economics of human systems integration: the pratt & whitney f119 engine dr. ricardo valerdi...
Post on 15-Jan-2016
218 views
TRANSCRIPT
Economics of Human Systems Integration: The Pratt & Whitney F119 Engine
Dr. Ricardo Valerdi
2ndLt. Kevin Liu, USMC
Dr. Donna Rhodes
seari.mit.edu
Background
1980s
UK Ergonomics Research Society
US Human Factors Society
Human Engineering Guide to Equipment Design
Government Agency focus on safety and human factors
Industrial Revolution - WWII
Industrial Engineering
Human Factors Engineering (HFE)
HSI in the Air Force
seari.mit.edu 3
Manpower—the number and mix of personnel (military, civilian, and contractor) authorized and available to train, operate, maintain, and support each system.
Personnel—the human aptitudes, skills, and knowledge, experience levels, and abilities required to operate, maintain, and support a system at the time it is fielded.
Training—the instruction and resources required providing personnel with requisite knowledge, skills, and abilities to properly operate, maintain, and support a system.
Environment—the conditions in and around the system and the concepts of operation that affect the human’s ability to function as a part of the system as well as the requirements necessary to protect the system from the environment.
Safety—hazard, safety and risk analysis in system design and development to ensure that all systems, subsystems, and their interfaces operate effectively, without sustaining failures or jeopardizing the safety and health of operators, maintainers and the system mission.
Occupational Health—the consideration of design features that minimize risk of injury, acute and/or chronic illness, or disability, and/or reduce job performance of personnel who operate, maintain, or support the system.
Habitability—factors of living and working conditions that are necessary to sustain the morale, safety, health, and comfort of the user population that contribute directly to personnel effectiveness and mission accomplishment, and often preclude recruitment and retention problems.
Survivability—the ability of a system, including its operators, maintainers and sustainers to withstand the risk of damage, injury, loss of mission capability or destruction.
Human Factors Engineering—the comprehensive integration of human capabilities and limitations into systems design, to optimize human interfaces to facilitate human performance in training operation, maintenance, support and sustainment of a system.
Economics of HSI
DoDI 5000.02, Operation of the Defense Acquisition System
seari.mit.edu 4
(Begins)
seari.mit.edu 5
Research Questions
• How did Pratt & Whitney predict how much HSI effort would be needed?
• How much did HSI effort eventually cost?
• How did HSI fit into the larger systems engineering picture?
The F-22 Raptor Air Superiority Fighter
Replaces F-15
Air dominance, multi-role fighter
Dominance through stealth, speed, agility, versatility, supportability
First Look – First Shot – First Kill
seari.mit.edu 6
The Pratt & Whitney F119 Engine
Best practice of HSI
Reliability & Maintainability emphasis from 1984 ->-Air Force leadership
New requirements introduced during Engineering and Manufacturing Development (EMD)
P&W F119 beat GE F120 because it demonstrated “least technical risk and lowest cost”
Yankel, J. & Deskin, W. (2002). “Development of the F-22 Propulsion System.”
seari.mit.edu © 2008 Massachusetts Institute of Technology 8
Engine Design for the Mechanic
Integrated Product Development (IPD)Integrated master plan (IMP), Integrated Master Schedule (IMS), Integrated Product Teams (IPTs), Integrated Program Management Team (IPMT) Component IPTs (CPTs).
Supportability Awareness“Blue Two” visit program.Internal presentations reiterated lessons learned.
Supportability Reviews and Trade StudiesMonthly reviews evaluated adherence to IMP and IMS.Over 200 studies weighed HSI features against cost, weight, and performance.
Early Support Tool InvolvementTools annotated to design drawings
Full-Scale Engine MockupFull-scale engine mockups used to test reality of one-deep LRU - allowed engineers to simulate servicing parts.Held engineers accountable.
HSI Early in F119 Development
AF Acquisition Community-led requirements definition studies
40% fewer parts than previous engines
Leadership and IPD
seari.mit.edu 10
…advances were intended to reduce operational level and intermediate level maintenance items by 75% and depot level tools by 60%, with a 40% reduction in average tool weight,” (Aronstein, et al. 1998).
F119 Successes Span Domains of HSI
HSI Domain Work Done Cost BenefitManpower -Fewer Maintainers
-Men and Women could work on engines- Reduced man-hours spent on maintenance
Personnel - All maintenance tasks designed to accommodate women maintainers
-Improved understanding of procedures
Training - Documentation - Effort spent preparing documentation
Human Factors Engineering
(HFE)
-6 Tools total- 1 Tool/ LRU, One-Deep LRU's- Tools redesigned for easier handling
- Weight
Environment
Safety - Captured Fasteners- Self-contained engine
- Weight -Fewer reported mishaps
Occupational Health
- CBR Suits -Reduced exposure to harmful elements
Habitability - Mock-Ups- "Blue Two" Visits
-Funding for trips- $2M/ Mock-Up
Survivability -Designed to contain fan blades- Single-engine mentality
-Zero Scheduled Maintenance- Reduced engine failure rate- 75% reduced O&I time
seari.mit.edu 12
Development of Cost DriversThe 10 Principles of Effective HSI (from
the Handbook on HSI)1. Top-level leadership
2. Focus on human-centered design (HCD)
3. Source selection policy
4. Organizational integration of all HSI domains
5. Documentation integration into procurement process
6. Quantification of human parameters
7. HSI technology
8. Test and evaluation=assessments
9. Highly qualified practitioners
10. Education and training program
(Booher, 2003)
Prioritized List of Critical Elements for Successful HSI (from The Art of Successfully
Applying Human Systems Integration)1. Management and Organizational Commitment
2. User/stakeholder involvement
3. Education and awareness of all
4. HSI process ownership
5. Holistic, enabled view
6. Funding support
7. Documented and technically sound processes
8. Qualified personnel
9. Open collaborative environment
10. Practical applications based on sound human factors research
(Landsburg et. al., 2008)
Observations
seari.mit.edu 13
•How did Pratt & Whitney predict how much HSI effort would be needed?
•How much did HSI effort eventually cost?
•How did HSI fit into the larger systems engineering picture?
• USAF Requirements-driven• Competition, Business need
• Estimation by analogy•“HSI Slice” unclear
• IPD, CICR, CCB, IPT, CIPT, etc.• Emphasis in requirements, pre-milestone A/B
seari.mit.edu 14
Development of Cost Drivers
– Requirements Understanding – Architecture Understanding – Level of Service
Requirements – Migration Complexity – Technology Risk – Documentation – # and diversity of
installations/platforms
Existing COSYSMO Cost Drivers:– # of recursive levels in the
design – Stakeholder team cohesion– Personnel/team capability – Personnel experience/continuity– Process capability – Multisite coordination – Tool support
COSYSMO
seari.mit.edu 15
COSYSMO
SizeDrivers
EffortMultipliers
195Person Monthsof HSI effort
200 easy, 200 nominal, 50 difficult Requirements2 easy, 3 difficult Interfaces5 difficult Algorithms
High Requirements UnderstandingHigh Technology RiskHigh Process Capability
Acknowledgments
seari.mit.edu 16