LifeCycle of a Complex Product Perspectives on Product Design and Development

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Life-Cycle of a Complex ProductPerspectives on
Product Design and Development

• Bob Manney
• Director, F-16 Block 60 Program
• Lockheed Martin

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A little bit about the program we work

• Almost 2 years into an 8 year program
• Program value 6.4 billion FIRM FIXED PRICE for
  80 aircraft
• Largest COMMERCIAL contract license ever issued
  by US State Department
• 50 of contract value is in subcontracts
• LM Aero team is 850 people and will peak at
  1600
• Hopefully this brief program overview will help
  you understand where we live.
• My Chief Engineer, members of his team, and I
  hope to provide you some industry perspective /
  insight
• that may help you in your career.

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What is the best design?

• The most elegant?
• The most innovative, state-of-the-art?
• The best it can be?

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Life-Cycle of a Complex Product
Planning
Concept Definition
Requirements Definition /
Allocation
DESIGN
Development of System
Elements
VERIFICATION
Integration of System Elements
Verification
Production
Support
Decommission
Management / Control / Accountability
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Life-Cycle of a Complex Product
Planning
Concept Definition
Requirements Definition /
Allocation
DESIGN
Development of System
Elements

• the right amount of risk
• available in time
• affordable
• releasable, marketable
• adaptable, extensible
• producible
• Þ System Architecture
• modular, reusable elements
• maintainable
• simple interfaces not time-critical
• risk isolation

VERIFICATION
Integration of System Elements
Verification
Production
Support
Decommission
Management / Control / Accountability
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Mustang I Concept Car
Mustang I boasted a host of exotic engineering
features, but had no chance of becoming a
production car.
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Mustang II Productionized Car
Mustang II designed for production,and it looks
more like the first mass produced Mustang.
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Concept Car to Production Mustang

• Producible
• Marketable
• Affordable
• Supportable
• Adaptable
• Low risk
• Extensible

MOST SUCCESSFUL CAR (Guinness Book of World
Records)The most instantly successfulall-new
model car from any manufacturerwas the Ford
Mustangwhich was introduced in April 1964.Sales
in the first three years amounted to 1½ million.
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Life-Cycle of a Complex Product
Planning
Concept Definition
Requirements Definition /
Allocation
DESIGN
Development of System
Elements
VERIFICATION

• specify capabilities, not implementation
• unambiguous
• verifiable
• supportable
• achievable (with stretch)
• at each stage of allocation

Integration of System Elements
Verification
Production
Support
Decommission
Management / Control / Accountability
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Life-Cycle of a Complex Product
Planning
Concept Definition
Requirements Definition /
Allocation
DESIGN
Development of System
Elements
VERIFICATION
Integration of System Elements

• Apply engineering principles (What they teach
  you in school.)
• Configuration control of many co-evolving
  elements
• Know when to stop!
• Design for Producability
• Maintainability / Supportability
• Extensible

Verification
Production
Support
Decommission
Management / Control / Accountability
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Use model carsto illustrate extensible
designand common parts.
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Life-Cycle of a Complex Product
Planning
Concept Definition
Requirements Definition /
Allocation
DESIGN
Development of System
Elements
VERIFICATION
Integration of System Elements
Verification
Production

• Success depends on previous steps.
• planned integration order
• incremental build-up
• defined handoffs

Support
Decommission
Management / Control / Accountability
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Life-Cycle of a Complex Product
Planning
Concept Definition

• verifiable requirements
• diagnostic hooks
• test equipment
• test planning / test environment selection

Requirements Definition /
Allocation
DESIGN
Development of System
Elements
VERIFICATION
Integration of System Elements
Verification
Production
Support
Decommission
Management / Control / Accountability
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Life-Cycle of a Complex Product
Planning
Concept Definition
Requirements Definition /
Allocation

• producibility
• modularity
• recurring cost
• robust sources (DMS)

DESIGN
Development of System
Elements
VERIFICATION
Integration of System Elements
Verification
Production
Support
Decommission
Management / Control / Accountability
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Life-Cycle of a Complex Product
Planning
Concept Definition

• reliability
• maintainability / modularity
• testability / fault isolation
• affordability of spares
• availability of spares (DMS)
• warranty cost

Requirements Definition /
Allocation
DESIGN
Development of System
Elements
VERIFICATION
Integration of System Elements
Verification
Production
Support
Decommission
Management / Control / Accountability
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Life-Cycle of a Complex Product
Planning
Concept Definition
Requirements Definition /
Allocation
DESIGN
Development of System
Elements
VERIFICATION

• forward backward compatibility
• disposability
• liability
• re-use / modification

Integration of System Elements
Verification
Production
Support
Decommission
Management / Control / Accountability
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Management Tools and Techniques
Planning

• Task Schedules / Earned-Value Statusing
• Written Commitments
• Contracts
• Handoffs
• Action Items
• Requirements Allocation
• Issue Resolution
• Configuration Control through Tiered Decision
  Boards
• Shared Resource Management
• Risk Management
• Team Accountability Reviews
• Customer Communication

Management / Control / Accountability
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