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Driving Affordable Common Solutions with Mission Analysis
44th Annual NDIA Gun and Missile Systems Conference
Andrew J. HinsdaleSr. Engineering Fellow
Dan F. CheesemanSr. Engineering Fellow
David G. StoneVice President
Raytheon Missile SystemsTucson, AZ
April 9, 2009
Copyright © 2008 Raytheon Company. All rights reserved.Customer Success Is Our Mission is a registered trademark of Raytheon Company.
4/13/2009 Page 2
Burning Platform
Our customers needs are continually evolving, performance expectations grow while cost expectations drop.To meet their needs, we must:
• Be Faster - in development and to the field…• Reduce time to concept demos• Reduce product development time (SDD)
• Be Cheaper – in SDD and Life Cycle…• Reduce total cost of ownership for customers
• Be Better – continually address improved performance and…• Increase the quality of our products• Provide extensible, adaptable, modifiable solutions to increase value to the customer
Technological innovation is only a part of the solution!
4/13/2009 Page 3
The Modularity Vision Described:“Be Key Enabler for Design 2010 Precepts”
UnderstandsThe Use Of
The Product
Makes Requirements
Capability Trades Around
Affordability
Determines The
Manufacturing Strategy
Identifies Where To Buy From
Designs To Maximize
This Strategy
Lean Innovation and Development
Manufacturing Technology
Capability Based Manufacturing Design
Supplier Integration
Selection Metrics Identify Best ValueManuf. Capability is Flowed to Design Team
AffordabilityManager
Modeling and Simulation
Utilize Models to Assess Cost and Performance Trades
Workshops Include Customer and Partners to Define End-In-View and Identify Top Level Values
ChiefEngineer
AffordabilityManager
SubsystemIPTL
MissileIPTL
SupplierIPTL
ProgramManager
SupplierIPTL
SubsystemIPTL
MRM Leadership
• Performance• Producibility
• Performance• Producibility
• Performance• Producibility
• Performance• Producibility
• Performance• Producibility
Manufacturing StrategyTest PhilosophySupplier EngagementProducibility / AUPP
MSOperations
MSEngineering
Land CombatProduct Line
Performability
Profordability
Robustability
Operations-ability
Assemble-ability
Technology-ability
Resource-ability
Deliverability
Supplier Y
12345678910
Performability
Profordability
Robustability
Operations-ability
Assemble-ability
Technology-ability
Resource-ability
Deliverability
Supplier X
12345678910
RequirementsBased Simulation
Model(Performance)
ManufacturingFlow Based
PriceModel
Design Based Test
Model
R6σ Tool Set
●Performance ●Schedule ●Development Cost ●Product Price
•Risk Mgmt•CP Mgmt
Events Based,Product Driven
IMP/IMS
MRMSystem
•DOE•VRD
•DTC/CAIV•5-Whys
•DFMA•FMECA
•SPC•EVMS
•Robust Test•FRACAS
•Reliability Growth
• Develop Models
• Develop Actionable Metrics Based on Models
• Develop Future State from Proposal
• Develop Current State from Hindsight
• Identify Gaps
• Close Gaps Using R6σ Tool Set, Cost Reduction Opportunities
• CMMI Using Model Metrics
RequirementsBased Simulation
Model(Performance)
ManufacturingFlow Based
PriceModel
Design Based Test
Model
R6σ Tool Set
●Performance ●Schedule ●Development Cost ●Product Price
•Risk Mgmt•CP Mgmt
Events Based,Product Driven
IMP/IMS
MRMSystem
•DOE•VRD
•DTC/CAIV•5-Whys
•DFMA•FMECA
•SPC•EVMS
•Robust Test•FRACAS
•Reliability Growth
• Develop Models
• Develop Actionable Metrics Based on Models
• Develop Future State from Proposal
• Develop Current State from Hindsight
• Identify Gaps
• Close Gaps Using R6σ Tool Set, Cost Reduction Opportunities
• CMMI Using Model Metrics
Material Cost Derivation
Labor CostDerivation
Cost toCustomerDerivation
TransportationCost
DerivationTotal Material$
Total LaborCost$
TotalPrice
@ NextFacility
MaterialCost
Assembly Time, Inspection Time,
Test Time, Rework, Support Ratio
UPP Factory ModelYield
Packaging Labor, Packaging Material, Transportation Cost
MaterialBurden
Index, Labor Rates
TransportationBurdens
Price@Qnty
Σ
SEPM
SEPM Rate
Material Cost Derivation
Labor CostDerivation
Cost toCustomerDerivation
TransportationCost
DerivationTotal Material$
Total LaborCost$
TotalPrice
@ NextFacility
MaterialCost
Assembly Time, Inspection Time,
Test Time, Rework, Support Ratio
UPP Factory ModelYield
Packaging Labor, Packaging Material, Transportation Cost
MaterialBurden
Index, Labor Rates
TransportationBurdens
Price@Qnty
Σ
SEPM
SEPM Rate
UPP CostEfficiency
AssemblyEfficiency
Manufacturing Efficiency
Number ofKey Control
Characteristics
Material FlowEfficiency
Support to Touch
Efficiency
4
7
Subsystem Price Efficiency
Material Efficiency
1
2
3
4
5
6
7
8
9
10
4
Seekerhead Profordability –Manufacturing Drivers
UPP CostEfficiency
AssemblyEfficiency
Manufacturing Efficiency
Number ofKey Control
Characteristics
Material FlowEfficiency
Support to Touch
Efficiency
4
7
Subsystem Price Efficiency
Material Efficiency
1
2
3
4
5
6
7
8
9
10
4
Seekerhead Profordability –Manufacturing Drivers
IRSource
LaserSource
LaserDetector
MM WaveSeekerSeeker
PASSPASS PASS PASS
SeekerSeeker
RF Test
Fusion EO FoFFusion EO FoF
IRSource
LaserSource
LaserDetector
MM WaveSeekerSeeker
PASSPASS PASS PASS
SeekerSeeker
RF Test
Fusion EO FoFFusion EO FoF
Bill of Characteristics
Bill of Processes
Recommended Annotations/PMI
DesignConstraints
Acrobat 3D PDF
SelectMfg Processes
Identify PartCharacteristics
3D CAD Model
ProcessInsights
Bill of Documents
ManufacturingProcess Rules
For Design Engineering
For Supply Chain/QA
For Manufacturing Engineering
Bill of Characteristics
Bill of Characteristics
Bill of Processes
Bill of Processes
Recommended Annotations/PMIRecommended
Annotations/PMI
DesignConstraints
DesignConstraints
Acrobat 3D PDF
Acrobat 3D PDF
SelectMfg Processes
Identify PartCharacteristics
3D CAD Model
3D CAD Model
ProcessInsightsProcessInsights
Bill of Documents
Bill of Documents
ManufacturingProcess RulesManufacturingProcess Rules
For Design Engineering
For Supply Chain/QA
For Manufacturing Engineering
Core Values Creators of Waste
• Create Platform for Usable Design Data• Create Platform for “Agility”• Create Model for True Lean Design• Show High Level Integration into the Manufacturing and SupplyChain Architecture
• Platform for Lowest Cost Design of Product• Be Model to Extend to other products!!
4/13/2009 Page 4
Evolutionary Acquisition – DoD 5000.2
CDD1TechnologyDevelopmentAoA
DAB
EMD Increment 1
Materiel SolutionAnalysis
DAB
DAB
DAB
JROC JROC JROCGap
Ana
lysi
s
ICD CPD1
JROC
CDD2
JROC
CBA
TechnologyDevelopment
EMD Increment 2 CPD2
DAB
C
DAB
JROC
CDD3
JROC
TechnologyDevelopment
EMDIncrement 3 CPD3
DAB
C
B
B
. . .
Joint Operating ConceptsJoint Functional Concepts
DoDStrategic Guidance
DAB
A
DAB
A
MDD
Continuous Technology Development and Maturation
“ Evolutionary acquisition is the preferred strategy for rapid acquisition of mature technology for the user.”
DoD5000.02, December 2008
Phased IncrementsRecognize up-front the need
for future capability improvements
CDD Evolves Through Increments to introduce capability improvements
4/13/2009 Page 5
Modularity Vision Tied to Business Strategy
Understand customer
needs
Influence AoAwith Product
Family offerings in simulations
Traditionally wait for
customer to determine what we’ll developDemos utilize
re-usable building blocks
Product Development
based on Product
Families, re-useable
building blocks
Modularity and Reuse are a comprehensive Product Strategy that support and influence the acquisition process through the use of simulations and demos
Capability-Based System DevelopmentMission, Threat, Environment, …
AssessAssess
“Gap” / Needed Capability
DoD Systems (DOTMLPF)
Mission, Threat, Environment, …
AssessAssess
“Gap” / Needed Capability
DoD Systems (DOTMLPF) IntegrationIntegration
AoA, Demos, Cost/Benefit
AoA, Demos, Cost/Benefit
Mature Building Blocks
ContractDefinitionContractDefinition
“No Risk”Concept
ProductDevelopment
ProductDevelopment
Requirements
New Product – On Time, On Budget
4/13/2009 Page 6
ProgramTeamProgram
TeamProgramTeam
Notional Workflow – Missile Development
Product Family Architecture and Product Center Expertise enable faster delivery of affordable, high quality customer solutions
Customer
RMS Architecture
Team
ProductCenters
External Suppliers
ProgramTeam
Solution
Need Statement
Contractual Documents
Program Specific Architecture
Modular Missile Architecture Change Requests
Modular Missile Architecture
Architecture Guidance
Architecture Repository
Program Architecture Approval
Product Repository (RMS, COTS, NDI…)
Product Roadmaps
Product Selection Support
Program Specific Design Approval
Delivered (RMS) Product
Product Needs (internal, external)
Program Specific Product Design
RMS Product Change Requests
External Product Needs
Delivered Products
Selected Suppliers
SCM
RMS Composite Requests, Purchases
PO & Contractual Documents
Consistency across Programs achieved through Product Centers & Architecture Team
4/13/2009 Page 7
Physical Architecture
Stds defined: Id re-usable
modules, rqmts, I/O
Standard Products
Development Process
Product Repository
Logical Architecture
Functions, data
descriptions
Modularity Process and Benefits
UnderstandWhat
Modularity means
Generate Arch ModelReflecting Business
Needs
DecomposeFunctional
Areas
Evaluate Logical
Architecture
Translate
To Physical
Architecture
Logical Arch Design to Standards
Repository Of
Compliant Products
Assemble/Integrate To Order
Process
OutputsQuality
Attribute Scenarios
Architectural Principles
Foundation Architecture
Technical Reference
Model (TRM)
Common functions, needed
variations
Customer Specific
Solutions
Benefits of using common architecture, reusable modules:Staffing flexibility- allows staff to move easily from program to program (core set of modules and architecture looks same; only need to learn the program specific deltas) Productivity increase – low learning curve, easier to work multiple programs, learning transfers across programsPredictability – mature the modules, mature the process - enables more accurate estimates, performance prediction for people and productsIncreased time for innovation – reuse what’s ordinary; be creative in specializing for customer, building new products from reusable product base
4/13/2009 Page 8
Design 2010 – Changing the ParadigmPrinciples– Architecture Driven
Analysis of Alternatives– Model Driven
vs. Specification Driven– Rapid Prototype
Spiral Cycles – Virtual1st Hardware and SW
– Lean Design PlanningDesign Profit Day 1
– End to End Solutions Studied
Results (An Early Project)– Arch to Design Cycle 45
Days to Proto-type– Model-driven 6-DOF – Early– Design –Target Cost Model– Lean Design
Modeled/Design Profit– Design Cycle Improvement
Digitally Connected Concept,
Design, and Manufacturing
OperationsModeling ATLO
Changing The Systems Design Perspective
Architecture Alternatives
Design 2010 VSD - Model Driven, Robust Architecture Based Solutions
4/13/2009 Page 9
VSD Operational View of Architecture (OV-1)
Concepts to Meet
Customer Needs
Operations Research
Performance Simulation
Product Design
Manufacturability Analysis
Process Design
Supportability Engineering
Dome Shroud Dome
Semi-Active Laser
MMW Radar
IR Camera & ElectronicsGimbaledPlatform
IR telescopeDome Shroud Dome
Semi-Active Laser
MMW Radar
IR Camera & ElectronicsGimbaledPlatform
IR telescope
Commonality/Modularity Data• Design• Cost• Performance
• Manufacturability• Supportability• Etc.
Tools
Repo
sito
ryVi
ewer
Proc
ess
Data Ac ces s Data Servi cesD D D D
MapsMIDBStores
MapsMIDBStores
I MINT, MASINTStoresI MINT, MASINTStores
New DataStore s
New DataStore s
S rv S rv S rv Srv SrvDa ta Int egrati on
Visu alization User Authenti cati onCollaboratio n
New App licat ionVie ws
Appli cat ion Framework Ba ck pla ne
Serv ice Integra tion
DPC
TempStore
C IPMngr
CIP
DPC
TempStore
C IPMngr
CIP
DPCDPC
TempStoreTempStore
C IPMngrC IPMngr
CIPCIP
MTI,Video Stores
MTI,Video Stores
Tas k Inte grat ionWo rkflow & Messaging ServicesExploitation WorkflowC ollection Workflow Exploitation WorkflowC ollection Workflow
Ada pters
Me ta Dat aCa tal og
MultiViz Store
MultiViz Store
Distr
ibut
edSc
reenin
g
Mult
i-INT
Explo
itatio
n
Miss
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anag
emen
t
Expl
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anag
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Mult
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Visu
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tion
Exte
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Task
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Distr
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Sens
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lannin
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Softc
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Targ
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Infor
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Distr
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strib
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Scree
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Mult
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Explo
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ulti-I
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Miss
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ission
Man
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Expl
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Man
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Mult
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Visu
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Mult
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Visu
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tion
Exte
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Task
ing
Exte
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Task
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Distr
ibuted
Sens
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lannin
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stribu
tedSe
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Plan
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Softc
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Targ
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ervice
Softc
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Targ
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ervice
Infor
matio
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rvice
sInf
orma
tion
Serv
ices
New
App
licat
ionNe
w A
pplic
ation
New
Servi
ceNe
w Se
rvice
G OTSPr oce s s ors
WebPortal
Secu
rity S
ervic
es
DMZ
Int
rusion
Dete
ction
Comm
unica
tion I
nfras
truct
ure
WANJWICS
SIPRNET
IMI NTV id eo
SI GIN T
MA SINT
MSI A2
IP B/
E IP BEO
/ IRS AR
GOT S/ COT S/OT SClient Vie ws
IMI NTV id eo
SI GIN T
MA SINT
MSI A2
IP B/
E IP BEO
/ IRS ARIMI NT
V id eoSI G
IN TMA SIN
T
MSI A2
IP B/
E IP BEO
/ IRS AR
GOT S/ COT S/OT SClient Vie ws We b-Based Vi ewsWe b-Based Vi ews
2D V is
3D Vi s
DSP
S TF D SC MT IXWT X
ETS
Web- Ba sed Views2D
V is
3D Vi s
DSP
S TF D SC MT IXWT X
ETS
Web- Ba sed Views
S&W
M TIX/JS WS
DE
SIGIN T
Vide o
Natl IM INT
VPC
IMINT
Predato r
U- 2
U-2
RJ
GH
M TIU- 2
JSTARS
S&W
M TIX/JS WS
DE
SIGIN T
Vide o
Natl IM INT
VPC
IMINT
Predato r
U- 2
U-2
RJ
GH
M TIU- 2
JSTARS
How We Bring Architecture Together!
A focus on modular and scalable designs
Customer Needs
4/13/2009 Page 10
VSD Link Lean Architecting to Lean Design
DevelopBusiness and Mission
Approach with Con Ops
DevelopOperational ViewsAnd Infrastructure
“The OV Set”
Execute Lean DesignDFA/DFM QA Report Card
Cost Target
Develop SystemViews “SV Set”
Update PrinciplesPerformance….
FoundationalConcept
DocumentsArtifacts
IterateUntil Metrics
Balance
RiskPerformance
ScheduleCost
Foundational Approach to Lean Systems Design …DoDAF and Zachman Methods
All Views Concept of Ops
Timeline/SequenceDefine Principles
Mission OrientedOperational Views
OV-1,2,4,6a.
ArchitectureModeling
PerformanceModeling
ManufacturingModeling
MDO OptimizationModeling
Intense CostModeling
Synergy Modeling
4/13/2009 Page 11
Cultural Obstacles to Lean Design and Reuse
Engineering and production rework
Linear Design
Weak Systems Thinking
Little Re-use of Previous Solutions –“Designer Preference/NIH”
Weak “Outsight”
Lack of Effective Collaboration
Weak Management Support for Innovation
Resistance to Changing Engineering Processes
Management Must Demand Design Reuse Or It Will Not Happen!
4/13/2009 Page 12
Systemic Obstacles to Lean Design and Reuse
Defense Projects are “Cellular” – Designed to “stand alone”– Unique, inflexible specifications– Unique contractual requirements– Unique security/AT requirements– Difficulty in facility and capital
equipment sharing– Inter-service differences– Intra-service differences
Company & Government accounting systems geared for cellular structure
Greater Flexibility in Contracting and Specifications Development are needed to achieve higher levels of lean design and reuse
4/13/2009 Page 13
SummaryDefense Customers are demanding that industry be faster, cheaper, and betterModularity and Reuse are key enablers for future systems Modularity and Reuse Benefits Everybody!Modularity and Reuse will not happen by themselves –it will take a concerted effort by Industry and Government