquisition decision.

In fact, the total lifecycle cost is quickly displacing initial system or equipment cost as the criteria for awarding contracts.

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Importance

For many of the world’s top A&D firms, the solution to the Sustainability and Supportability issue lies in Integrated Logistics Support (ILS)

By installing and applying ILS tools and processes, A&D firms are able to significantly lower sustainment costs, such that they’re able to easily differentiate their products in competitive situations, and win more profitable contracts

Read on and discover how ILS is reshaping the way A&D companies are now managing sustainment as part of the overall lifecycle

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Scope of logistic support management

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Definition

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Scope of logistic support management

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Standards

ILS has been categorized by the United Kingdom Ministry of Defense (UK MoD) Through Life Support (TLS) Directorate into:

Reliability Engineering, Maintainability Engineering and Maintenance (preventive, predictive and corrective) Planning

Supply Support (Spare part) / acquire resources

Support and Test Equipment Manpower and Personnel

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Standards

Training and Training Support Technical Data / Publications Computer Resources Support Facilities Packaging, Handling, Storage, and

Transportation Design Interface

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Standards

In USA initial efforts to collect logistics information in a standardized way were accomplished by the US Army with the issuance of MIL-STD-1388-2B

MIL-STD-1388 was eventually replaced by MIL-PRF-49506 Logistics Management Information

This change reflected a shift towards identifying a project’s performance outcomes, rather than recording the detailed technique to achieve them.

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Standards in Europe

In Europe, the Ministry of Defence of the United Kingdom adapted the specification to meet their own needs and issued DEF-STAN-00-60This was the first specification to formally

link the previously separate disciplines of Provisioning, LSA and Technical Publications under a common specification, and also the first to attempt to formalize a product lifecycle as part of an acquisition process

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Integrated Logistics Support Elements

All elements of ILS are ideally developed in coordination with the system engineering effort and with each other

Tradeoffs may be required between elements in order to acquire a system that is: affordable (lowest life cycle cost), operable, supportable, sustainable, transportable, and environmentally sound

The planning for ILS for a system may be contained in an Integrated Logistics Support Plan (ILSP)

ILS planning activities coincide with development of the system acquisition strategy, and the program will be tailored accordingly

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Integrated Logistics Support Elements

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Adoption

Influence on Design. ILS will provide important means to identify (as early as possible) reliability issues / problems and can initiate system or part design improvements based on reliability, maintainability, testability or system availability analysis (for example by the proper use of detailed functional and/or piece part FMECA techniques, Event tree and Fault tree analysis / assessments, Reliability Block Diagrams, Importance measurements, Reliability centered maintenance (RCM) / Maintenance steering Group 3 and Monte Carlo techniques).

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Adoption

Design of the Support Solution for minimum cost. Ensuring that the Support Solution considers and integrates the elements considered by ILS. This is discussed fully below.

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Adoption

Initial Support Package. These tasks include calculation of requirements for spare parts, special tools, and documentation. Quantities required for a specified initial period are calculated, procured, and delivered to support delivery, installation in some of the cases, and operation of the equipment.

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Overview of ILS Process Requirements

The Logistics Support Analysis (LSA) process provides the basis for the ILS program. Through the LSA, the source data and maintenance plans are generated and documented.

The LSA is designed both to examine the product design and to recommend improvements in design that can result in increased maintainability, reliability and supportability of the equipment or system.

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Overview of ILS Process Requirements

This is accomplished by defining and recommending changes in design that will result in:

1. Reduced time to perform maintenance

2. Greater reliability of components

3. Maintenance procedures requiring little or no specialized support equipment or specialized training

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System Engineering Process

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TOC and CAIV

Total Ownership Cost (TOC) and Cost As an Independent Variable (CAIV). TOC is the sum of all life cycle costs and the cost of the supporting infrastructure that plans and manages an asset. Over 50% of the TOC is incurred during the sustainment of an asset. One of the primary goals of logistics and the systems engineering process is to provide a system and support at a reasonable/right cost.

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TOC and CAIV

As much as 80% of the TOC is determined during the initial acquisition. The application of TOC procedures through tradeoffs can greatly reduce the out-year costs while maximizing operational effectiveness. Program managers and personnel tasked with acquiring Coast Guard assets shall make the reduction of TOC one of the key components of the acquisition.

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TOC and CAIV

The CAIV concept is based on setting aggressive (low), realistic cost objectives and managing to achieve them by conducting trade-off analyses that consider cost, performance, schedule, and supportability. The objectives must balance operational needs with projected out-year resources. The key principles are: Set realistic but aggressive cost objectives (defined

as ranges) early in the acquisition. Manage risk to achieve cost, schedule,

performance, and life cycle support objectives.

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TOC and CAIV

Use metrics to track progress in setting and achieving the cost objectives.

Make use of tools such as cost estimating, requirements analysis, tradeoff risk analysis, Pareto analysis (focus on biggest payback items), and Value Engineering (identify reductions where cost and performance are out of balance).

Motivate managers and industry and provide incentives for meeting program objectives.

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TOC and CAIV

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Logistics Support Analysis

When the optimum design is defined, other ILS elements, such as training, technical publication and provisioning, are planned, guided and completed. This process ensures that the maintenance protocol will meet the program maintenance concept. It also ensures that supportability requirements are considered and incorporated into the design of the equipment or system early in the product design phase.

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Logistics Support Analysis

The ILS process typically begins with an LSA Plan. This document gathers and defines program requirements and objectives. This plan would detail the activities to be accomplished to ensure that these requirements and objectives will be met. The plan would include the scheduling of LSA activities relative to program scheduled events, such as the Preliminary and Critical Design Reviews.

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Logistics Support Analysis

The LSA is not an isolated, internally-based activity. Instead, it requires data/input from subcontractors, vendors, engineering, and the customer. At a high level, there are specific areas that are included in LSA. These include:

1. Maintenance Planning2. Supply Support3. Support and Test Equipment/Equipment

Support4. Manpower and Personnel

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Logistics Support Analysis

5. Training and Training Support6. Technical Data7. Computer Resources Support8. Facilities9. Packaging, Handling, Storage and

Transportation10. Design Interface

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Maintenance planning

Maintenance planning begins early in the acquisition process with development of the maintenance concept. It is conducted to evolve and establish requirements and tasks to be accomplished for achieving, restoring, and maintaining the operational capability for the life of the system. Maintenance planning relies on Level Of Repair Analysis (LORA) as a function of the system acquisition process. Its planning will: Define the actions and support necessary to ensure

that the system attains the specified system readiness objectives with minimum Life Cycle Cost (LCC).

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Maintenance planning

Set up specific criteria for repair, including Built-In Test Equipment (BITE) requirements, testability, reliability, and maintainability; support equipment requirements; automatic test equipment; and manpower skills and facility requirements.

State specific maintenance tasks, to be performed on the system.

Define actions and support required for fielding and marketing the system.

Address warranty considerations.

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Maintenance planning

The maintenance concept must ensure prudent use of manpower and resources. When formulating the maintenance concept, analysis of the proposed work environment on the health and safety of maintenance personnel must be considered.

Conduct a LORA repair analysis to optimize the support system, in terms of LCC, readiness objectives, design for discard, maintenance task distribution, support equipment and ATE, and manpower and personnel requirements.

Minimize the use of hazardous materials and the generation of waste.

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Supply support

Supply support encompasses all management actions, procedures, and techniques used to determine requirements to: Acquire support items and spare parts. Catalog the items. Receive the items. Store and warehouse the items. Transfer the items to where they are

needed.

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Supply support

Issue the items. Dispose of secondary items. Provide for initial support of the system. Acquire, distribute, and replenish

inventory.

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Support and test equipment

Support and test equipment includes all equipment, mobile and fixed, that is required to perform the support functions, except that equipment which is an integral part of the system. Support equipment categories include: Handling and Maintenance Equipment. Tools (hand tools as well as power tools). Metrology and measurement devices. Calibration equipment. Test equipment.

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Support and test equipment

Automatic test equipment. Support equipment for on- and off-

equipment maintenance. Special inspection equipment and depot

maintenance plant equipment, which includes all equipment and tools required to assemble, disassemble, test, maintain, and support the production and/or depot repair of end items or components.

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Manpower and personnel

Manpower and personnel involves identification and acquisition of personnel with skills and grades required to operate and maintain a system over its lifetime. Manpower requirements are developed and personnel assignments are made to meet support demands throughout the life cycle of the system. Manpower requirements are based on related ILS elements. Human factors engineering (HFE) or behavioral research is frequently applied to ensure a good man-machine interface.

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Manpower and personnel

Manpower requirements are predicated on accomplishing the logistics support mission in the most efficient and economical way. This element includes such requirements during planning and decision process: Man-machine and environmental interface Special skills Human factors considerations during the

planning and decision process

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Training and training devices

Training and training devices support encompasses the processes, procedures, techniques, training devices, and equipment used to train personnel to operate and support a system. This element defines requirements for the training of operating and support personnel throughout the life cycle of the system.

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Training and training devices

It includes requirements for: Competencies management Factory training Instructor and key personnel training New equipment training team Resident training Sustainment training User training

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Technical data

Technical Data and Technical Publications consists of scientific or technical information necessary to translate system requirements into discrete engineering and logistic support documentation. Technical data is used in the development of repair manuals, maintenance manuals, user manuals, and other documents that are used to operate or support the system.

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Technical data

Technical data includes, but may not be limited to: Technical manuals Technical and supply bulletins Transportability guidance technical manuals Maintenance expenditure limits and calibration

procedures Repair parts and tools lists Maintenance allocation charts Corrective maintenance instructions Preventive maintenance and Predictive

maintenance instructions

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Technical data

Drawings/specifications/technical data packages Software documentation Provisioning documentation Depot maintenance work requirements Identification lists Component lists Product support data Flight safety critical parts list for aircraft Lifting and tie down pamphlet/references

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Computer resources support

Computer Resources Support includes the facilities, hardware, software, documentation, manpower, and personnel needed to operate and support computer systems and the software within those systems. Computer resources include both stand-alone and embedded systems. This element is usually planned, developed, implemented, and monitored by a Computer Resources Working Group (CRWG) or Computer Resources Integrated Product Team (CR-IPT) that documents the approach and tracks progress via a Computer Resources Life-Cycle Management Plan (CRLCMP).

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Computer resources support

Developers will need to ensure that planning actions and strategies contained in the ILSP and CRLCMP are complementary and that computer resources support for the operational software, and ATE software, support software, is available where and when needed.

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Packaging, handling, storage, and transportation (PHS&T)

PHS&T includes resources and procedures to ensure that all equipment and support items are preserved, packaged, packed, marked, handled, transported, and stored properly for short- and long-term requirements. It includes material-handling equipment and packaging, handling and storage requirements, and pre-positioning of material and parts. System constraints (such as design

specifications, item configuration, and safety precautions for hazardous material)

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Packaging, handling, storage, and transportation (PHS&T)

Special security requirements Geographic and environmental restrictions Special handling equipment and procedures Impact on spare or repair parts storage

requirements Emerging PHS&T technologies, methods,

or procedures and resource-intensive PHS&T procedures

Environmental impacts and constraints

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Facilities

The Facilities logistics element is composed of a variety of planning activities, all of which are directed toward ensuring that all required permanent or semi-permanent operating and support facilities (for instance, training, field and depot maintenance, storage, operational, and testing) are available concurrently with system fielding. Planning must be comprehensive and include the need for new construction as well as modifications to existing facilities.

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Facilities

It also includes studies to define and establish impacts on life cycle cost, funding requirements, facility locations and improvements, space requirements, environmental impacts, duration or frequency of use, safety and health standards requirements, and security restrictions. Also included are any utility requirements, for both fixed and mobile facilities, with emphasis on limiting requirements of resources.

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Design interface

Design interface is the relationship of logistics-related design parameters of the system to its projected or actual support resource requirements. These design parameters are expressed in operational terms rather than as inherent values and specifically relate to system requirements and support costs of the system. Programs such as "design for testability" and "design for discard" must be considered during system design.

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Design interface

The basic requirements: Reliability Maintainability Standardization Interoperability Safety Security Usability Environmental and HAZMAT Privacy, particularly for computer systems

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Benefits and Value of ILS

This data, if developed in an integrated logistics environment, will be used as part of the analysis and design improvement process. It will then be leveraged to produce the training, provisioning and technical publications required to support the system or equipment. Here are some specific examples of realized benefits: Initial Design Improvements Provisioning Data Technical Publications Training and eLearning

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Implementing an ILS Solution: Pitfalls of aPoint-Solution Approach

It is clear that ILS offers tremendous benefits to manufacturers, hence its adoption as a best practice for the A&D industry. Since compliance is increasingly being demanded by customers, the question that needs to be answered is: What are the most common pitfalls in an ILS implementation, and how can they be overcome?

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Implementing an ILS Solution: Pitfalls of aPoint-Solution Approach

To meet ILS requirements, organizations must deploy specialized and highly structured solutions with such core elements: a basic LSA sub-system a provisioning sub-system a technical publication development sub-

system a training/eLearning solution sub-system an information publishing delivery system

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Implementing an ILS Solution: Pitfalls of aPoint-Solution Approach

Even when a point solution is architected and deployed within an organization, it is often incomplete and lacks the necessary automation. Thus, organizations are left to define the processes of:

1. Accessing and reusing design information in the various sub-systems

2. Creating graphics and illustrations specific to product configurations

3. Triggering documentation updates when designs or configurations change

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References

James V. Jones. Integrated Logistics Support Handbook. McGraw-Hill Logistics Series, 2006. - 528 p.

Blanchard B.S. System Engineering Management, Prentice-Hall. 1998.

Blanchard B.S., Fabrycky W.J. Systems Engineering and Analysis, 3rd Edition, Prentice-Hall. 1998.

Ebeling C. An Introduction to Reliability and Maintainability Engineering, McGraw-Hill. 1996.

Mark Willis. System Supportability Engineering – SMART Integrated Logistics Support. 14th International Mirce Symposium, 1-3 December 2004, Woodbury Park, Exeter, UK.

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Handbooks

MIL-HDBK-217, Reliability Prediction of Electronic Equipment, U.S. Department of Defense.

MIL-HDBK-338B, Electronic Reliability Design Handbook, U.S. Department of Defense.

MIL-HDBK-781A, Reliability Test Methods, Plans, and Environments for Engineering Development, Qualification, and Production, U.S. Department of Defense.

NASA PRA - Probabilistic Risk Assessment Handbook

NASA Fault Tree Assessment handbook

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Standards

Army Regulation 700-127 Integrated Logistics Support, 27 September 2007

British Defence Standard 00-600 Integrated Logistics Support for MOD Projects

Federal Standard 1037C in support of MIL-STD-188MIL-STD-785, Reliability Program for Systems and

Equipment Development and Production, U.S. Department of Defense.

MIL-STD 1388-1A Logistic Support Analysis (LSA)MIL-STD 1388-2B Requirements for a Logistic

Support Analysis RecordMIL-STD-1629A, Procedures for Performing a

Failure Mode, Effects and criticality analysis