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

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reenin

g

Mult

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Explo

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Miss

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Expl

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Mult

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Visu

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Exte

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Task

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Distr

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Sens

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Softc

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Targ

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Infor

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Scree

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Man

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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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Exte

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Distr

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Sens

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Softc

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Infor

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rvice

sInf

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Serv

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New

App

licat

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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

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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