Dr. Daniel P. Schrage Professor and Director Center of Excellence in Rotorcraft Technology (CERT)
description
Transcript of Dr. Daniel P. Schrage Professor and Director Center of Excellence in Rotorcraft Technology (CERT)
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Aerospace Systems Engineeringas an Integrating Function
for the Georgia Tech Graduate Program in Aerospace Systems
DesignDr. Daniel P. SchrageProfessor and Director
Center of Excellence in Rotorcraft Technology (CERT)Center for Aerospace Systems Analysis (CASA)
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Presentation Outline• Overview of the Graduate Program
Aerospace Systems Design Program
• The Evolution from an IPPD to an IPPD through RDS to a Modern Aerospace Systems Engineering Approach
• Description of the Graduate Course in Aerospace Systems Engineering
• Opportunities for Collaboration with the School of ISYE
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Georgia Tech School of AE
• School of Aerospace Engineering– One of original six Guggenheim Schools of Aeronautics– 34 full time faculty– ~600-700 undergraduate students (AE majors)
– ~250 -300 graduate students– Highest Rated Public Aerospace School (Overall: UG – 2nd to
MIT;GR-3rd to MIT & Stanford, U.S. News & World Report)
• Six Disciplinary Groups (Full A.E. School)
• Aerodynamics and Fluid Mechanics
• Structural Mechanics and Materials
• Propulsion and Combustion
• Flight Mechanics and Controls
• Structural Dynamics and Aeroelasticity
• System Design and Optimization
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Graduate Program in Aerospace Systems Design
• Includes core and elective courses to:– Provide a Practice-oriented M.S. Program– Provide a Integrated-Discovery Focused Ph.D program
• Includes a combination of disciplinary, methods and synthesis courses for System Design of Complex Systems:– Aircraft and Rotorcraft– Missiles and Space– System of Systems: Army/DARPA FCS; FAA/NASA NAS
• Integrates Research and Education– Two active research laboratories, ASDL and SSDL– Approx. 100 students (~80 supported)– Approx. 15 research engineers
• Uses an IPPD through RDS Approach and a modern Aerospace Systems Engineering Course as an Integrating Function for the Program
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Evolution of the Georgia Tech Aerospace Systems Design Program
CE/IPPD CE/IPPD
RSM forAdvanced Synthesis
RSM forAdvanced Synthesis
RDSRDS
FPIFPI
CASA CASA
‘94
‘96
‘97
‘98
Focus: Affordable Aerospace Systems Design Methodology; ASDL Estab.
Focus: Pioneering Research into Response Surface Methodology (RSM) for advanced sizing/synthesis
Focus: Addressing Economic Uncertainty & Viability results in Robust Design Simulation
Focus: Efficient Probabilistic Analysis through Fast Probability Integration (FPI)
Focus: Systems & Systemof Systems Analysis forComplex Systems andMovement toward a ModernApproach to Systems Engineering
Aero + Structures
FLOPS-IMAGE-RSE Interface developed
• Morphological
Matrices• Pugh Diagram
CustomerRequirements
Establishthe Need
FPI
Sizing
Econ.
x2
x1 xn
y1
y2 yn
Probabilistic Feasibility AND
Viability
x1
x2
$/RPM
Target
Pro
bab
ilit
y
$/RPM
DesiredSolution
FeasibleSolution
BaselineMean
‘84 - Graduate Rotorcraft Design Program Established
‘92 - Graduate, CE/IPPD Fixed-Wing Design Program Established w/ NASA’s USRA ‘89 - Intro to Concurrent Engineering (CE) & Design for LCC courses
Graduate Program Development
‘94- NASA MDA Fellowship Grant
and New Approaches to MDO Grant
‘95-’96 Space Systems Design
Laboratory (SSDL) Established
‘97- NRTC Center of Excellence
Renewal
‘98- Center for Aerospace Systems Analysis (CASA)
Initiated
‘99- Boeing Awards GTAE/CASA
Faculty Chair in Aerospace Systems
Analysis’00 GEAE USA
‘95
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Why it is Unique?• Is the Only Formal Graduate Aerospace Systems Design Program in
the U.S., and probably throughout the world• Addresses the System Design of Complex Systems (Not Conceptual
Design) utilizing a Generic IPPD Methodology, as a modern approach for Systems Engineering
• Provides an engineering approach to Risk Based Management through Robust Design Simulation (RDS) environment for Implementing the IPPD Methodology at the “Front End” that can be continued for Process Improvement and Merging with Six Sigma methods
• Provides a practical way of incorporating “lean” and other initiatives into the front end of a complex system’s life cycle
• Has spun off various methods, tools, and techniques from this IPPD through RDS approach for a variety of customers
• Have moved to address “System of Systems” problems such as FCS and air transportation architectures for the NAS
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Who are the Primary & Supporting Faculty?• School of A.E.:Primary Faculty
– Dr. Dimitri Mavris, Director of ASDL and Boeing Chair Professor in Advanced Aerospace Systems Analysis
– Dr. John Olds, Associate Professor and Director of SSDL– Dr. Jim Craig, Professor and Co-Director of CASA– Dr. Dan Schrage, Professor and Director, CASA & CERT– Two recruitments: Lewis Chair in Space Systems Technologies;
Junior Faculty in Design Methodology & ToolsSupporting Faculty: Dr. Amy Pritchett (AE/ISYE), Dr. Eric Johnson, &
Dr. JVR Prasad
• Some Participation from the School of M.E.– Dr. Farokh Mistree, Professor and Director of SRL– Dr. Bob Fulton, Professor
• Some Participation from the School of E.C.E– Dr. George Vachtsevanous, Professor and Director of the Intelligent
Control Laboratory
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Overview of Center for Aerospace Systems Analysis (CASA)
• Established in1998 based on successful development of the ASDL from 1992 and the successful development of the SSDL from 1995; Serves as oversight for these labs
• Through its laboratories provides the primary research support to the graduate program in Aerospace Systems Design which currently has ~ 100 students of which over 80 % are U.S. citizens
• Research support provides over $5M per year in sponsored research and supports ~ 80 students & 15 research engineers
• Provides a modern approach to systems engineering based on an Integrated Product/Process Development (IPPD) methodology executed through Robust Design Simulation (RDS)
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Why Systems Analysis?• Systems Analysis is a scientific process, or methodology,
which can best be described in terms of its salient problem-related elements. The process involves:– Systematic examination and comparison of those alternative
actions which are related to the accomplishment of desired objectives– Comparison of alternatives on the basis of the costs and the
benefits associated with each alternative– Explicit consideration of risk
• NASA, DoD, and Industry are realizing that more emphasis must be placing on enhancing systems analysis at the front end of the life cycle using modern systems engineering approaches
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
CASA’s Laboratories
Aerospace Systems Design Labwww.asdl.gatech.edu
Aerospace Systems Design Labwww.asdl.gatech.edu
B.S.A.E. - M.S. - Ph.D DegreesB.S.A.E. - M.S. - Ph.D Degrees
Space Systems Design Labwww.ssdl.gatech.edu
Space Systems Design Labwww.ssdl.gatech.edu
Design Frameworks Lab
Flight Sim Lab
IPERT Lab Uninhabited Aerial VehicleResearch Facility
Design, Build, Fly Lab
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
An Integration and Practice-Oriented M.S.Program in Aerospace Systems Design
Legend: Core Classes Elective Classes
SummerSemester IISemester I
Design Methods/Techniques ISE/PLMCDevelopment
SpecialProject
Safety By Design
Aerospace Systems
Engineering
DisciplinaryElectives
PropulsionSystemsDesign
SystemsDesign I
AppliedDesign I
SystemsDesign II
AppliedDesign II
Design Tools/Infrastructure
ModernDesign
Methods I
Modern Design
Methods II
ProductLife Cycle
Management Internship
Mathematics (2 Required) Other Electives
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Classroom Implementation
Aerospace SystemsDesign Laboratory
MethodsMethods StudentsStudents
Aerospace Systems Design Education & Research Philosophy
Funding
• Methods Formulation• Supports Basic Research• Implementation of Methods
Partners:ONRNASAAFRLNRTC
Government Industry
RelevantProblems
Data & Tools
Partners:GEAERRA
LMTASBoeing
SikorskyFunding
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Design Process Paradigm Shift(Research Opportunities in Engineering Design, NSF Strategic Planning Workshop Final Report,
April 1996)
100%
50%
0%
Today’s Design Process Future Design Process
Kno
wle
dge
Abo
ut D
esig
n D
esig
n Fr
eedo
m
Cos
t Com
mitt
ed
Con
cept
Pre
limin
ary
Des
ign
Analysis and Detail
Design
Prototype Development
Redesign Product Release
• A paradigm shift is underway that attempts to change the way complex systems are being designed
• Emphasis has shifted from design for performance to design for affordability, where affordability is defined as the ratio of system effectiveness to system cost +profit
• System Cost - Performance Tradeoffs must be accommodated early
• Downstream knowledge must be brought back to the early phases of design for system level tradeoffs
• The design Freedom curve must be kept open until knowledgeable tradeoffs can be made
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
What is IPPD?
• Integrated Product/Process Development (IPPD) is a management methodology that incorporates a systematic approach to the early integration and concurrent application of all the disciplines that play a part throughout a system’s life cycle (Technology for Affordability: A Report on the Activities of the Working Groups to the Industry Affordability Executive Committee, The National Center for Advanced Technologies (NCAT), January 1994)
• IPPD evolved out of the commercial sector’s assessment of what it took to be world class competitive in the 1980s
• The DoD has required IPPD and the use of IPTs where practical throughout the DoD Acquisition Process for Major Systems (DoD 5000.2R)
• Conduct of IPPD requires Product/Process Simulation using Probabilistic Approaches
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Quality Revolution - Where Competition is Today
Cost Advantage
Statistical Process Control Variability reduction Customer Satisfaction
Quality
Cheap LaborHi Volume, Lo Mix Production
Cycle time Comparison (JIT)Integrated Product/Process DevelopmentProduct/Process SimulationHi Skill adaptable Workforce
Time-to-Market
Cost Independent of VolumeAgility Commercial/Military Integration Virtual Companies
Product Variety
Company Goodness
Environment
1960 1970 1980 1990 2000
Manufacturing Enterprise Flexibility
NCAT Report, 1994
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Japanese Auto Industry Made Changes Earlier Than U.S. Auto Industry
90% Total Japanese
Changes Complete
U.S. Company
Japanese Company
20
-24
M
on
ths
14
-17
M
on
ths
1-3
M
on
ths
Job
#1
+3
M
on
ths
Nu
mb
er
of
En
gin
eeri
ng
Pro
du
ct
Ch
an
ges
Pro
cess
ed
Japanese/U.S. Engineering Change Comparison
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Concurrent vs Serial Approach
Design & Development
Test & Production
Supporthigh
low
Nu
mb
er
of
De
sig
n C
ha
ng
es
Time
Cost of Change
Serial Approach
Concurrent Engineering
Approach
IPPD Focus
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Traditional Design & Development Using only a Top Down Decomposition Systems Engineering Process
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
IPPD Requires the Computer Integration of Product and Process Models and
Tools for System Level Design Trades and Cycle Time Reduction
SYSTEMPROCESS
RECOMPOSITION
SYSTEMFUNCTIONAL
DECOMPOSITION
COMPONENTFUNCTIONAL
DECOMPOSITION
COMPONENTPROCESS
RECOMPOSITION
PARTPROCESS
RECOMPOSITION
PARTFUNCTIONAL
DECOMPOSITION
ProductTrades
ProcessTrades
ProductTrades
ProcessTrades
PRELIMINARYDESIGN
(PARAMETER)
PRELIMINARYDESIGN
(PARAMETER)
DETAILDESIGN
(TOLERANCE)
DETAILDESIGN
(TOLERANCE)
MANUFACTURINGPROCESSES
CONCEPTUALDESIGN
(SYSTEM)
ProcessTrades
INTEGRATEDPRODUCTPROCESS
DEVELOPMENT
ProductTrades
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Integrated Product and Process Development Modeling Flow (Aircraft Example)
Top-Down Aircraft
LCC Model
ComponentCost Modeling
AircraftSynthesis(Sizing)
FiniteElementAnalysis
wingplanformgeometry
bottom-upwing costestimate
KBSProcessModeling
cust. requirements
perf. requirements
materials
loads
labor rates
learning curves
cost model
req’d inputs
weights
labor hoursmaterial costs
ENGINEERING MODELSProduct Decomposition
MULTI-LEVEL LCC MODELProcess Recomposition
IntegratedDesign
Environment
costmetrics
performancemetrics
productmetrics
processmetrics
structural concepts
alternative processes
re-designdecision
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Wing Point Design Regions
• Representative structure at each location– upper and lower panels
– rib and spar structure
William J. Marx
Aft wing box–variable chordwise load
intensities due to wing bending
–high spanwise load intensities
Forward wing box–low load intensities with respect to
wing bending
–minimum gage region
Wing tip box–stiffness critical due to
aeroelastic effects
–high load intensities
HSCT Integrated Design & Manufacturing Ph.D Thesis (W. Marx, 1997)
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Aircraft Life Cycle Cost Analysis (ALCCA) - including Economic Analysis
AIRLINERETURN ON
INVESTMENT
AIRLINEOPERATING
COST
CALCULATEAIRLINE ROI
MANUFACTURERCASH-FLOW
ROI
AIRCRAFTMANUFACTURING
COSTS
CALCULATEMANUFACTURER
CASH-FLOW
AIRCRAFTWEIGHTS
LABORRATES
LEARNINGCURVES
PRODUCTIONQUANTITY
RDT & ECOSTS
UNITCOSTS
AVERAGECOST
YES
NO
PRODUCTION
SCHEDULE
AIRLINE
PAYMENT SCHEDULE
MANUFACTURERROI VS PRICE
AIRCRAFT MISSIONPERFORMANCE
FUEL, INSURANCEDEPRECIATION RATES
LABOR & BURDENRATES
YES
NO
DIR
EC
T
CO
ST
S
IND
IRE
CT
CO
ST
S
TOTALOPERATING
COST
AIRLINEROI VS PRICE
REVENUE
TAX RATE
ACQUISITION
SCHEDULE
PREPAYMENT
& DEPR. SCHEDS
ENGINETHRUST & WGHT.
ROI
PRICE
AirlineYield
ProductionQuantity
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Component WeightsEngine Thrust and
WeightLabor Rates
Production QuantityLearning Curves
Component CostsUnit CostsRDT&E CostsAvg. Costs
AircraftManufacturing
Costs
AircraftManufacturing
Costs
Previous MfgCost Module
Labor RatesProduction
QuantityLearning Curves
Component Weights
Engine Thrust
Manufacturing Hours Quality Assurance Hours
Tooling Hours(Raw Material Costs)(Buy-To-Fly Ratios)
Material CostsMaterial Breakdown
Mfg. Labor RateQual.Assur. Labor RateMaterial Burden Rates
Mfg. Labor L. CurveQA Labor L. Curve
Tooling L. CurveMaterial L. Curve
fromCLIPS
newALCC
Ainput
Aircraft Manufacturing Costs
New Wing Production Module
WingProduction
PBC
Module
WingProduction
PBC
Module
TheoreticalFirst Unit
Cost
TheoreticalFirst Unit
Cost
Non-Recurring
& RecurringProduction
Non-Recurring
& RecurringProduction
Component CostsUnit Costs
RDT&E CostsAverage Unit Costs
Wing TFUCManufacturing Hours & CostQuality Assur. Hours & CostTooling Hours & CostMaterial CostsCost/Time Analysis
NewALCCA
output
Aircraft Process Based Manufacturing Cost Model
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Cost Time Analysis for Theoretical Production
[Source: MIL-HDBK-727]
FinishingOperations
Material Cost
Cumul. time
Cost / Unit
Production
Setup
DesignTools
PurchaseMaterial
Tool Design Cost
SetupCost
Production Cost Largest Run
Finishing Operations Cost Largest Run Production Cost Smallest Run
Finishing Operations Cost Smallest Run
Cost/Time Curve
End Points for WideRange of ProjectedLot Sizes
Largest Run
Smallest Run
Theoretical First Unit Cost
(TFUC)
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Cost/Time Constraint Curve for Candidate Selection
[Ref. MIL-HDBK-727]
TIME
Process AEnd Point
UNIT COST
Process BEnd Point
Process CEnd Point
Process DEnd Point
Cost/Time Curve
Process E
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
[Ref. MIL-HDBK-727]
FinishingOperations
Material Cost
Production
Setup
DesignTools
PurchaseMaterial
Tool Design Cost
SetupCost
Production Cost Largest Run
Finishing Operations Cost Largest Run Production Cost Smallest Run
Finishing Operations Cost Smallest Run
End Points for WideRange of ProjectedLot Sizes
Largest Run
Smallest Run
Cumul. time
Cost / Unit
Cost/Time Curve
Theoretical First Unit Cost
(TFUC)
Probabilistic Cost/Time Production Analysis
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Georgia Tech Generic IPPD Methodology
• Methodology provides a procedural design (trade-off iteration) approach based on four key elements:
– Systems Engineering Methods and Tools (Product design driven, deterministic, decomposition approaches; MDO is usually based on analytic design approach)
– Quality Engineering Methods and Tools (Process design driven, nondeterministic, recomposition approaches; MDO is usually based on experimental design approach)
– Top Down Design Decision Process Flow (Provides the design trade-off process)
– Computer Integrated Design Environment(Information Technology driven)
• Methodology has been implemented through Robust Design Simulation (RDS) for a number of applications
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Georgia Tech Generic IPPD Methodology
COMPUTER-INTEGRATED ENVIRONMENT
PR
OD
UC
T D
ES
IGN
DR
IVE
NP
RO
CE
SS
DE
SIG
N D
RIV
EN
REQUIREMENTS & FUNCTIONAL
ANALYSIS
SYSTEM DECOMPOSITION &
FUNCTIONAL ALLOCATION
SYSTEM SYNTHESIS THROUGH MDO
SYSTEM ANALYSIS &
CONTROL
ESTABLISH THE NEED
DEFINE THE PROBLEM
ESTABLISH VALUE
GENERATE FEASIBLE ALTERNATIVES
EVALUATE ALTERNATIVE
7 M&P TOOLS AND QUALITY FUNCTION DEPLOYMENT (QFD)
ROBUST DESIGN ASSESSMENT & OPTIMIZATION
ON-LINE QUALITY ENGINEERING &
STATISTICAL PROCESS
MAKE DECISION
SYSTEMS ENGINEERING METHODS
QUALITY ENGINEERING METHODS
TOP-DOWN DESIGN DECISION SUPPORT PROCESS
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
The Systems Engineering ProcessProcess Input• Customer Needs/Objectives/ Requirements - Missions - Measures of Effectiveness - Environments - Constraints• Technology Base• Output Requirements from Prior Development Effort• Program Decision Requirements• Requirements Applied Through Specifications and Standards
Requirements Analysis• Analyze Missions & Environments• Identify Functional Requirements• Define/Refine Performance & Design Constraint Requirement
Functional Analysis/Allocation• Decompose to Lower-Level Functions• Allocate Performance & Other Limiting Requirements to All Functional Levels• Define/Refine Functional Interfaces (Internal/External)• Define/Refine/Integrate Functional Architecture
Synthesis• Transform Architectures (Functional to Physical)• Define Alternative System Concepts, Configuration Items & System Elements• Select Preferred Product & Process Solutions• Define/Refine Physical Interfaces (Internal/External)
System Analysis& Control(Balance)
Verification
Requirement Loop
Design Loop
• Trade-Off Studies• Effectiveness Analysis• Risk Management• Configuration Management• Interface Management• Performance Measurement - SEMS - TPM - Technical Reviews
Process Output• Development Level Dependant - Decision Data Base - System/Configuration Item Architecture - Specification & Baseline
Related Terms: Customer = Organization responsible for Primary Functions Primary Functions = Development, Production/Construction, Verification, Deployment, Operations, Support Training, DisposalSystems Elements = Hardware, Software, Personnel, Facilities, Data, Material, Services, Techniques
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Aerodynamics Economics
Propulsion
Safety
Aerodynamics
S&C
Propulsion
Performance
Manufacturing
Economics
Safety
Structures
Manufacturing
Structures Performance
Conceptual Design Tools (First-Order Methods)
Synthesis & Sizing
Preliminary Design Tools (Higher-Order Methods)
Geometry
Mission
Increasing Sophistication and
Complexity
Approximating Functions Direct Coupling of Analyses
Integrated Routines Table Lookup
Modeling and Simulation:Varying Fidelity of Synthesis and Sizing
S&C
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
The Quality Engineering Process provides Recomposition Methods & Tools
CustomerQuality Function
Deployment
Off-Line
Quality Function
Deployment
Off-Line
Seven Managementand Planing
ToolsOff-Line
Seven Managementand Planing
ToolsOff-Line
Statistical Process Control
On-Line
Statistical Process Control
On-Line
RobustDesign Methods(Taguchi, Six -Sigma, DOE)
Off-Line
RobustDesign Methods(Taguchi, Six -Sigma, DOE)
Off-Line
Knowledge Feedback
•Needs• Identify Important Items
•Variation Experiments
•Make Improvements
•Hold Gains
•Continuous Improvement
Having heard the “voice of the customer”, QFD prioritizes where improvements are needed; Taguchi provides the mechanism for identifying these improvements
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
CoVE: Collaborative Visualization Environment
for Complex Systems Design
Funded by the
Defense University Research Instrumentation Program (DURIP)
February 2003
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
CoVE Objectives• A semi-immersive, very high resolution, Collaborative
Visualization Environment (CoVE). • Used to investigate the use of semi-immersive virtual
environments in collaborative design processes. • Basic concept for the CoVE is a large, high resolution
display wall similar to those developed for media companies and operations centers.
• It will allow us to apply emerging probabilistic design methods to problems at an industrial scale.
• It is expected to promote new research in design, visualization and usability with other leading centers on campus.
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
CoVE Features
• A single CoVE with a 25 M-pixel resolution curved data wall measuring 20 ft wide by 12 ft tall.
• Seating for up to 12 participants, each with their own computers and local displays.
• The basic design will be configured so that it can be used with another CoVE to execute distributed collaborative design with another team at a remote location.
• The CoVE will include both single person and group video conferencing capabilities.
• Project budget: $630k
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Examples
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Examples
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
PRICE $K
ROIA
Den
sity
Criterion 1
Cri
teri
on 2
Alternative 1
Alternative 3Alternative 2
Area ofInterest
z1maxz1min
z2min
z2max
3K
FB
(lb
)6
K F
B (
lb)
Ra
ng
e (
nm
i)E
ng
eW
t (lb
)F
an
Dia
(in
)S
FC
(1
/hr)
ZOPRD ZPQD25 ZTH41 ZSDE12 ZSDE2 ZSDE25 ZSDE41 ZSDE49 ZSWC41 ZSWC42 WT_ADDEROPRD PQD25 TH41(R)
Fan Boost CPR HPT LPT HPT Ch.(%W25)
HPT NCh.(%W25)
Wt. Adder(lbs)
Technology MetricsDesign Variables
Ou
tpu
t C
TQ
s
1X
6-1
Torpedo Length
Torpedo Velocity
Torpedo Range
Torpedo Noise
-1 X8 1
Defi ne the
Problem
Defi ne Concept Space
Modeling and
Simulation
I nvestigate Design Space
Feasible or
Viable?
I dentif y Technologies
Evaluate Technologies
Select Technologies
1 2 3 4 5 6 7 8Defi ne
the Problem
Defi ne Concept Space
Modeling and
Simulation
I nvestigate Design Space
Feasible or
Viable?
I dentif y Technologies
Evaluate Technologies
Select Technologies
1 2 3 4 5 6 7 81 2 3 4 5 6 7 8
50,000 ft.
1. Taxi & T.O.F.L.=11,000 ft.
3. CruiseM=0.9
8. Abort3000 ft.
10. LandF.L.= 11,000 ft.
7. LoiterM=0.6
9. ReserveM=0.6
2. Climb
67,000 ft.
35,000 ft.
4. Climb
5. CruiseM=2.4
6. Descent
200 nm100 nm750 nm50 nm5,000 nm
Technology Space Mission Space
R
esp
on
ses
Mission Requirements
Snapshot 1
R
esp
on
ses
Technology Dials
Snapshot 3
Vehicle Attributes
Snapshot 2
Concept Space
(Vehicle Attributes)
Baseline +
Fixed Geometry, Technology SetFixed Requirements, Geometry
Fixed Requirements, Technology Set
Res
po
nse
s
R
esp
on
ses
(Technology Dials)(Mission Requirements)
Installed Power [SLS,MCP]
Empty Weight
Alpha = .052Beta = .0076Scale = 1.145
Beta Distribution
Normal Distribution
Mean = 1.0
Std Dev = .007
JPM(lines of constantprobability)
EDF(plottingsample data)
Area of Interest
JPDM
Video Conference
RAM Model
CFD Visualization
Morphological Matrix Unified Trade-off Environment
QFD
Technology Impact Matrix
Constraint AnalysisMission Profile
CDF
Technology Profiles
Example ASDL Application
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
STAIR CIR/15B/235
CIR/5C/305
STAIR
DOWN
CLS
APPROXIMATE SCALE:
2D
2D
CIR/5D/820LOUNGE - 6/700
2D
CLS
2D
2D
DOWNCIR/5E/305
STAIR
CLS
STAGE
5A/460/0
PROJECTION RM.
5/2440/90
LECTURE RM.
DOWN
CLS
CIR/5A/235STAIR
UP
DN.
PROJECTION RM.
4/2440/90
LECTURE RM.
CLS
PROJECTION RM.
3/2440/90
LECTURE RM.
1
STAGE/3A/460/0
DOWN
0 2 4 6 8 10
3/2440/90
LECTURE RM.
CLS CLS
CoVE Conceptual Layout
Weber 2nd Floor SiteOperations
Video Conferencing
Observers
Data Wall
Participants
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
CoVE Tentative Schedule• Award announcement: February 2003
• Final specifications: April 2003
• Site preparations: May 2003
• Construction & Installation: July 2003
• Testing: September 2003
• Acceptance: October 2003
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Aerospace Systems Engineering Course: AE 6370
• Introduces new graduate students to Aerospace Systems Engineering and a methodology for Implementing it through IPPD through Robust Design Simulation (RDS)
• Consists of covering traditional systems engineering methods and tools; introduces quality engineering methods and tools; introduces multi-attribute decision methods; and introduces the need for a computer integrated environment
• Course consists of a mid-term exam and team projects (~5 students per team) addressing the concept formulation for complex systems or system of systems
• Utilizes a simple set of integrated tools to allow the teams to conduct the first iteration through a complex system design
• Will be offered as a distance learning course for the first time in Fall 2003
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Aerospace Systems Engineering Taught using an Integrated Set of Tools
Baseline 1 st Option 2 nd Option
Engine Type MFTF Mid-TandemFan
Turbine Bypass
Fan 3 Stage 2 Stage No Fan
Combustor Conventional RQL LPP
Nozzle Conventional Conventional +Acoustic Liner
Mixer EjectorNozzle
AircraftTechnologies
None CirculationControl
Hybrid LaminarFlow Control
a lt. c o n c e p ts
crite
ria
H O W s
M o rp h o lo g ic a l M a tr ix
B e s tA lte rn a tiv e
T e c h . A lte rn a t iv eId e n tif ic a t io nQ F D
M A D MM A D M
W e ig h ts
P u g h E v a lu a tio n M a tr ix
S u b je c t iv e E v a lu a t io nS u b je c t iv e E v a lu a t io n( th ro u g h e x p e r t o p in io n ,( th ro u g h e x p e r t o p in io n ,
s u rv e y s , e tc .)s u rv e y s , e tc .)
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Ten Complex System Formulation Projects from AE6370, Fall 2002
• AIAA Graduate Student Missile Design Competition: “Future Target Delivery System(Missile Multipurpose Target”
• RFP for a “High Firepower Payload for Missile Defense (Missile Interceptor)
• NASA Sponsored University Competition for the “Conceptual Design of a Titan (Saturn’s largest moon) Vertical Lift Aerial Vehicle”
• AHS/NASA Student Design Competition for “VTOL Urban Disaster Response Vehicle”
• NASA “Personal Air Vehicle Evaluation Program: to identify VTOL and ESTOL Concepts”
• RFP for a “Quiet Supersonic Business Jet” in conjunction with Gulfstream Aerospace Company
• DoD Potential Joint Program for an “Air Maneuver & Transport Concepts for the Objective Force”
• AIAA Student Competition for “Subsonic Commercial QuEST”• AUVS International Aerial Robotics Competition and DARPA Project:
“Intelligent Uninhabited Aerial Vehicle (UAV) using Software Enabled Control (SEC)”
• Army Aviation Recapitalization Program: “Technology and Risk Assessment for the Army’s UH-60M Helicopter Improvement Program”
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
What is IPPD Through RDS
• Integrated Product/Process Development (IPPD) means applying Concurrent Engineering at the front end of a system’s life cycle where design freedom can be leveraged and product/process design tradeoffs conducted in parallel at the system, component, and part levels
• Implementation of IPPD requires moving from a deterministic point design approach to a probabilistic family design approach to keep the design space open and from committing life cycle cost before the system life cycle design trade-offs can be made
• Robust Design Simulation (RDS) provides the necessary simulation and modeling environment for executing IPPD at the System level
• Continuation of RDS along the system life cycle implies the creation of a Virtual Stochastic Life Cycle Design Environment
• An Overall Evaluation Criterion (OEC) based on System Affordability should be identified early and its variability tracked along the life cycle time line
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Roadmap to Affordability Through RDS
Objectives:ScheduleBudgetReduce LCCIncrease AffordabilityIncrease Reliability. . . . .
Customer Satisfaction
Synthesis & Sizing
Technology Infusion
Physics-Based
Modeling
Activity and Process-
Based Modeling
Technology Infusion
Physics-Based
Modeling
Activity and Process-
Based Modeling
Subject to
Economic & Discipline
Uncertainties
Economic & Discipline
Uncertainties
Impact of New Technologies-Performance & Schedule Risk
Impact of New Technologies-Performance & Schedule Risk
Robust Solutions
Robust Design SimulationRobust Design Simulation
Simulation Operational Environment
Economic Life-Cycle Analysis
Design & Environmental Constraints
Design & Environmental Constraints
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Interactive RDS Environment
Aero
Structures
Weights
Etc.
DISCIPLINARY RSEs
SYNTHESIS & SIZING
FPI
RSEs
Objective0%
100%
Pro
babi
lity
Criterion 1or Requirement 1
Cri
teri
on 2
or R
equi
rem
ent 2
R
esponse
s R
esponse
sM
etrics/
Obje
ctives
Metrics/
Obje
ctives
Cons
train
tsCons
train
ts
R
esponse
s R
esponse
sM
etrics/
Obje
ctives
Metrics/
Obje
ctives
Cons
train
tsCons
train
ts
R
esponse
s R
esponse
sM
etrics/
Obje
ctives
Metrics/
Obje
ctives
Cons
train
tsCons
train
ts
Concept Space
Technology Space Requirements
Space
1
TWR
-1
² %$/ RPM
TOFLm odSLNm od
-1 SW 1
CDF
JPDM
DynamicContourPlots
FPI / MC
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Risk & Uncertainty are Greatest at the Front
KNOWN-UNKNOWNS
UNKNOWN-UNKNOWNS
KNOWNS
CONCEPT VALIDATION FULLSCALE
DEVELOPMENT
PRODUCTION DEVELOPMENT
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
OverallEvaluationCriterion
(OEC)Response
Time
OEC Target
System Design (Preliminary/Parameter)
System Integration (Detail/Tolerance)
Manufacturing (On-Line Quality)
Uncertainty Risk Management/Reduction
OEC Target
Initial Distribution
System Definition &
Tech. Development (Conceptual/System)
Reduced Variability and Improved Mean Response
Traditional C p and C p k Approach for Continuous, On-line Process Improvement
Continuous Product Improvement / Innovation
Fuzzy Front End
Upper Specification
Lower Specification
Define Distributions
Bring the Development Process Under Control, C p = 1
Approach Six-Sigma, 1 < C p < 2
Upper Specification
Lower Specification
Six-Sigma Achieved, C p = 2
OverallEvaluationCriterion
(OEC)Response
Coninuous RDS along the System Life Cycle to link the “fuzzy front end” to the “process capability approaches”
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
The VSLCDE- Key Characteristics
The purpose of VSLCDE is to facilitate design decision- making over time (at any level of the organization) in the
presence of uncertainty, allowing affordable solutions to be reached with adequate confidence. It is a research testbed.
Virtual . . . Simulation-based system life-cycle prediction Stochastic . . . Time-varying uncertainty is modeled; temporal decision-making Life-Cycle . . . the design, engineering development, test, manufacture, flight test,
operational simulation, sustainment, and retirement of a system. The operational simulation includes virtual testing, evaluation, certification, and fielding of a vehicle in the existing infrastructure, and tracking of its impact on the economy, market demands, environment.
Design . . . Implies that the environment’s main role is to provide knowledge for use by decision-makers, especially for finding robust solutions
Environment . . . Implies the support of geographically distributed analyses and people through collaboration tools and data management techniques
CERT/CASADr. Daniel P. SchrageGeorgia Institute of TechnologyAtlanta, GA 30332-0150www.asdl.gatech.edu
Some Opportunities for Collaboration between the Schools of AE and ISYE
• Integration of ISYE Logistics with AE Aerospace Systems Design Program for a variety of customers (Industry and Government)
• With Lockheed Martin on a Modern Systems Engineering Approach (addressing Product Life Cycle tradeoffs from the Outset) based on the Joint Strike Fighter (JSF) Development Approach successes and Lessons Learned (POC: Bill Kessler, LM Lean Enterprise Mgr and Tom Burbage, LM JSF VP)
• With OSD/DOD/USAF New Focus on Systems Engineering Education and Research
• With USAF – GT(CEE) Initiative in taking over the Lean Sustainment Initiative from MIT
• With NASA Langley National Institute of Aerospace (NIA) and with NASA Ames Engineering of Complex Systems (ECS) programs
• Others?