Continuing Education Program on Systems Engineering Process 13-17th april 2004 Center for Aerospace Systems Design and Engineering Department of Aerospace Engineering Indian Institute of technology, Bombay Mumbai – 4000076 Course details 1. Fundamentals of Systems Engineering ( JJ ) ( 1.5 hours )

• Why systems engineering – drivers to change • Systems, classifying systems, system characteristics,

characteristics of large scale complex systems • System hierarchy • System states and modes, state transition diagrams • History of systems engineering • Objectives of systems engineering, system life cycle, steps in

system life cycle • Systems engineering, example, system engineering process • System context, environment, context diagram, system

boundary • IDEF diagram, • System development, system design • Comparison of scientific method, systems engineering and

SIMILAR methods • System design engineering, system design engineering tasks

activities • Typical trade studies • FOM, TPM, Metrics • Systems engineering and design engineering • Cost effectiveness • System specification • Functions of a systems engineer • System solution overview mapped to a life cycle stage • Systems engineering and systems management • Systems engineering standards evolution • Systems engineering summary

2. Requirements capture analysis and management ( JJ ) ( 1.5 hours ) • Need for requirements • Requirements definition • Essence of a requirement • Specification, requirements vs. specification • Requirements rationale • Requirements , types, typical list, typical

requirements with principles of classification • Types of system requirements • Categorization of requirements • Primitive requirements list, PRL diagrams • Requirements criteria ( FACTS ) • Attribute of good requirements • Attribute of individual requirements, attributes of set of

requirements • Requirement analysis , it’s importance, steps in

requirements analysis • Requirement development and it’s processes • QFD, advantages of QFD, 7 basic steps in QFD

requirements generation • Originating requirements • Outline of originating requirements document • Roles and responsibilities during requirements

generation • Requirement management • Requirement management functions with roles

responsibilities • Specification practices • Requirement tools characteristics • Requirement trace ability • Requirements validation and verification

3. Design for function ( JJ ) ( 1.5 hours )

• Concepts : function, behavior, configuration • Types of functions • Role of functions in systems engineering • Functionality • System functions • Activities related to functions • Functional analysis • Functional decomposition • Why functional analysis • Functional data format • History of Design for Function • Techniques of functional analysis • Functional decomposition • Functional decomposition process • Common graphical representations used • Relationship of all graphical representations • Functional analysis techniques • Rules to improve function identification ability • Logical design vs. physical design • Different views of task • Function analysis system technique • Function structure • Architecture synthesis • Black box view white box view • Functional analysis and allocation • Functional analysis synthesis • Function metrics • ATC problem

4. Design for Manufacture and Assembly ( JJ ) ( 1.5 hours )

• Successful and pragmatic cases of product development • US DoD’s analysis – attainment of design and manufacturing

knowledge • benefits of DFMA • illustrated cases before and after DFMA • advantages of DFMA • DFMA in world war II • Essence of DFMA • What is DFMA • DFMA methodology • DFMA tools • DFMA application areas • When to apply DFMA • Who are using DFMA • DFMA BDI software • Motor drive assembly problem • DFMA applied to electrical electronic products

PCBs , cables and wire harness, case studies • FMEA concurrent product and process development

Design, Process, examples • Activities to achieve manufacturing knowledge • Process capability index • Examples of prototypes used • Best approach to product development

5. System Operational Effectiveness and Life Cycle Cost Analysis ( JJ ) ( 1.5 hours )

• Concepts system effectiveness, operational effectiveness • Definition of terms • System effectiveness product efficiency flow chart • A total system evaluation • Stages of system evaluation during the life cycle • System efficiency merit • System design integration requirements • Design adequacy • Reliability • Maintainability • Maintenance, maintainability • Interchangeability, accessibility • Visibility, testability, dependability • Human factors • System safety • Integrated logistics support • Availability • Survivability • Operational readiness • Elements of life cycle cost • Cost breakdown structure • Operations and support cost • Affordability • Issues of functional worth and affordability • Cost driving relationships • Cost estimating methods • Parametric methods • Technology refreshment • Technology readiness levels • Cost as an independent variable methodology ( CAIV ) • Cost effectiveness • Basic ingredients of cost effectiveness

6. Concept selection, trade study analysis and design decision making ( JJ ) ( 1.5 hours )

• Conceptual design • 8 elements of smart choices • System design and development process • Identification of alternatives • Need for scientific decision making • Concurrent engineering • Conceptual design and analysis process • Conceptual design synthesis analysis and evaluation • Pughs concept selection • QFD concept selection

traditional QFD, seven basic QFD steps, Boeing’s QFD facilitation check list

• Modified QFD selection method • Fuzzy QFD selection method • Objective function • 777 system architecture design drivers and selection process • Trade studies • Criteria for trade offs • Typical trade studies • Typical trade studies in aircraft design • Examples of trade studies • What are is trade studies • Trade study methodologies • Trade study steps • Controlling the trade study process • Selection methodology to screen , select or perform a trade

study • selecting the selection rule

analytic hierarchy process multi attribute utility theory

• Decisions • Decision analysis • Motivation for decision analysis • Categories of decision analysis

• Typical activity steps in decision analysis • Products of a formal decision analysis • Characteristics of decisions • Decision tree • Theoretical foundations of decision analysis • Decision analysis consequences • Recognition of risk and complexity reality • Risk assessment • Decision support systems • Conceptual differences between MIS, PMIS and DSS • Using models • Risk • Risk management • Risk handling • Risk control • Risk monitoring methods • Risk perspective • Programmatic risk analysis

7. Systems integration, verification, validation and systems management ( JJ ) ( 1.5 hours )

• Concepts integration, verification and validation • Facets of integration • Architectures in support of system integration • Design for integration • Important system design integration issues • Integration process outcomes • Physical integration • Purpose of the integration process • Integration process activities • System integration and optimization responsibility • 777 flight controls integration test approach • System verification • System validation • System interfaces • What are interfaces • Functional vs. physical interfaces • Interface characteristics • Classes of interface media • Interface analysis tasks • N square diagrams • Schematic block diagrams • Interface codes • Triangular matrix diagrams • Square matrix diagrams • Interface dictionary • Interface responsibility • Interface control • Verification • Verification process flow • Verification program concept • Verification methods and techniques

• Stages of verification • Design and product verification • Integration and verification problems • Verification documentation • Golden rules for verification • Validation • Requirements validation • Systems requirements validation • Flow chart validate product requirements • Overall 777 flight controls validation process • 777 flight controls development and approval process • 777 flight controls validation through simulation • System validation • Lessons learnt 777 flight controls validation • Validation methods and phases • 777 validation methods • 777 flight controls requirements validation • 777 flight control system validation • 777 flight controls validation • Installation and validation • Systems analysis • Systems analysis and modeling • Systems engineering management • System engineering management plan • Technical project planning and control • Systems engineering process • Engineering specialty integration • Technical reviews • Review guidance

8. Integrated product and process development ( JJ ) ( 1.5 hours )

• Concepts product, process integrated product and process • Concurrent engineering – definition • Concurrent engineering and symphony orchestra • Integrated product and process definition • History: concurrent engineering, integrated product and

process • Military acquisition process • System acquisition process • Systems engineering cycle • Benefits of IPPD • Boeing 777 story • Essence of IPPD • Objective of IPPD • IPPD process • IPPD and systems engineering • The fundamental concepts of IPPD • Part break down structure and work break down structure • Relationship between PBS and WBS • Examples of WBS • Examples of WBS development errors • Key features of IPPD • Implementing IPPD • Integrated product team ( IPT ) • Key concepts of IPT • IPT organization examples • Team dynamics • Notional IPT structure • Team leader responsibilities • Team participation and cross functional integration • Example of F / A 18 E/F IPT structure • Concurrent engineering techniques and benefits • IPPD tools • New processes seen in aircraft and its systems

• IT and DSS • Trade studies • Examples of trade studies • Prioritization • FOM, TPM and Metrics • Product , Progress and process metric • DFMA and variability reduction • Variability reduction guidance • Virtual manufacturing • Virtual prototyping • Application of virtual reality to aircraft design and

manufacture • Simulation and modeling • Typical simulation benefits • Virtual testing • Process simulation • Manufacturing simulation • Education and training

9. Mechatronics ( HA ) ( 1.5 hours )

• What is mechatronics • History of mechatronics • Constituents of mechatronics • Key elements of mechatronics • Important components of mechatronics • Information systems • Modeling and simulation • Control system engineering • Optimization • Mechanical systems • Electrical systems • Actuators • Issues in actuator selection • Computer systems • Issues in interfacing • Real time interfacing • Real time systems • Issues in real time interfacing • Issues in processor selection • Sensors • Issues in sensor selection • Mechatronics design process • Example autonomous ground vehicle for indoor applications

10. System Design – New paradigm ( KS ) ( 1.5 hours )

• Systems design • Systems engineering • Meta design • Meta design to MDO • Researchers perception • Industry perception • Systems design • An example HCST ( 1991 – 99 ) • HCST – 4 • Where are we • New paradigms • MDO architectures • Best architecture • Framework • MDO frame work • A simple example 3D duct • 3D duct problem formulation • 3D duct : automation for CFD • 3D duct: automation for design • 3D duct design space reduction • 3D duct simulation time • 3D duct design process • concurrent engineering vs. MDO

11. System analysis modeling and simulation ( AJ ) ( 1.5 hours )

• Need for systems approach • System concept • Systems categories • Role of modeling • System model creation • Engineering models types and basis • Basic engineering effects • Example mechanical system • Example electrical system • Example hydraulic system • Example aircraft FCS • Example aircraft dynamics • Summary of modeling • Why simulation • What is simulation • Benefits of simulation • Simulation characteristics • Solution methods • Software simulation features • Software simulation benefits • Software simulation tools • Software simulation languages • Simulation in Fortran or c • Software simulation in CSMP • Example of CSMP code • Software simulation in Simulink • Example of Simulink model • Monte Carlo simulation- concept • Summary of software simulation • Off line vs. real time simulation • Real time simulation • Real time sensor simulation • Philosophy of simulator building • Software simulators • Hardware based simulators • Hardware simulator examples • 6-DOF motion platforms • In flight simulators

12. Case study – Office Stapler ( JJ ) ( 1.5 hours )

• Systems engineering process • Needs statement • Lessons learnt • Identify stakeholders • Operational concept • Other operational scenarios • Concept selection • Alternatives • Concept selection Pughs method • Modified QFD concept selection method • Concept ranking • Lessons learnt • Market and competitive assessment • Customer requirements wrt competition • Quality characteristics • Design data • Customer requirements vs. quality characteristics • Quality characteristics vs. quality characteristics • Quality characteristics wrt competition • Functions vs. quality characteristics • Functions vs. customer requirements • QFD • Technology deployment • Originating requirements document • Morphological table • Concept graph • Functional analysis system technique • FAST diagram for stapler • Function structure • Function configuration maps • A stapler configuration • Interfaces • Function costing • Life cycle cost analysis • Fault tree analysis • Failure modes and effects analysis • Design for manufacture and assembly • Function configuration map new design

• Function configuration map new design ( costing ) • DFMA analysis • Assembly time estimation • Future stapler as a result of DFMA • What to model • How much and how well to model • Modeling and simulation • Modeling approaches and planning • Modeling approaches and applicability • Critical parameter management • Defect prevention variability reduction • Prototyping • System specification document

13. Systems Engineering approach for a Defence Product Development ( PSK & AVS of ADE ) ( 1.5 hours )

• Theory of systems engineering • Example of a typical application Tejas ( LCA ) – FCS • System development elements – DOD standard – 2167A • LCA FCS block schematic • Reliability analysis DFCS • FCS development cycle ( SW & HW ) • Review • Audit • Major technical reviews • Internal reviews • System requirements review • System design review • Software specification review • Preliminary design review • Critical design review • Test readiness review • Functional configuration audits • Physical configuration audit • Example of a typical application Airborne Guidance and Control system

( AG&CS ) of Controlled Aerial Delivery system ( CADS ) • Prime item development specification for AG&CS • PIDS overview • Components • Performance characteristics • Physical characteristics • Environmental characteristics • Major component characteristics • Engineering test and evaluation • Prime item quality conformance inspections • Safety of flight • Requirements cross reference matrix • Case tool RDD – 100 features and usage • Requirements for a CASE tool • Selection of a CASE tool • RDD-100 CASE tool • RDD-100 data base • Facilities utilities in RDD-100

• Working with the data • ERA descriptions for time function • ERA descriptions for performance function • ERA description for discrete item • Report generation • LCA FCS OFP – SRS, IRS generation • Information complexity and utilization

14. Integrated Product and process solutions ( M/S Rolta India Limited ) ( 1.5 hours ) ( demo )

• Integrated product and process solutions – objective • A life cycle systematic approach • What is Rolta doing here in this integration • What does an example look like • Intangible advantages • Product definition – engineering layout • Product definition - engineering layout advantages • Product definition - assembly structure • Product definition - assembly structure advantages • Product definition – skeletons • Product definition – skeletons – advantages • 3 D design finally • Integrated tool and design • Tolerance analysis • Design verification • Validation • Continuous life cycle integrated