case study: deployment of a dfss culture into the rme organization
TRANSCRIPT
05-094
Case Study: Deployment of a DfSS Culture into the RME Organization
Raytheon, Rocky Mountain Engineering (RME)Karl Arunski
This briefing is intended for those in the process of establishing a Design for Six Sigma (DfSS) culture in their organization.
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Briefing Outline
I. Introduction – The business model/environment
– The Raytheon Design for Six Sigma (DfSS) definition
– The DfSS methodology
– The DfSS training
– The DfSS deployment objective
II. Process Integration– Integrating DfSS into the business process
III. Examples
IV. Conclusions
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I. Introduction
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What We Provide(The Business Model Environment)
• Command and Control
• Mission Management
• Sensor Data Processing
Operations
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Design for Six Sigma
Raytheon Definition
“Design for Six Sigma is a methodology, used within the Integrated Product Development Process (IPDP), to predict, manage, and improve Productivity, Affordability, and Robust Performance for the benefit of our customers.”
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The DfSS Methodology
• Define key parameters
• Define objectives
• Achieve and measure– Model– Predict– Design
– Measure– Iterate as required– Achieve
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The DfSS Training Class (Outline)
• Module 1. Process Integration
• Module 2. Voice of the Customer
• Module 3. Modeling and Optimization
• Module 4. Creating and EvaluatingArchitecture Alternatives
• Module 5. Value Delivery
• Module 6. Test Optimization
• Module 7. Program Integration
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The DfSS Deployment Objective
• Predict/Manage/Improve
• “Get people to think about the methodology and to try it out.”
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II. Process Integration
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II. Integrating DfSS into the Business Process
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Process Integration
Voice of the Customer
Modeling and Optimization
Create and Evaluate Architecture Alternatives
Value Delivery
Test Optimization
Program Integration
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III. Examples
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Integrating DfSS into the Business Process
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Process Integration
Voice of the Customer
Modeling and Optimization
Create and Evaluate Architecture Alternatives
Value Delivery
Test Optimization
Program Integration
• Equipment Failure Analysis
• Gap analysis tool simulation/modeling• Mod and sim tool selection• AFWA DMSP MSS porting study
• FPGA development suite solution• FTN/C++ interface standards
• Make online system (test) more like Goddard Operations• EMOS analysis test cycle• Antero Program regression test
• IDMO DfSS
DfSS projects!
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Example 1. IDMO DfSS
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Vision and Goal
• Vision– “Redesign the existing Generic Multi-purpose Board
using the most up to date technology available, while presenting the same form/fit/function to the customer.”
• Goal– Reduce the number of projected System Problem
Reports (SPRs)
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Prioritize: Defect Analysis
0
10
20
30
40
50
60
70
80
Production Engineering Vendor Handling Unknown Chassis Fail
Aurora
Valley Forge
Site
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Characterize: Production Failure Mode Effects Analysis (FMEA)
Over buy/test105519Component failure (major)
Over buy/test42240Component failure (minor)
New robust connectors/cables189924Conn. Interface
Complete power analysis during design. Power checks as part of TP.
10553Voltage issues (high/low)
Installation training21115Bent pins
Test/verification7167No communication with SBC
Design reviews and testing18993Short to ground (trace)
Testing2115Smoked
Testing/over buy parts147714Bad parts
Will capture in test; will not deliver any board without a personality pre-loaded.
101965Won’t download personality
WAVE solder will limit the occurrence of solder bridging.
138535Component shorts
Selected LEDs that do not require soldering to replace; will spare these items.
21115LED failures
Parts selection criteria is surface mount where possible. Allows for WAVE solder technique.
168875Poor solder flow
Action PlanScoreNon-
DetectionImpactOccurrencesSystem Problem Report
(SPR)
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Improve: New Architecture
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General Multi-Purpose (GMP) Board Architecture Current Proposed GMPII Architecture 1
VME Interface
XCVR
DPR
uP
LBUS MBUS
FPGA
Mez Card
FrontPanel
I/O
RAMVME
Interface TUND
MPU
SDRAM
LBUS
PCI
RBUS
MBUS
FPGA
PMC Slot
DPR
FrontPanel
I/O
FLASH
A/D
I/O
VIC
FIFOs
FPGAs
PROM
NCO
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Improve: New Architecture (cont.)
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Proposed GMPII Architecture 2 (selected)
VMEInterface TUND
SDRAM
LBUS
PCIBridge
RBUSMBUS
FPGA
PMC Slot
FrontPanel
I/O
FLASH
A/DandCS
I/O
MPU
DPR
• Everything on the PCI busstandard• Minimized the number devices on the boardless soldering• Ball grid arrayno pins to bend• Using surface mount partswave soldering technique• No ribbon cables• Micro robust connectorsfewer
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Achieve
0
2
4
6
8
10
12
Projected SPRs Actual SPRs
Aurora
Site
Other
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Example 2. Equipment Failure Analysis
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Vision and Goal
• Vision– To find new or improved methods to lower or
eliminate failures in the following items: circuit boards, swappable devices (i.e., hard drives)
• Goal– Eliminate failures
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Prioritize: Business Failure Analysis
Items That Failed
PowerSupplies
PC Boards CPUs Hard Drives Memory
Qu
anti
ty o
f F
ailu
res
Series 1
Series 2
Series 3
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Prioritize: Program A Failure Analysis
Mem
ory/E
CC
Mem
ory/D
IMM
CPUs
Power S
upply
Hard D
rives
Items That Failed
Qu
an
tity
of
Fa
ilure
s
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Characterize: Fishbone Analysis
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EquipmentFailures
Power
Vendor
Temperature
ElectrostaticDischarge
Humidity
Packing/Shipping
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Improve
• Rearchitect the environment– Temperature– Humidity– Power
• Procedures: electrostatic discharge requirements– Wrist straps– ESD carts– ESD benches
– Management involvement– Data collection– ESD-certified technicians replace items– ESD improvement program
• Equipment failure analysis process– Data collection and analysis
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Achievement Goal
Program A
Business
Before After
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Example 3. Online Ops-Like Test Environment
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Vision and Goal
• Vision– “By incorporating Design for Six Sigma, the intent is
to reduce the number of Discrepancy Reports (DRs) that are written against our software.”
• Goal– Reduce the number of Discrepancy Reports (DRs)
written against the Online System
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Prioritize: Online Ops-Like Test Environment Supporting Data
0
1
2
3
4
5
6
Enviro
nmen
t
Telem
etry
Cecil
Comm
and
HMI
Clock
Corr
Histo
ry
Nu
mb
er o
f D
Rs
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Prioritize: Online Ops-Like Test Environment Supporting Data
CecilCecil waitelrv failed to catch mem load acpt flag during MCL load_R0292
CommandSim cfgs will not allow command if set in past_T1678
CCRTES load commands padded with too many bits_R0272
CecilAuto step messages clutter commanding in central Cecil_R0271
Environmentmove_transferred_files script stopped_R0269
HistoryRTM files not closed automatically_R0261
Cecil“Analyst” misspelled in RTLOG impacts searches/filtering_R0242
CDH & COM derived points stale in eK_LA telemetry_R0234
IntegrationAccess to o:\online\paves_user\ch1\misc\xxxxx.hdp denied support_R0233
CecilFEOF function does not seem to be working_R0231
Awaiting withdrawal
USCCS clock corr. aborts when clock error exceeds approx. 24 hours_R0230
DatabaseOnline derived FMU/SSR telemetry points not accurate_R0229
CCROnline NCC connection anomaly_R0227
Awaiting withdrawal
EMOS error message during FSW log dumps_R0226
CategoryTitleDiscrepancy
Report
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Prioritize: Online Ops-Like Test Environment Supporting Data (cont.)
CategoryTitleDiscrepancy
Report
CommandTES time fields differ between online and MMS_R0376
DatabaseTES derived parameter needed for ICS motor current_R0370
DatabaseInput derived parameters for TES RCS temperatures_R0369
CCRCH_TDRSS_INFO.dat file update for TD9_R0363
Clock CorrOPS primary terminated during startup of config_R0344
DatabaseAdd limits to TES derived parameters_R0335
Environmentmake_intdmf_transfers. & make_history_transfers.pl died_A0958
EnvironmentInterface services died_R0330
TelemetrySuppression delta messages should be warning, not informational message
_R0329
EnvironmentRBD index only shows most recent file_A0954
Awaiting withdrawal
EMOS RT log incorrectly indicates missing SUROM packets_R0315
CommandError message received after GCMR proc sent_R0314
EnvironmentError when starting transfer scripts_R0294
CommandMulti-partition TES microprocessor loads have incorrect sequence flags_R0293
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Prioritize: Online Ops-Like Test Environment Supporting Data (cont.)
CategoryTitleDiscrepancy
Report
DatabaseRemove yellow limits from SUROM secondary test derived tlmy pts_R0556
InvestigatingGround config failed to start on EORS12_R0555
HMIPlots show “No Updates Yet”_R0545
DatabaseGNC star tracker voltage derived mnemonics are incorrect_R0535
CCRAQUA telem decommed by AURA EMOS system_R552
InvestigatingIncorrect time tag in real time log_R0512
TelemetryEMOS suppression delta detection incorrect _R0511
DatabaseDelete red limits for GNC mnemonics_R0493
InvestigatingESRS12 fell off talarian_R0462
Clock CorrRDD clock correlation report files deleted_A0999
HMITLM page cell can be “Frozen” with alarm state format_R0406
Telemetry1750a mnemonics not alarming_R0402
DatabaseUnused MLS derived parameters still in online system_R0388
TelemetryMLS temperatures are stale_R0387
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Characterize: Root Cause Analysis Results
• Not enough “ops like” testing procedures
• Not enough testing done by different users’ logins
• Not keeping interfaces running regularly
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Improve: Create a More Ops-Like Environment
• Update the “on-line” test procedures
• Implement ops-like procedures
• Test using several different user-name logins
• Keep interfaces running regularly
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0
1
2
3
4
5
Enviro
nmen
t
Telem
etry
Cecil
Comm
and
HMI
Clock
Corr
Histo
ry
Nu
mb
er o
f D
Rs
Achieve
No Discrepancy Reports!
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IV. Conclusion
• DfSS integration into the Business Process is underway
• People are trying it in all phases of the Business Model– Key parameters– Objectives– Achieve/measure
• More evolution required for– Modeling– Predicting