Economics of Human Systems Integration: The Pratt & Whitney F119 Engine

Dr. Ricardo Valerdi

2ndLt. Kevin Liu, USMC

Dr. Donna Rhodes

seari.mit.edu

Background

1980s

UK Ergonomics Research Society

US Human Factors Society

Human Engineering Guide to Equipment Design

Government Agency focus on safety and human factors

Industrial Revolution - WWII

Industrial Engineering

Human Factors Engineering (HFE)

HSI in the Air Force

seari.mit.edu 3

Manpower—the number and mix of personnel (military, civilian, and contractor) authorized and available to train, operate, maintain, and support each system.

Personnel—the human aptitudes, skills, and knowledge, experience levels, and abilities required to operate, maintain, and support a system at the time it is fielded.

Training—the instruction and resources required providing personnel with requisite knowledge, skills, and abilities to properly operate, maintain, and support a system.

Environment—the conditions in and around the system and the concepts of operation that affect the human’s ability to function as a part of the system as well as the requirements necessary to protect the system from the environment.

Safety—hazard, safety and risk analysis in system design and development to ensure that all systems, subsystems, and their interfaces operate effectively, without sustaining failures or jeopardizing the safety and health of operators, maintainers and the system mission.

Occupational Health—the consideration of design features that minimize risk of injury, acute and/or chronic illness, or disability, and/or reduce job performance of personnel who operate, maintain, or support the system.

Habitability—factors of living and working conditions that are necessary to sustain the morale, safety, health, and comfort of the user population that contribute directly to personnel effectiveness and mission accomplishment, and often preclude recruitment and retention problems.

Survivability—the ability of a system, including its operators, maintainers and sustainers to withstand the risk of damage, injury, loss of mission capability or destruction.

Human Factors Engineering—the comprehensive integration of human capabilities and limitations into systems design, to optimize human interfaces to facilitate human performance in training operation, maintenance, support and sustainment of a system.

Economics of HSI

DoDI 5000.02, Operation of the Defense Acquisition System

seari.mit.edu 4

(Begins)

seari.mit.edu 5

Research Questions

• How did Pratt & Whitney predict how much HSI effort would be needed?

• How much did HSI effort eventually cost?

• How did HSI fit into the larger systems engineering picture?

The F-22 Raptor Air Superiority Fighter

Replaces F-15

Air dominance, multi-role fighter 

Dominance through stealth, speed, agility, versatility, supportability

First Look – First Shot – First Kill

seari.mit.edu 6

The Pratt & Whitney F119 Engine

Best practice of HSI

Reliability & Maintainability emphasis from 1984 ->-Air Force leadership

New requirements introduced during Engineering and Manufacturing Development (EMD)

P&W F119 beat GE F120 because it demonstrated “least technical risk and lowest cost”

Yankel, J. & Deskin, W. (2002). “Development of the F-22 Propulsion System.”

seari.mit.edu © 2008 Massachusetts Institute of Technology 8

Engine Design for the Mechanic

Integrated Product Development (IPD)Integrated master plan (IMP), Integrated Master Schedule (IMS), Integrated Product Teams (IPTs), Integrated Program Management Team (IPMT) Component IPTs (CPTs).

Supportability Awareness“Blue Two” visit program.Internal presentations reiterated lessons learned.

Supportability Reviews and Trade StudiesMonthly reviews evaluated adherence to IMP and IMS.Over 200 studies weighed HSI features against cost, weight, and performance.

Early Support Tool InvolvementTools annotated to design drawings

Full-Scale Engine MockupFull-scale engine mockups used to test reality of one-deep LRU - allowed engineers to simulate servicing parts.Held engineers accountable.

HSI Early in F119 Development

AF Acquisition Community-led requirements definition studies

40% fewer parts than previous engines

Leadership and IPD

seari.mit.edu 10

…advances were intended to reduce operational level and intermediate level maintenance items by 75% and depot level tools by 60%, with a 40% reduction in average tool weight,” (Aronstein, et al. 1998).

F119 Successes Span Domains of HSI

HSI Domain Work Done Cost BenefitManpower -Fewer Maintainers

-Men and Women could work on engines- Reduced man-hours spent on maintenance

Personnel - All maintenance tasks designed to accommodate women maintainers

-Improved understanding of procedures

Training - Documentation - Effort spent preparing documentation

Human Factors Engineering

(HFE)

-6 Tools total- 1 Tool/ LRU, One-Deep LRU's- Tools redesigned for easier handling

- Weight

Environment

Safety - Captured Fasteners- Self-contained engine

- Weight -Fewer reported mishaps

Occupational Health

- CBR Suits -Reduced exposure to harmful elements

Habitability - Mock-Ups- "Blue Two" Visits

-Funding for trips- $2M/ Mock-Up

Survivability -Designed to contain fan blades- Single-engine mentality

-Zero Scheduled Maintenance- Reduced engine failure rate- 75% reduced O&I time

seari.mit.edu 12

Development of Cost DriversThe 10 Principles of Effective HSI (from

the Handbook on HSI)1. Top-level leadership

2. Focus on human-centered design (HCD)

3. Source selection policy

4. Organizational integration of all HSI domains

5. Documentation integration into procurement process

6. Quantification of human parameters

7. HSI technology

8. Test and evaluation=assessments

9. Highly qualified practitioners

10. Education and training program

(Booher, 2003)

Prioritized List of Critical Elements for Successful HSI (from The Art of Successfully

Applying Human Systems Integration)1. Management and Organizational Commitment

2. User/stakeholder involvement

3. Education and awareness of all

4. HSI process ownership

5. Holistic, enabled view

6. Funding support

7. Documented and technically sound processes

8. Qualified personnel

9. Open collaborative environment

10. Practical applications based on sound human factors research

(Landsburg et. al., 2008)

Observations

seari.mit.edu 13

•How did Pratt & Whitney predict how much HSI effort would be needed?

•How much did HSI effort eventually cost?

•How did HSI fit into the larger systems engineering picture?

• USAF Requirements-driven• Competition, Business need

• Estimation by analogy•“HSI Slice” unclear

• IPD, CICR, CCB, IPT, CIPT, etc.• Emphasis in requirements, pre-milestone A/B

seari.mit.edu 14

Development of Cost Drivers

– Requirements Understanding – Architecture Understanding – Level of Service

Requirements – Migration Complexity – Technology Risk – Documentation – # and diversity of

installations/platforms

Existing COSYSMO Cost Drivers:– # of recursive levels in the

design – Stakeholder team cohesion– Personnel/team capability – Personnel experience/continuity– Process capability – Multisite coordination – Tool support

COSYSMO

seari.mit.edu 15

COSYSMO

SizeDrivers

EffortMultipliers

195Person Monthsof HSI effort

200 easy, 200 nominal, 50 difficult Requirements2 easy, 3 difficult Interfaces5 difficult Algorithms

High Requirements UnderstandingHigh Technology RiskHigh Process Capability

Acknowledgments

seari.mit.edu 16