practitioner’s guide to supportabilityengineering •requirements ... software govt software...

Practitioner’s Guide to Supportability

Defense Acquisition University

Patrick M. Dallosta, CPL

Professor of Engineering Management

March 20, 2018

2018 PSM Workshop March 20, 2018 1

Cleared For Release

The Practitioner’s Guide to SupportabilityProcess Steps

1. Define/Establish an Analytical Framework

2. Translate Requirements into a Design

3. Mature the Design Through Testing

4. Use Analytical Tools to Conduct Trades

5. Develop, Maintain, Use and Report Data

6. Continuously Evaluate Suitability

2018 PSM Workshop March 20, 2018 Practitioner's Guide to Supportability 2

1. Define/Establish an Analytical FrameworkFrom Competencies to Outcomes


COMPETENCIES PROCESSES ACTIVITIES DATA TOOLS OUTCOMES

• Reliability,

Availability and

Maintainability

• Design Interface

• CBM+ / RCM

• Configuration

Management

• IUID

• PHST

• Transportability

• Sustaining

Engineering

• Technical Data

Management

• Integrated

Product and

Process

Development

(IPPD)

• Product

Support

Analysis (PSA)

• Supportability

Analysis

• Reliability

Growth

• RIO

Management

• Independent

Logistics

Assessment

• Requirements

Management

• Design

Interface

• Technical

Reviews

• Configuration

Management

• Test &

Evaluation

• Quality

• Sustaining

Engineering

• Requirements

• Performance

• Operational

• Logistics

Product Data

• Technical Data

/ IP

• DT/OT Test

• Field

Maintenance

• Business Case

Analysis

• SEP

• LCSP

• R&M Allocation &

Prediction

• Reliability Growth

Modeling

• FMEA/FMECA

• PowerLOG-J PSA

• COMPASS Level of

Repair Analysis

• CASA Life Cycle

Cost

• Post Fielding

Support Analysis

(PFSA)

• Capability

• KPP/KSAs

• Affordability

• Operational

Effectiveness

• Operational

Suitability

• Managed Risk

• Accountability

Practitioner's Guide to Supportability

1. Define/Establish the Analytical FrameworkApply Enterprise Standards


• US Army LOGSA

Logistics

Enterprise

Standards

define the

terminology,

requirements,

processes, and

relationships

necessary to

provide a

comprehensive

assessment of

system

architectures

and resources..

Click for HyperlinkSource: US Army LOGSA


https://www.logsa.army.mil/lec/policy_standards/standards_relationship.jpg



2. Translate Requirements into DesignObjective #1: Failure Identification / Prediction


Built-In-Test (BIT) Fault Detection - a

measure of recorded BIT indications which

lead to confirmed hardware failures.

BIT Fault Isolation - A measure of

recorded BIT indications which correctly

identify the faulty replacement unit, either

directly or through prescribed

maintenance procedures.

BIT False Alarms - A measure of

recorded BIT indications showing a failure

when none has occurred

Attributes Which May be Considered

KPPs or KSAs Include:

The ability of the system to

identify and/or predict failures

down to a certain subsystem

within a given percentage of

accuracy.

Potential attributes include

health management,

prognostics and diagnostics

capabilities, Condition-Based

Maintenance Plus (CBM+)

enablers, support equipment

and parts

commonality.

Supportability as a

JCIDS Design Objective


2. Translate Requirements into DesignObjective #2: Rapid Restoration of Service


Corrective Maintenance - All actions performed as a

result of any failure, to restore a system, subsystem, or

component to a required condition.

Mission Maintainability - The ability of the system to be

retained in or restored to a specified mission condition.

Maintenance Burden - A measure of maintainability

related to the system's demand for maintenance manpower

Attributes Which May be Considered

KPPs or KSAs Include:

The ability of the system to be

brought back to a state of normal

function or utility.

Normally expressed as Mean Down

Time (MDT), Mean Time To Repair

(MTTR) or a calculation of ease of

maintainability.

Maintainability as a

JCIDS Design Objective

Maintainability Design Attributes

Accessibility – Physical placement of hardware to facilitate maintenance.

Modularity – Grouping of similar functions within a physical area.

Testability – Extent to which the operational status of modules can be tested


2. Translate Requirements into DesignObjective #3: Affordable Cost / Effective Sustainment


JCIDS

Design ObjectiveDefinition / Attributes

Cost

Included as one of the O&S Cost KSA, normally expressed as the total O&S

costs regardless of the funding source over the projected life cycle of the

capability solution in base year dollars

Sustained OperationsThe ability of the system to be employed in an operational context for a given

timeframe without logistics resupply or support

Transportability &

Deployability

The ability of the system to be moved and deployed within the Department's

transportation infrastructure

Logistics FootprintMateriel, mobility, and space required to effectively sustain the system in the

field


3. Mature the Design Through TestingDesigning for R&M / Developmental Test


Design for Reliability (DFR) is a System Engineering process that identifies and eliminates

failure modes, and ensures the reliability and supportability of designs:

Redundancy

Derating

Thermal Design

Integrity Analysis

Software RAM

Parts Selection Program

Critical Items Analysis

Storage Analysis

Sneak Circuit Analysis

Environmental Testing

(MIL-STD-810C)

• Altitude

• Hi / Low Temp / Shock

• Vibration

• Heat/Cold

• Solar Radiance

• Rain (Wind and Ice)

• Humidity / Fungus

• Wind/Fog

• Salt

Developmental Test & Evaluation

(DT&E)

• Laboratory

• Limited Operational

• Simulation

The Failure Reporting And Correction System (FRACAS)

Is An Integral Part Of The Development Process


4. Use Analytical Tools to Conduct TradesMIL-HDBK-502A Design Interface-Support Trades


Task Outputs

RAM Allocation, Prediction, Modeling &

Analysis

• Requirements / Traceability

• MTBF, MTTR Predictions / Allocations Reliability Modeling

Redundancy Requirements

Failure Modes, Effects and Criticality

Analysis

• Single Points of Failure

• Maintainability Information/Accessibility/Modularity/Testability

• Criticality Analysis

Fault Tree Analysis • Root Cause Analysis

Maintenance Task Analysis• Preventive and Corrective Tasks, Skills, Tools, Test Equipment,

Facilities

Reliability Centered Maintenance / Condition

Based Maintenance

• Preventive Maintenance Tasks, Cost and Schedule

• Prognostics and Health Management

Level of Repair Analysis

• Maintenance Concept

• Repair v Discard / Maintenance Allocation Chart

• Operational Availability Maintenance Cost


4. Use Analytical Tools to Conduct Trades FMECA Appendix A - Maintainability Information


1 2 3 4 5 6 7 8 9 10

ITEM FUNCTION

FAILURE

MODES

AND

CAUSES

FAILURE

EFFECTS

LOCAL

LEVEL

FAILURE

EFFECTS

NEXT

HIGHER

LEVEL

FAILURE

EFFECTS

END

EFFECTS

SEVERITY

CLASS

FAILURE

PREDICTABILITY

FAILURE

DETECTION

MEANS

MAINTENANCE

ACTIONS

Power

Supply

Diode

Bridge

Provide

regulated

electrical

power

1.Diode fails

“open”;

2.Root cause to

be determined

a.Materials

quality

issue

b.Excessive

voltage/

c. Excessive

current

Loss of

electrical

connectivity

in the circuitry

1.Loss of

regulated

electrical

power

1.No power for

operations

2.Cannot

transmit

3.Cannot

receive

4.May require

alternative

design for

incorporation

of internal

battery

5.Single point of

failure

•HIGH Class

4 TBD

•Loss of

Mission

•Loss of

Equipment

QUESTION(s)

1.Was the diode

selected as a

known reliability

item?

2.Is the diode

performing within

its known

specification

profile?

3.Given usage,

where is the diode

in its life profile

within the bath tub

curve?

QUESTION(s)

1.What is the

level of

Performance

Monitoring

Fault Location

(PMFL)

capability

within the

design?

2.What level of

ambiguity

exists within

the Built-In-

Test (BIT)

capability?

1.Inspect

2.Test

3.Remove &

Replace

System UHF/VHF Radio Indenture Level A304 Diode Bridge Mission Rx Tx Full Duplex

Identifies Engineering and Product Support Information for Design, CBM / RCM, Tech Manuals


4. Use Analytical Tools to Conduct TradesDoD Product Support Analytical Tools


Disclaimer

The product support analytical tools identified in this database are

provided solely to assist defense acquisition workforce

professionals to identify best value product support solutions

which optimize system readiness and life cycle cost. Neither the

Department of Defense or the Defense Acquisition University

provide any warranty of these tools whatsoever, whether express,

implied, or statutory, including, but not limited to, any warranty of

merchantability or fitness for a particular purpose or any warranty

that the contents of the item will be error-free. This analytical tools

database should under no circumstances be considered as being

all-encompassing, and is in no-wise meant to endorse the

capabilities or products of any particular individual, company, or

organization.

USA AMSAA

Center for Reliability Growth

USA LOGSA

Logistics Engineering

Analysis Center

Products


https://www.logsa.army.mil/lec/analysis/

https://www.logsa.army.mil/lec/analysis/

https://www.dau.mil/tools/p/AMSAA-Suite

https://www.dau.mil/tools/p/AMSAA-Suite

https://shortcut.dau.mil/JST/psa-tools

https://shortcut.dau.mil/JST/psa-tools

5. Develop, Maintain, Use and Report DataLogistics Product Data (LPD) / Data Sources


Engineering Analyses

Maintenance Task AnalysisCDD Inputs Bill of Materials

Purchase Orders

Drawings

Facilities

Test Equipment Specifications

MIL-HDBK-502A, Product Support Analysis, and GEIA-STD-0007 Logistics Product Data

define over 100 logistics product data (LPD) tables that document information

for the 12 Integrated Product Support (IPS) elements.

T

A

B

L

E

S

D

A

T

A


5. Develop, Maintain, Use and Report DataIndustry Standards Facilitate Data Exchange


SAE GEIA-STD-0007 Logistics Product Data

Has Been Adopted by the DoD for the

Acquisition and Exchange of Logistics Product Data (LPD)

• Universal Data Item Description (DID)

• Standard reports supporting IPS

Elements

• Data requirements/attributes

• Exchange protocols for data

communication

• Table relationships

• Shared, common terminology

10101010101010010

Enables

Error Free

Data Transfer

GOVTOEM

Contracts can require the OEM provide

SAE GEIA-STD-0007 compliant data

to the Government.

Commercial

Software

Govt

Software


5. Develop, Maintain, Use and Report DataLSA Reports Detail IPS Element Resources


Over 80 Reports


5. Develop, Maintain, Use and Report DataData-Driven Decision Making / Governance


Sustainment Quad Chart


6. Continuously Evaluate SuitabilityIndependent Logistics Assessment (ILA)


The 2009 DoD Weapon Systems Acquisition Reform Product Support Assessment (WSAR-PSA) included the

recommendation to implement independent Logistics Assessments during Weapon System Development,

Production and Post-initial Operational Capability (Post IOC)

(3) Risk Rating Summary

(2) ILA Rating Criteria(1) Assessment Criteria

ILA Provides Critical Technical And Management Information To Support the Governance Process


6. Continuously Evaluate SuitabilityInitial Operational Test & Evaluation (IOT&E)


Suitability is the

degree to which a

system can be

satisfactorily

placed in field use,

with consideration

given to reliability,

availability,

compatibility,

transportability,

interoperability,

wartime usage rates,

maintainability,

safety, human

factors, manpower

supportability,

logistics

supportability,

documentation,

environmental

effects, and training

requirements.

The Log Demo evaluates the Suitability of system support that ensures the right resources, with the

appropriate skill level, under the appropriate environment conditions, to achieve the maintenance

task in the time allotted.

$ Ao

Logistics Footprint

MTTR

Maintenance Concept


6. Continuously Evaluate SuitabilityPost Fielding Data & Supportability Analysis (PFSA)


Air Force Total Ownership

Cost Management

Information System

(AFTOC)

Army Operating and

Support Management

Information System

(OSMIS)

Navy Visibility and

Management of Operating

and Support Cost

(VAMOSC)

US Army Logistics Support Activity (LOGSA)

Post Fielding Support Analysis (PFSA) Tool

Weapon System Report

A two-year window rolling weapon system performance assessment

Equipment Availability

Demand Drivers

Maintenance Drivers

Fleet Usage


6. Continuously Evaluate SuitabilitySustaining Engineering


Sustaining Engineering spans engineering and sustainment domains

(and analyses) to ensure continued operation and maintenance of a

system with managed (i.e., known) risk.

Sustaining Engineering: Technology Insertion

Service Life Extensions

Correction of Deficiencies

Incorporation of New Capabilities

Improved Product Support

Are the Levels of Performance, Reliability and Product Support

Sufficient to Meet System Sustainment Requirements?

Click Pic for Hyperlink

Technology Insertion

Click Pic for Hyperlink

Service Life Extension


https://www.defensenews.com/smr/2017/07/27/dod-slashes-amraam-missile-buy-as-raytheon-struggles-with-tech-refresh/

https://www.defensenews.com/smr/2017/07/27/dod-slashes-amraam-missile-buy-as-raytheon-struggles-with-tech-refresh/

https://www.defensenews.com/air/2017/10/19/boeing-pitches-upgrading-super-hornets-during-upcoming-life-extension/

https://www.defensenews.com/air/2017/10/19/boeing-pitches-upgrading-super-hornets-during-upcoming-life-extension/

Supportability Analysis Links


LOG 211 Supportability Analysis (Classroom)

CLL 008 Designing for Supportability in DoD Systems

CLL 012 Supportability Analysis

MIL-HDBK-502A Product Support Analysis

MIL-HDBK-502A Product Support Analysis ACQuipedia Article

Logistics Assessment Guidebook

CLL 020 Integrated Logistics Assessment

Integrated Logistics Assessment (ILA) Guidebook ACQuipedia Article


http://icatalog.dau.mil/onlinecatalog/courses.aspx?crs_id=1900



http://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=201462

https://www.dau.mil/acquipedia/Pages/ArticleDetails.aspx?aid=01d169cf-3334-4be2-8de5-232a8c4f55d9

https://www.dau.mil/tools/t/Logistics-Assessment-Guidebook


https://www.dau.mil/acquipedia/Pages/ArticleDetails.aspx?aid=0520ca9c-1242-4991-bcce-47fa81e2bfb9

Questions & Answers


Patrick M. Dallosta, CPL

Professor of Engineering Management

Defense Acquisition University / Mid-Atlantic Region

2330 Cottonwood Parkway

California, MD 20619

[email protected]

(240) 895-7364 / (703) 201- 4543

Thank You for the Opportunity to Support the

2018 Product Support Manager (PSM) Workshop

“An Ounce of Design Interface is Worth a Pound of Supply Chain.”


mailto:[email protected]

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