The need for speed bloodhound presentation

ENGINEERING ADVENTURE

www.BLOODHOUNDSSC.com

BLOODHOUND Education Team Allan Reid FAPM

STEM & Bloodhound SSC Ambassador

17 February, 2015



Bloodhound SSC Overview

• Introductions – Background and Ambassador Programme

– Bloodhound SSC Mission Statement

• Discussion points – Background to this Engineering Adventure (ALR)

– Planning & Integrated Programme (CH)

– Where we are and where go from here (SH)

• Outcomes and Review – Benefits from the Bloodhound SSC Project (CH)

– Questions



Ambassador Programme

• Over 700 Volunteers share the passion for the Project and want to ensure that BLOODHOUND SSC educational objectives are achieved.

• Designed to inform, advise and enthuse teachers, students and the general public about the BLOODHOUND SSC Project. Above all “MAKE IT FUN” to learn.

• BLOODHOUND SSC STEM Ambassadors are all registered STEMNET Ambassadors and DBS (CRB) “cleared”.

• Ambassador assignments include explaining the technology behind BLOODHOUND SSC, the Design, Manufacturing, Testing and Trials processes and progress leading up to the Land Speed Record attempts.



BLOODHOUND SSC - Mission Statement

To create a national surge in the popularity of Science, Technology, Engineering and Mathematics - (STEM) subjects



The Problem UK Faces:

100,000 STEM graduates are needed per year from now until 2020.

Just 64,000 actually go into a STEM field.

We need to cover the shortfall or risk losing our place as an engineering and innovation

leader in the world.



Bloodhound SSC Engineering Adventure

• Registered Charity

• Receives No Government Funding

• Totally Funded by Corporate Sponsorship and

Public Donations

• Project Launched 28th October 2008

• Build Programme planned to complete July 2015

• World Land Speed Record Attempt starts late 2015

• Final Land Speed Attempt 2016 (1053mph)



Bloodhound SSC



The World Land Speed Record

1983 - Thrust 2 633.468mph

Richard Noble



The World Land Speed Record

1997 - Thrust SSC 763.035mph - Mach 1.02

Andy Green



The first 1000mph car

Key Statistics • Length - 13.4 Metres (44ft)

• Height - 4 metres (13.2 ft) • Wheel Diameter – 0.9m (35.4in) • Weight Fuelled - 7.5 tonne • After run Weight - 6.5 tonne • Turning Radius – 120 m (394ft)

Design Performance and Speed – 1,689 km/h (1,053 mph) 469 metres per sec or Mach 1.4 • 0 – 1000 mph in 55 secs • 0 – 1000 - 0 mph 120 secs – Distance 12.5 miles • Length of Track 20km (12.5 miles) • Travels faster than a bullet from a .357 Magnum Revolver Current Record Thrust SSC - 15th Oct 1997 1,227.99 km/h (763.035mph)



EJ200 Jet Engine & Hybrid Rocket



Vehicle Composition

Driver

Fuel Tanks

EJ200 Jet Engine

Nammo Rocket

F1 Racing Car Engine



The Record Attempt Track

Hakskeen Pan



Support Bloodhound SSC Project

Name on the FIN – Donate £15 and get your name Printed on the FIN

Go to www.BloodhoundSSC.com



Join the Adventure

Find us on Facebook: www.facebook.com/BLOODHOUNDSSC

Follow us on Twitter: www.twitter.com/BLOODHOUND_SSC

Sign up to the 1K Club: www.BLOODHOUNDSSC.com



Questions



The Need for Speed Colin Higginson - Principal Consultant BMT Hi-Q Sigma

The Challenge

22nd January 2015



The Bloodhound Definition

The Bloodhound Programme Ltd is an unreasonable

and disruptive aerospace and education company dedicated to innovation

and financed by sponsorship and public donation revenues.



The man with a problem



The Hi-Q Sigma Challenge

To maximise the delivery schedule through best utilisation of available resource and identify opportunities to accelerate the programme through scenario modelling using a fully resourced schedule.

Resourcing would be people only, cost would be considered separately.



4 Scenarios to be considered

1. South Africa date achievable with current resources

2. Resource required to achieve South Africa in 2014 weather window

3. Resource required to achieve South Africa in 2015 weather window

4. Impact of a Media Jet Test 2013/14



Hakskeen Pan, South Africa

Hakskeen Pan



Benefits ID

Benefits Identification

• Assist the building of a one team ethos

• Provide focus for the team on end delivery

• Demonstrate to each individual team member how important their contribution will be.

• Provide assurance to existing sponsors of the projects delivery timescales

• Provide the Bloodhound team with the ability to demonstrate to new sponsors an achievable plan.



The Approach to Boodhound



Development of Schedule

• Car broken down to 15 Major Assemblies (PBS)

O1 Lower Chassis

O2 Monocoque

O3 Intake Duct

O4 Front Susp

O5 Rear Susp

O6 APU - Intake

O7 Internal Ducting/Pipework Connections

O8 Upper Chassis

O9 Airbrake Doors

O10 Front Structure

O11 Fin

O12 Fin Fairing

O13 Fin Strake

O14 Support Kit

O15 Assembly Jigs & Fixtures

• Containing 100 Sub Assemblies



Complex Design



Development of Schedule (WBS)

• Major & Sub assembly life cycles identified

1. Concept Design

2. Analysis

3. Detail Design

4. Manufacture

5. Assembly

6. Installation / Test



Complex Construction

The BLOODHOUND Build Team trial fit one of the carbon fibre 'cheek' pieces to the jet and rocket powered car. These run from the Monocoque forward over the cooling ice tanks, front subassembly and front suspension



Complex Multiple Power Plant

BLOODHOUND SSC engineers test fitting the

EJ 200 to the car’s chassis ready for

connection of all the engine’s services and

alignment checks, the engine weighs 991 Kg



Complex Multiple Power Plant Pt 2

• BLOODHOUND's rocket partner, Nammo, successfully fired the new hybrid rocket. This firing lasted for a predefined 16 seconds, producing a maximum thrust of 30 kN (or 3 tonnes). The temperature in the rocket reached 2,500°C and 1,400°C in the plume.

• The rocket started instantly after ignition and the firing was terminated in a controlled manner by closing the main oxidiser valve.

• BLOODHOUND will use one rocket for high speed testing 2015 and a cluster of three rockets to reach 1,000mph in 2016.



Development of Schedule

• Predecessor and successor identified for each sub assembly and linked in schedule

• For each sub assembly activity an estimated duration and existing available resource allocated.

• Major Assemblies given priority order for design, manufacture & assembly.

• Major Assemblies for Media Jet Test identified and prioritised



Initial Logic and Critical Path Analysis

• Sanity check of activity scheduling to ensure logic correct and 1st critical path identified to be front structure.

• Resource levelling applied with existing team allocated, identified

delivery to S Africa Q1 2017.

Jul-13 Mar-17

Oct-13 Jan-14 Apr-14 Jul-14 Oct-14 Jan-15 Apr-15 Jul-15 Oct-15 Jan-16 Apr-16 Jul-16 Oct-16 Jan-17

INITIAL CRITICAL PATH CHECK - LOGIC LINKED, CURRENT RESOURCE APPLIED, LEVELLED



Scenario 1 – Date with Current Resources

Refining the Schedule • To ensure the resource levelling did not influence activity

scheduling, priorities were applied to all sub assemblies. • The full schedule was then reviewed by the team to identify

potential conflicts. This addressed a significant number of improvements both in dependencies and resource allocation.

• The activity durations were revisited by the team to drive out any over pessimistic estimates and whilst some durations were revised down they did not lie on the critical path and failed to reduce the overall duration.

• The resource graphs were analysed to ensure maximum utilisation of resource and some smoothing of resource was achieved through reprioritisation of activities.



Scenario 1 – Date with Current Resources

• The output from further resource levelling resulted in a delivery

to S Africa end Q3 2016

Jul-13 Mar-17


SCEN 1 - CURRENT RESOURCE APPLIED, LEVELLED




Scenario 2 - South Africa 2014

• To understand the level of resource required to achieve a SA 2014 date the ‘maximum availability’ of current resources was increased to 1000%

• The schedule was then levelled to provide a date in Q4 2014…..HOWEVER…..

Jul-13 Mar-17



SCEN 2 – 2014, UNCONSTRAINED RESOURCE





This scenario proved unachievable due to the requirement for :

• 75 additional designers immediately

• 31 additional stress engineers immediately

• 5 additional assembly engineers

• Unlimited availability of parallel manufacturing facilities




• The achievement of a 2014 date, even provided with unlimited funds and the immediate recruitment of a huge amount of additional resource, is impossible due to:

– The number of resources physically able to gain access to the assembly

– The loss of valuable existing resource utilisation whilst providing oversight and mentoring to new resource, i.e. current resources become full time managers.



POSTCARD FROM SOUTH AFRICA

THE HAKSKEEN PAN, SOUTH AFRICA

Jaguar XF

Jaguar F-TYPE R AWD

L39 jet aircraft



Scenario 3 ‘What Ifs’

Jul-13 Mar-17


WHAT IF 1 – TWO ADDITIONAL ASSEMBLY ENGINEERS ADDED

WHAT IF 2 – THIRD ADDITIONAL ASSEMBLY ENGINEER ADDED

BASELINE – CURRENT RESOURCE APPLIED, LEVELLED

8 Months Saved

Aug-15

Commence Desert Running - TARGET

No further saving

WHAT IF 3 – ONE ADDITIONAL DESIGN ENGINEER ADDED 3 Months Saved

This is the point at which the Critical Path is no longer driven by resource constraints, but by task durations



Scenario 3 – South Africa 2015

The team then concentrated on developing a REALISTIC and ACHIEVEABLE schedule based upon the recruitment of a limited number of additional resources, to be allocated to critical activities

This resulted in a date in Q2 2015, a 15 month saving

compared to Scenario 1

Jul-13 Mar-17



SCEN 3 - ADDITIONAL RESOURCE APPLIED, LEVELLED


15 MONTHS




4WD v 0WD




• This scenario is based upon the recruitment of:

Type Major Task Start Finish Months

Mechanical Designer Front Structure Concept & Detail Sep-13 Jun-14 9

Composites Designer Front Structure Concept & Detail Sep-13 Jun-14 9

Mech Des Detail Front Structure Detail Apr-13 Jun-13 3

Mech Des Detail Front Structure Detail Apr-13 Jun-13 3

Stress Analysis Eng Front Structure Analysis Dec-13 Apr-14 5

Mech Des Detail Fin Detail Sep-13 Oct-13 2

Designer Support Kit Design Aug-13 Feb-15 7

Assembly Fin Assembly Feb-14 Sep-14 7





Scenario 3 - Critical Path




• Total average cost per month of additional resource would be £30k, peaking at £65k

• However, the project completing 15 Months earlier results in a saving of £380k*

• Mechanisms for increasing resource -

– Recruit additional premium rate (£65/hr) resources (included in Scenario 3 schedule)




• Prerequisite for bringing in premium resource

– Uncapped overtime at an enhanced rate for current resources (not included in schedule – contingency for risk mitigation)

– Estimated monthly cost £20k



Scenario 4 – Media Jet Test

Jul-13 Mar-17



SCEN 3 - ADDITIONAL RESOURCE APPLIED, LEVELLED

SCEN 4 – MEDIA JET TESTSCEN 4 – POST MEDIA JET TEST


15 MONTHS

TBC




Scenario 4 – Media Jet Test

• Initial planning process indicates that a media Jet Test could occur during Q4 2014

• This will inevitably have an adverse impact on the SA date, this is estimated at 10 weeks

• Further detailed planning is required to fully understand the schedule for the Jet Test and the remaining activities post Jet Test



The inevitable over optimism



Task Dependant Critical Path

Next Steps;

Re-assess logic and durations of critical activities

Investigate ‘outsourcing’ some of this work

Decide whether Aux Intake Cassette Assembly is required



Progress Metrics



Bloodhound Laid Out



The lessons

• Invariably most plans are optimistic.

• Over optimism is inherent in most people and difficult to overcome

• Even the best constructed plans can only be realised by people and there is your biggest problem!

• Understanding the personalities of key personnel is essential

• You will never capture all the activities required for the ultimate schedule.

• Be prepared for the schedule to increase in size and complexity as it matures before you can simplify and reduce working complexity

• The analysis of data and its presentation needs to be tailored to your customer.

• Some like lots and the decision making is paralysed

• Others like to keep it simple and make effective decisions

• Know and understand your customer, help them to help themselves



The Need for Speed Simon Harrison – Consultant BMT Hi-Q Sigma

Developing the Plan

22nd January 2015



Contents

• My role in Bloodhound

• My approach

• Difficulties encountered



Aims

• Develop the schedule

• Improved control

• Accurate and realistic

• Understand resource requirements

• Present information



The Schedule

• Detailed, fully resourced schedule

• Set deadline dates

• Investigate resource constraints

• Run simulations

• Project update meetings

• 1-2-1 updates



• Identified the logic needed updating

• Carried out a sticky note exercise

• Investigate the order the car would be assembled

• Develop a clearer picture

Getting the Logic Correct



Re-build the Schedule

• Reduced the level of detail

• Easier to see the whole picture

• Clearly understand the order of assembly

• Identify the critical path items for design and manufacture



• Held integration workshops

• Produced detailed timelines

• Action registers

• Great understanding & control

Uncovering the Detail



• Engagement of team members

• Segregation of sub teams

• Flow of information

• Present information

Improving Communication

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Maintaining a Realistic View

• Optimistic durations

• Changes to timings

• Believe in the plan



Summary

• Produced a detailed schedule

• Greater control of the project

• Inform and align the team

• Clearly present the information

• Ensure it remains up to date



Join the Adventure

Find us on Facebook: www.facebook.com/BLOODHOUNDSSC

Follow us on Twitter: www.twitter.com/BLOODHOUND_SSC

Sign up to the 1K Club: www.BLOODHOUNDSSC.com



Are the benefits being Realised?

• Assist the building of a one team ethos – There are visible signs in both behaviours, project knowledge and respect of others contribution which demonstrate greater cohesion and ownership of the project across the whole team

• Provide focus for the team on end delivery – Whilst some pessimism remains among a few the vast majority are showing real commitment to achieving the 2015 South Africa milestone

• Demonstrate to each individual team member how important their contribution will be – The bloodhound technical centre rest room is plastered with the latest delivery schedules and are a constant source of information used by the team



Are the benefits being Realised?

• Provide assurance to existing sponsors of the projects delivery timescales – The Castrol PR lady and the world cup

• Provide the Bloodhound team with the ability to demonstrate to new sponsors an achievable plan - Jaguar now a major sponsor



QUESTIONS