05-094

Case Study: Deployment of a DfSS Culture into the RME Organization

Raytheon, Rocky Mountain Engineering (RME)Karl Arunski

This briefing is intended for those in the process of establishing a Design for Six Sigma (DfSS) culture in their organization.

04/15/23 Page 205-094

Briefing Outline

I. Introduction – The business model/environment

– The Raytheon Design for Six Sigma (DfSS) definition

– The DfSS methodology

– The DfSS training

– The DfSS deployment objective

II. Process Integration– Integrating DfSS into the business process

III. Examples

IV. Conclusions

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I. Introduction

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What We Provide(The Business Model Environment)

• Command and Control

• Mission Management

• Sensor Data Processing

Operations

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Design for Six Sigma

Raytheon Definition

“Design for Six Sigma is a methodology, used

within the Integrated Product Development

Process (IPDP), to predict, manage, and

improve Productivity, Affordability, and Robust

Performance for the benefit of our customers.”

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The DfSS Methodology

• Define key parameters

• Define objectives

• Achieve and measure– Model

– Predict

– Design

– Measure

– Iterate as required

– Achieve

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The DfSS Training Class (Outline)

• Module 1. Process Integration

• Module 2. Voice of the Customer

• Module 3. Modeling and Optimization

• Module 4. Creating and EvaluatingArchitecture Alternatives

• Module 5. Value Delivery

• Module 6. Test Optimization

• Module 7. Program Integration

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The DfSS Deployment Objective

• Predict/Manage/Improve

• “Get people to think about the methodology and to try it out.”

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II. Process Integration

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II. Integrating DfSS into the Business Process

05-094-1.1

Process Integration

Voice of the Customer

Modeling and Optimization

Create and Evaluate Architecture Alternatives

Value Delivery

Test Optimization

Program Integration

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III. Examples

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Integrating DfSS into the Business Process

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Process Integration

Voice of the Customer

Modeling and Optimization

Create and Evaluate Architecture Alternatives

Value Delivery

Test Optimization

Program Integration

• Equipment Failure Analysis

• Gap analysis tool simulation/modeling• Mod and sim tool selection• AFWA DMSP MSS porting study

• FPGA development suite solution• FTN/C++ interface standards

• Make online system (test) more like Goddard Operations• EMOS analysis test cycle• Antero Program regression test

• IDMO DfSS

DfSS projects!

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Example 1. IDMO DfSS

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Vision and Goal

• Vision– “Redesign the existing Generic Multi-purpose Board

using the most up to date technology available, while presenting the same form/fit/function to the customer.”

• Goal– Reduce the number of projected System Problem

Reports (SPRs)

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Prioritize: Defect Analysis

0

10

20

30

40

50

60

70

80

Production Engineering Vendor Handling Unknown Chassis Fail

Aurora

Valley Forge

Site

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Characterize: Production Failure Mode Effects Analysis (FMEA)

System Problem Report (SPR) Occurrences Impact

Non-Detection Score Action Plan

Poor solder flow 75 8 8 16 Parts selection criteria is surface mount where possible. Allows for WAVE solder technique.

LED failures 15 1 1 2 Selected LEDs that do not require soldering to replace; will spare these items.

Component shorts 35 5 8 13 WAVE solder will limit the occurrence of solder bridging.

Won’t download personality 65 9 1 10 Will capture in test; will not deliver any board without a personality pre-loaded.

Bad parts 14 7 7 14 Testing/over buy parts

Smoked 5 1 1 2 Testing

Short to ground (trace) 3 9 9 18 Design reviews and testing

No communication with SBC 7 6 1 7 Test/verification

Bent pins 15 1 1 2 Installation training

Voltage issues (high/low) 3 5 5 10 Complete power analysis during design. Power checks as part of TP.

Conn. Interface 24 9 9 18 New robust connectors/cables

Component failure (minor) 40 2 2 4 Over buy/test

Component failure (major) 19 5 5 10 Over buy/test

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Improve: New Architecture

05-094-4.1

General Multi-Purpose (GMP) Board Architecture Current Proposed GMPII Architecture 1

VME Interface

XCVR

DPR

uP

LBUS MBUS

FPGA

Mez Card

FrontPanel

I/O

RAMVME

Interface TUND

MPU

SDRAM

LBUS

PCI

RBUS

MBUS

FPGA

PMC Slot

DPR

FrontPanel

I/O

FLASH

A/D

I/O

VIC

FIFOs

FPGAs

PROM

NCO

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Improve: New Architecture (cont.)

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Proposed GMPII Architecture 2 (selected)

VMEInterface TUND

SDRAM

LBUS

PCIBridge

RBUSMBUS

FPGA

PMC Slot

FrontPanel

I/O

FLASH

A/DandCS

I/O

MPU

DPR

1. Everything on the PCI busstandard2. Minimized the number devices on the boardless soldering3. Ball grid arrayno pins to bend4. Using surface mount partswave soldering technique5. No ribbon cables6. Micro robust connectorsfewer

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Achieve

0

2

4

6

8

10

12

Projected SPRs Actual SPRs

Aurora

Site

Other

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Example 2. Equipment Failure Analysis

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Vision and Goal

• Vision– To find new or improved methods to lower or

eliminate failures in the following items: circuit boards, swappable devices (i.e., hard drives)

• Goal– Eliminate failures

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Prioritize: Business Failure Analysis

Items That Failed

PowerSupplies

PC Boards CPUs Hard Drives Memory

Qu

anti

ty o

f F

ailu

res

Series 1

Series 2

Series 3

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Prioritize: Program A Failure Analysis

Mem

ory/E

CC

Mem

ory/D

IMM

CPUs

Power S

upply

Hard D

rives

Items That Failed

Qu

anti

ty o

f F

ailu

res

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Characterize: Fishbone Analysis

05-094-3.105-094-3.2

EquipmentFailures

Power

Vendor

Temperature

ElectrostaticDischarge

Humidity

Packing/Shipping

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Improve

• Rearchitect the environment– Temperature

– Humidity

– Power

• Procedures: electrostatic discharge requirements– Wrist straps

– ESD carts

– ESD benches

– Management involvement

– Data collection

– ESD-certified technicians replace items

– ESD improvement program

• Equipment failure analysis process– Data collection and analysis

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Achievement Goal

Program A

Business

Before After

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Example 3. Online Ops-Like Test Environment

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Vision and Goal

• Vision– “By incorporating Design for Six Sigma, the intent is

to reduce the number of Discrepancy Reports (DRs) that are written against our software.”

• Goal– Reduce the number of Discrepancy Reports (DRs)

written against the Online System

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Prioritize: Online Ops-Like Test Environment Supporting Data

0

1

2

3

4

5

6

Enviro

nmen

t

Telem

etry

Cecil

Comm

and

HMI

Clock

Corr

Histo

ry

Nu

mb

er o

f D

Rs

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Prioritize: Online Ops-Like Test Environment Supporting Data

Discrepancy Report Title Category

_R0226 EMOS error message during FSW log dumps Awaiting withdrawal

_R0227 Online NCC connection anomaly CCR

_R0229 Online derived FMU/SSR telemetry points not accurate Database

_R0230 USCCS clock corr. aborts when clock error exceeds approx. 24 hours Awaiting withdrawal

_R0231 FEOF function does not seem to be working Cecil

_R0233 Access to o:\online\paves_user\ch1\misc\xxxxx.hdp denied support Integration

_R0234 CDH & COM derived points stale in eK_LA telemetry

_R0242 “Analyst” misspelled in RTLOG impacts searches/filtering Cecil

_R0261 RTM files not closed automatically History

_R0269 move_transferred_files script stopped Environment

_R0271 Auto step messages clutter commanding in central Cecil Cecil

_R0272 TES load commands padded with too many bits CCR

_T1678 Sim cfgs will not allow command if set in past Command

_R0292 Cecil waitelrv failed to catch mem load acpt flag during MCL load Cecil

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Prioritize: Online Ops-Like Test Environment Supporting Data (cont.)

Discrepancy Report Title Category

_R0293 Multi-partition TES microprocessor loads have incorrect sequence flags Command

_R0294 Error when starting transfer scripts Environment

_R0314 Error message received after GCMR proc sent Command

_R0315 EMOS RT log incorrectly indicates missing SUROM packets Awaiting withdrawal

_A0954 RBD index only shows most recent file Environment

_R0329 Suppression delta messages should be warning, not informational message

Telemetry

_R0330 Interface services died Environment

_A0958 make_intdmf_transfers. & make_history_transfers.pl died Environment

_R0335 Add limits to TES derived parameters Database

_R0344 OPS primary terminated during startup of config Clock Corr

_R0363 CH_TDRSS_INFO.dat file update for TD9 CCR

_R0369 Input derived parameters for TES RCS temperatures Database

_R0370 TES derived parameter needed for ICS motor current Database

_R0376 TES time fields differ between online and MMS Command

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Prioritize: Online Ops-Like Test Environment Supporting Data (cont.)

Discrepancy Report Title Category

_R0387 MLS temperatures are stale Telemetry

_R0388 Unused MLS derived parameters still in online system Database

_R0402 1750a mnemonics not alarming Telemetry

_R0406 TLM page cell can be “Frozen” with alarm state format HMI

_A0999 RDD clock correlation report files deleted Clock Corr

_R0462 ESRS12 fell off talarian Investigating

_R0493 Delete red limits for GNC mnemonics Database

_R0511 EMOS suppression delta detection incorrect Telemetry

_R0512 Incorrect time tag in real time log Investigating

_R552 AQUA telem decommed by AURA EMOS system CCR

_R0535 GNC star tracker voltage derived mnemonics are incorrect Database

_R0545 Plots show “No Updates Yet” HMI

_R0555 Ground config failed to start on EORS12 Investigating

_R0556 Remove yellow limits from SUROM secondary test derived tlmy pts Database

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Characterize: Root Cause Analysis Results

• Not enough “ops like” testing procedures

• Not enough testing done by different users’ logins

• Not keeping interfaces running regularly

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Improve: Create a More Ops-Like Environment

• Update the “on-line” test procedures

• Implement ops-like procedures

• Test using several different user-name logins

• Keep interfaces running regularly

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0

1

2

3

4

5

Enviro

nmen

t

Telem

etry

Cecil

Comm

and

HMI

Clock

Corr

Histo

ry

Nu

mb

er o

f D

Rs

Achieve

No Discrepancy Reports!

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IV. Conclusion

• DfSS integration into the Business Process is underway

• People are trying it in all phases of the Business Model– Key parameters

– Objectives

– Achieve/measure

• More evolution required for– Modeling

– Predicting