16.885J/ESD.35J - Sep 4, 2003 16.885J/ESD.35J Aircraft Systems Engineering September 4, 2003 Prof. “John” Hansman Prof. “Earll” Murman 16.885J/ESD.35J - Sep 4, 2003 Today’s Class ? Course introduction ? Course learning objectives & measurable outcomes ? 21st Century Jet: The Building of the 777 – Interleaved video and discussion on aircraft systems engineering ? Semester case study ? Administrivia ? Grading ? Class discussion 16.885J/ESD.35J - Sep 4, 2003 Course Introduction ? Holistic view of aircraft as a system – Systems Engineering and System Level Attributes (12 lectures) – Subsystems: The Anatomy of an Aircraft (7 lectures) – System Realization (6 lectures) ? Retrospective analysis - studying existing aircraft to learn about design choices and features ? Apply knowledge to semester long case study ? Emphasis is more on “aircraft systems” than on “systems engineering” ? Learning community approach – We are all teachers and learners – Be engaged 16.885J/ESD.35J - Sep 4, 2003 Course Learning Objectives At the completion of 16.885, students will have gained: ? An appreciation of an aircraft as a system, operating within a larger air transportation or air defense system, and comprised of many subsystems ? Understanding of, and ability to apply, basic concepts for: – Systems engineering: requirements, interface mgmt, verification & validation – Cost and weight analysis and estimation. – Performance analysis – Reliability and safety – The function, architecture and key performance issues of major subsystems – Risk analysis and management – Design closure to deliver lifecycle value ? An ability to understand complex systems and design choices through the retrospective analysis of existing aircraft systems. 16.885J/ESD.35J - Sep 4, 2003 Course Measurable Outcomes ? Retrospective analysis of an existing aircraft design, delivered in both written and oral forms. ? Individual contributions to case study team effort as reported by student and teammates. ? Class participation. ? End of semester interview with course faculty on achievement of learning objectives. 16.885J/ESD.35J - Sep 4, 2003 Segment from PBS Home Video 21st Century Jet: The Building of the 777 Part I - 9:15-16:10 (6 min 50 sec) Covers the 777 “Value Proposition” struck between United Airlines and Boeing 16.885J/ESD.35J - Sep 4, 2003 Value Creation Framework worth, utility, benefit, or reward in exchange for their respective contributions to the enterprise. Value - how various stakeholders find particular Value Identification Value Value Delivery Proposition Value Phases Develop a robust value proposition to meet the expectations Identify the stakeholders and their value expectations Deliver on the promise with good technical and program performance Source: Lean Enterprise Value: Insights from MIT’s Lean Aerospace Initiative, Murman, et. al 2002 16.885J/ESD.35J - Sep 4, 2003 The Challenge of Architecting and Engineering Aircraft Systems Employees Customer Acquirer Partners Shareholder Corporation Society Suppliers Union Enterprise End User Consumer A fundamental challenge of any program is to satisfy multiple stakeholders expectations for product – Performance/quality – Schedule/availability – Cost/financial return with acceptable risk. Stakeholders 16.885J/ESD.35J - Sep 4, 2003 Segment from PBS Home Video 21st Century Jet: The Building of the 777 Part I - 17:12-20:32 (3 min 30 sec) Addresses the technical complexity of aircraft with its many components which interact, requiring the use of mockups, originally physical and now digital, to visualize the interactions. 16.885J/ESD.35J - Sep 4, 2003 Technical Dimension 6 Level Hierarchy 0 - Physical environment of the world 1 - The air transportation system or the air defense system 2 - The aircraft and/or related systems 3 - Major subsystems or subassemblies: both hardware and software 4 - Components or major software units 5 - Parts or lines of code 16.885J/ESD.35J - Sep 4, 2003 The “Inters” ? Interrelationship: “mutual or reciprocal relation or relatedness”. ? Interrelationships take various forms with increasing degrees of relatedness – Interconnections (or interfaces): “a state of being connected reciprocally” – Interactions: “mutual or reciprocal action or influence” – Interdependencies: “mutual dependence” ? Large-scale systems are characterized by many elements which, through their interrelationships, deliver greater capability than the sum of the individual elements alone. Source: http://www.dictionary.com/ 16.885J/ESD.35J - Sep 4, 2003 Examples of Technical Dimension Inters 6 Level Hierarchy ? Emissions from engines (3) multiplied by size of a/c fleet 0 - Physical environment of the world (1) impacts global 1 - The air transportation system or the air defense system 2 - The aircraft and/or related systems environment (0). ? Engine (3) provides thrust for wing (3) which provides lift for engine, both coupled through aerodynamics ? AA Flight 261 accident 3 - Major subsystems or subassemblies: – Stripped elevator lead both hardware and software screw (5) caused loss of a/c system (2) 4 - Components or major software units – Maintenance system (2) interacted with a/c system 5 - Parts or lines of code (2) 16.885J/ESD.35J - Sep 4, 2003 Segment from PBS Home Video 21st Century Jet: The Building of the 777 Part I - 22:05-27:45 (5 min 40 sec) Introduces Design Build Teams (or Integrated Product Teams) and shows one in action sorting out solutions to crack formation and growth in a passenger door 16.885J/ESD.35J - Sep 4, 2003 Social Dimension 6 Level Hierarchy 0 - Society, nations, communities, etc. 1 - Extended multi-organization enterprises, including partners and suppliers 2 - Single organizations 3 - Organizational units 4 - Working groups/teams 5 - Individuals 16.885J/ESD.35J - Sep 4, 2003 Examples of Social Dimension Inters 6 Level Hierarchy ? Enterprise leader (2) affects lives of many employees (5). 0 - Society, nations, communities, etc. ? Employee productivity (5) affects enterprise success (2). 1 - Extended multi-organization enterprises, including partners ? Airbus & Boeing (2) mutually and suppliers dependent upon competition. ? International terrorism (0) 2 - Single enterprise impacts future of entire US aerospace enterprise (1-5). 3 - Organizational units ? Creative genius of individual (5) like Kelly Johnson affects 4 - Working groups/teams fate of enterprise (2) and nation (0). 5 - Individuals 16.885J/ESD.35J - Sep 4, 2003 Segment from PBS Home Video 21st Century Jet: The Building of the 777 Part I - 27:45-30:50 (3 min 5 sec) Shows a verification test of passenger door opening with 1/2” of ice - a step in the systems engineering process 16.885J/ESD.35J - Sep 4, 2003 Simplified System Engineering Process Steps Needs: ?End user Verification is assuring the system meets the requirements Validation is assuring the system meets the needs Source: Adapted from Jackson, S. Systems Engineering for Commercial Aircraft Functional Analysis ?Customer ?Enterprise ?Regulatory Requirements Verification Synthesis Validation 16.885J/ESD.35J - Sep 4, 2003 Segment from PBS Home Video 21st Century Jet: The Building of the 777 Part I - 40:36-43:56 (3 min 20 sec) Covers Working Together, the new approach used by the 777 for open and honest communication. Working Together 16.885J/ESD.35J - Sep 4, 2003 Learning Community ? Establish and maintain program credibility ? Open and honest communication ? Encourage and reward asking for help ? Utilize knowledge regardless of where it originate ? Share responsibilities for decisions using a well-defined process ? Maintain two way dialog in working relationships, do both listening and talking ? Value people for the skills they contribute to the program with mutual respect and appreciation Source: Adapted from Stanke, A. “A Framework for Achieving Lifecycle Value in Product Development” 16.885J/ESD.35J - Sep 4, 2003 Segment from PBS Home Video 21st Century Jet: The Building of the 777 Part I - 52:30-55:40 (3 min 10 sec) Covers the task ahead to design and produce a product that takes several years and lasts decades, all in an uncertain world market and environment 16.885J/ESD.35J - Sep 4, 2003 Notional Lifecycle Costs Source: Fabrycky, W.J. and Blanchard, B.S. Life-Cycle Cost and Economic Analysis Conceptual/ preliminary Design Detail design/ development Production and/or construction Product use/ support/ phaseout/dispos al 100% 80% 66% Ease of Change LCC committed Cost Incurred Figure 2 - Lifecycle cost committed vs incurred (Fabrycky and Blanchard, 1991) Long lifecycles are a significant driver in aircraft systems engineering and architecting 16.885J/ESD.35J - Sep 4, 2003 Lifecycle Issues ? Lifecycle Costs – ~1/3 of lifecycle cost is acquisition, 2/3 is operation ? The “ilities” dominate the life cycle – Reliability, maintainability, supportability, upgradeability ? Product evolution – E.G. B-52 was designed as a strategic bomber with predetermined missions, yet used in Afghanistan in a tactical delivering JDAMs directed by ground spotters. ? Knowledge management Long lifecycles are a significant driver in aircraft systems engineering and architecting 16.885J/ESD.35J - Sep 4, 2003 Semester Case Study ? Retrospective analysis of an existing aircraft to understand key design drivers, decisions, and features ? Done in small teams ? Suggested outline in syllabus appendix – Last year’s cases serve as models ? Will evolve during semester in written and oral versions – Written Versions I (9/25), II (10/16), III (11/13), IV (12/9) – Oral presentations scheduled near Versions II and III ? Candidate case studies with Subject Matter Experts (SMEs) available: ? Douglas DC-9 ? Saab Farchild 340 ? Sikorsky S-92 Dynamics F-111 ? Cessna Citation X ? USAF Boeing C-17 ? USAF Boeing B-52 ? USAF General ? Space Shuttle 16.885J/ESD.35J - Sep 4, 2003 Administrativia ? No formal prerequisites ? Lecture classes Tue and Thu 9:30-11:00 – Handouts of lecture material – Expect class questions, discussion, participation ? Additional hour for case study team time or oral reports ? Field trip to Sikorsky in Stratford CT to be scheduled ? References many and varied – Books and case studies on reserve in AA library – Need to exploit all resources: www, SME, …. ? Course web site - see syllabus ? Turn in student profile form at end of class ? E-mail to me by Monday a one paragraph bio 16.885J/ESD.35J - Sep 4, 2003 Grading Team Grades for Case Study Written Version 1 10 Written Version 2 10 Oral presentation 1 10 Written Version 3 15 Oral presentation 2 10 Final Written Version 20 Total team grade 75 Individual Grades (Further guidelines will be given on these) Midterm written assessment 10 End of term oral assessment 15 Total individual grade 25